AQUA-LAB HD/XD - Hydra-Flex, Inc....AQUA-LAB HD/XD (WALL MOUNT) 1. Drill (4) 5/32” holes on the wall. 16 3/8” wide, 27 5/8” tall. 2. Press Aqua-Lab HD/XD board tight against

© Hydra-Flex, Inc. 2017 Page | 1

AQUA-LAB HD/XD™CHEMICAL DISPENSING SYSTEM

User ManualREV F

4000087 revF0917© Hydra-Flex, Inc. 2017


TABLE OF CONTENTS

FOR ADDITIONAL SUPPORT CALL952-808-3640

OR VISIT US ON THE WEBwww.hydraflexinc.com

Specifications 3

LayoutDrawing 4

PanelDiagram 5

EstimatedInstallationTimeline 6

InstallationInstructions 6

ElectricalConnections 7

HFIBoosterPump&MCU 8ComponentDiagram 9WiringDiagram 10StartUpInstructions 12

HFIGrundfosPump&VariableFrequencyDrive(VFD) 14ComponentDiagram 14WiringDiagram 15StartUpInstructions 17

Appendix 19InitialInjectorSetup 19TripleFoamSetup 19OptimizingTheSystem 20NozzleSetup 20ChemicalUsageMeasuring 21RecommendedMaintenance 22AirOperatedValveReplacement 22BAMValveReplacement 22Troubleshooting 23

PumpIssues 23InjectorIssues 23PressureRegulatorIssues 24Flow/Archissues 24ValveIssues 24VFDIssues 24

InjectorOptimizationTool 25InjectorVacuumCheck 26HighTempShutdownRestartInstructions 26Chem-FlexInjectors-ChemicalDilutionRatios 27RecommendedSetupStartingPoints 27Chem-FlexInjectorPartNumbers 28PressureLossInRunLength 29Aqua-LabAccessories 31Aqua-LabPanelPartsDiagram 32Aqua-LabPumpPartsDiagram 34Aqua-LabControlPartsDiagram 35Aqua-LabWarranty 36


SPECIFICATIONSSPECIFICATIONS

*Recommended for use with 30A breaker.

POWER REQUIREMENTS20 GPM (75 LPM) 3 HP

Booster Pump20 GPM (75 LPM) 5 HP

Grundfos Pump40 GPM (150 LPM) 7.5 HP

Grundfos Pump Air-Actuated Valves

230V/3PH/60Hz/8.9A460V/3PH/60Hz/4.2A

230V/3PH/60Hz/12.2A460V/3PH/60Hz/5.6A

230V/3PH/60Hz/18.6A*460V/3PH/60Hz/8.9A

24 VAC, 24 VDC, or 120VAC,3.5 Watts/Port

WATER INLET LINES20 GPM (75 LPM) Booster Pump 20 GPM (75 LPM) Grundfos Pump 40 GPM (150 LPM) Grundfos Pump

1” ID 1.25” ID 2” ID

SPACE REQUIREMENTS FOR MCU, VFD, & MD PANELS (DEPTH X WIDTH X HEIGHT)

Motor Control Unit VFD HD/XD Panels

9” x 14” x 15”(23 x 36 x 38 cm)

14” x 21” x 20”(36 x 54 x 51 cm)

7” x 32” x 34”(21 x 69 x 110 cm)

SPACE REQUIREMENTS GRUNDFOS PUMPS(DEPTH X WIDTH X HEIGHT)

20 GPM Grundfos Pumps 40 GPM Grundfos Pumps

17” x 14” x 41”(44 x 36 x 104 cm)

19” x 15” x 42”(49 x 38 x 107 cm)

SPACE REQUIREMENTS WALL-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT)

1-PumpWall-Mount

2-PumpWall-Mount

3-PumpWall-Mount

12” x 24” x 48”(31 x 61 x 122 cm)

12” x 24” x 48”(31 x 61 x 122 cm)

12” x 36” x 48”(31 x 91 x 122 cm)

SPACE REQUIREMENTS FLOOR-MOUNTED BOOSTER PUMPS (DEPTH X WIDTH X HEIGHT)

1-PumpFloor-Mount

2-PumpFloor-Mount

3-PumpFloor-Mount

12” x 24” x 54”(31 x 61 x 138 cm)

12” x 32” x 54”(31 x 82 x 138 cm)

22” x 32” x 54”(56 x 82 x 138 cm)

OPERATING WATER PRESSURE200 PSI (14 bar) Factory Set

(Assumes 40 PSI (2.8 bar) City Feed)

MAX. WATER SOURCE TEMP.Recommended 110°F (43°C) Max water temp 137°F (58°C)

AIR INLET LINE3/8” OD Polyflow per Panel

WATER FILTRATION (SUGGESTED)

50 Micron

AIR OUTLET LINE3/8” OD Polyflow per Application

AIR INLET PRESSURE20 CFM @ 80-120 PSI (5.5-8.3 bar) Dry Air

*Assuming line length is 50’ (15 m) or less. Refer to user page 28 for recommended size chart for other lengths.

SOLUTION OUTLET LINESUp to 2.25 GPM (8.5 LPM) 3.25 - 4.5 GPM (13.3 - 17 LPM) 5.5 GPM (20.8 LPM) 10.0 - 15.0 GPM (37.9 - 56.8 LPM)

3/8” ID (1/2” OD Polyflow*) 1/2” ID* 5/8” ID* 3/4” ID

OUTLET CONNECTION FROM MANIFOLD20 GPM VERTICAL GRUNDFOS PUMP 40 GPM VERTICAL GRUNDFOS PUMP

.5” FNPT 1” FNPT

WATER SUPPLY MAX FLOW PER PORTMax Flow Per Hydra-Cannon Port 6 GPM

Max Flow Per BAM Port 15 GPM

FLANGE TORQUE20 or 40 GPM VERTICAL GRUNDFOS PUMP

37-44 ft-lbs

PRESSURE TRANSDUCER (VFD)

Pressure Range 0-300 PSI

Set point 200 PSI

Cord Length 7 Meter


LAYOUT DRAWING

***Pump configuration will vary depending on specific order options.

18.8

19.7

29.1

32.7

41.3 APPROX32 - 36"

PUMP INLET HOSE INCLUDED40 GPM: 2" HOSE INLETPROVIDED20 GPM: 1.25" HOSE INLETPROVIDED

1” x 6' QUICK CHANGEFLEXIBLE HOSE WITHREGULATOR AND WYE-STRAINER TO AQUALAB WITH 1" QUICKCONNECT AND BALL VALVEINCLUDED WITH EACHPANEL

AQUA LAB XDPANEL

1x 8ft 230V / 480VPUMP POWER CORDINCLUDED WITH EACHPUMP

PUMP STANDLOCATED WITHIN 5' OFEACH HD/XD BOARD

SIGNAL CONTROLCABLE INCLUDED

PRIMARY AIRREGULATOR3/8" POLY FLOWAIR INLET TUBINGPROVIDED BY OTHERS(100 PSI MAX)

4x TAPCON ANCHORSINCLUDED FOREACH HD/XD PANEL

VFD BOXLOCATED WITHIN 6' OFPUMP MOTORAQUA LAB 3 PHASE480V OR 230VPOWER IN PROVIDED BY OTHERS

3x 20' SIGNAL WIRETO AQUA LABINCLUDED

4X 3/8 CONCRETEANCHORS INCLUDEDWITH EACH PUMP STAND

WYE STRAINERINTEGRATED INTO OULET MANIFOLD

PRESSURE TRANSDUCERCABLE 10 FT

40 GPM: 2"NPT HOSE BARB TOCONNECT TO WATER FEED20 GPM: 1.25" NPT HOSE BARB TOCONNECT TO WATERFEED

PRESSURETRANSDUCER CABLE

POWER FROM WALL

POWER TO PUMP

18.8

41.3

16.4

40.3

20 GPMPUMP

40 GPM PUMP

19.7

19.7 20.9

18.1 12.2

VFD BOX

NOTE: MOUNT 32"FOR EASY ACCESS


PANEL DIAGRAM

Air Ports

Air Ports

Individual Air Regulators

Individual Air Regulators

Hydra-Cannon Manifold

BAM Manifold

Primary Air Regulator

Primary Air Regulator

M12 Junction Block

M12 Junction Block

Home Run Cable (Goes to car wash controller for control voltage)

Home Run Cable (Goes to car wash controller for control voltage)

Gray M12 Cable (Goes to MCU/VFD)

Gray M12 Cable (Goes to MCU/VFD)

BAM Valve

BAM Valve

Triple Foam Manifold

Triple Foam Manifold

Solenoid ActuatedAir Valves

Solenoid ActuatedAir Valves

1

1

2

2

3

3

4

4

5

5

6

6

7A

7A

7B

7B

7C

7C


WHO TASK EST. TIME

DISTRIBUTOR MONITOR&RECORDPERFORMANCE 2HR/WK

DISTRIBUTOR MAINTENANCEPERSCHEDULEORASNEEDED

POST INSTALLATION

TOTAL HOURS SPENT

INSTALLATION

TOTAL CUSTOMER 1 HR

TOTAL DISTRIBUTOR/TECHNICIAN 15 HR

TOTAL ELECTRICIAN 4 HR

TOTAL PLUMBER 4 HR

PRE-INSTALLATION

ESTIMATED INSTALLATION TIMELINE

WHO TASK EST. TIME

DISTRIBUTOR&CUSTOMER DETERMINELOCATIONTOINSTALLEQUIPMENT 1 HR

PLUMBER INSTALLWATERSUPPLYLINE 4 HR

ELECTRICIAN INSTALLELECTRICALSUPPLYLINE 4 HR

TECHNICIAN LABEL ALL CONTROLLER RELAYS AT CONTROLLER 1 HR

TECHNICIAN RUNSOLUTIONANDAIRLINES(IFNECESSARY) 5HR

TECHNICIAN INSTALLAIRSUPPLYLINE 1 HR

TOTAL LABOR HOURS 16 HRS

WHO TASK EST. TIME

DISTRIBUTOR/TECHNICIAN HANGEQUIPMENT 1 HR

TECHNICIAN CONNECTWATER,AIRANDSOLUTIONLINES 1 HR

TECHNICIAN CONNECTCONTROLLEADSTOMAINCONTROLLERORJUNCTIONBOX 2 HR

DISTRIBUTOR/TECHNICIAN STARTUP(INJECTOR,METERINGTIPANDNOZZLESELECTION) 3HR

DISTRIBUTOR/TECHNICIAN DOCUMENTCONFIGURATION 1 HR

TOTAL LABOR HOURS 8 HRS

InstallationtakesapproximatelyONEday.Anelectricianandaplumberareneededforhalfaday.

General Skill Level• Mechanical:Basic-mountingequipment• Electrical:Advanced-threephasepowerandcontrolsknowledge(localcodesknowledgerequired)• Plumbing:Moderate-principalsupplylinerequired• Pneumatic:Basic-pneumaticutilityconnectionrequired• ChemicalKnowledge:Moderate-chemicaltitrationsrequired

INSTALLATION INSTRUCTIONS

• Hammer

• Tapemeasure

• Level

• Utilityknife

• Wirestripper

• Socketset

• Adjustablewrench

• Screwdriverset

• Teflontape

Tools & Equipment Needed:• DrillwithPhillipshead

• Concretedrillbit3/8”

• Concretedrillbit5/32”

Useful Tools:• AmpMeter

• VoltMeter


UNPACKINGWhenunpackingyourAqua-LabHD/XDbesurenottodiscardthemanualoranyaccessories.Inspecttheshipmentforanydamageormissingcomponents.Ifpumpsareincludedwithorder,takecaremovingthepump(s).Utilizeproperliftingtechniqueandmechanicalassistanceifnecessary.

LOCATION & MOUNTING **IflocationwasnotidentifiedduringthePre-InstallationProcess,makesuretoconsidertheproximitytofeedwater,powersupply,andthecontrolcabinetaswellasspacenearthesystemtostorechemicalcontainers.Mountbaseofpanel32”fromfloorforeasyinjectoraccess.

***See drawing in reference for general layout

AQUA-LAB HD/XD (WALL MOUNT)1. Drill(4)5/32”holesonthewall.163/8”wide,275/8”tall.

2. PressAqua-LabHD/XDboardtightagainstthewall.

3. Screwin3/16”concretescrewswithawasher.

SYSTEMS WITH BOOSTER PUMPS & MCU PUMP ASSEMBLY - NEED TO BE WITHIN 6’ OF FURTHEST AQUA-LAB HD/XD PANEL1. Drill3/8”holesinwallforbottomslots(20”oncenterpumpnosedown,

3.5”oncenterpumpnosesideways-dualstand).

2. Insertconcreteanchors,setpumponboltsandtightendown.

3. Holdpumpstandinplace,drilltopholes,insertanchorsandtighten.

MOTOR STARTER1. Mounttothewallwith4appropriateanchors.

SYSTEMS WITH VFD & GRUNDFOS PUMPS1. Before bolting components down, ensure the water lines, electrical

cables, etc. have enough length to connect.

2. Removepumpfrompackaging.

3. Locatepumpindesiredlocation.

4. Securelyanchorpumptoconcretefloor.

5. MountVFDtothewall.

PNUMATIC CONNECTIONS• Connectpre-run3/8”ODpolyfeedlinetopushconnectfittingonthe

sideoftheprimaryregulator.

• Connect3/8”ODpolylinesfromarchtoeachportthatwillbefoaming.

**If there are unused air ports, counter-clockwise turn the individual line regulator until air no longer flows.


7 PORT AQUA-LAB (NON-HFI MOTOR CONTROL UNIT)

Make sure all VIOLET wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects (One Wire Per Nut!).

7 PORT AQUA-LAB (HFI MCU STARTER/VFD)

Make sure all BLUE wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects (One Wire Per Nut!).

ELECTRICAL CONNECTIONS (HFI MOTOR CONTROL UNIT)a. Wire homerun control cables to car wash control panel. (See diagram on page 16 for wiring schematic)

• Manifold position below designates which Hydra-Cannon port is associated to what color wire.• Example: if you want Presoak 1 to be on manifold port 2, connect the green wire to your

controller relay for Presoak 1.


HFI BOOSTER PUMP & MCU(SINGLE SOURCE / SINGLE PUMP SHOWN)

Timer Relay

Contactor

Thermal Overload

Temperature Shutdown Relay

Current Switch3 Phase Disconnect

Quick Connect Pump Plug Female

Grey M12 Cables (Carry signal from M12 distribution block to motor starter that turns on the pump)

FOR PART NUMBERS & DIAGRAMS - SEE PAGES 34-35

HFI BOOSTER PUMP SECTION

Wye-Strainer

Pump Outlet Feed Line To MD Panels

Bypass Pressure Regulator

Back-up Pump

Temperature Switch

Quick Connect 9’ Cordset For Pump (Plugs Into Bottom Of Motor Starter)


NOT3T2T1

NOL3L2L1

A2A1

Contacter

95

T3T2T1

989796

ThermalOverload A21816

15B1A1

TimerRelay

1 1TS1

TS2 3 3 2 2

2T1/

1

4T2/

1

6T3/

1

PE

1L1 3L2 5L3

2T1 4T2 6T3

CurrentSwitch

From BreakerFrom GreyM12 Cables(Port 6 on M12 Block)

To Temp Switch To Pump Through Power Fast Quick Connect

3 Phase

Disconect

V+

Valve

Sig

nal

V-

Jumper Jumper

JumperJumper

3 Phase

Control Voltage

Light

Relay

Switch

MCU WIRING DIAGRAM(SINGLE SOURCE SINGLE PUMP)



NO

T3T2

T1

NO

L3L2

L1

A2

A1Contacter

95

T3T2

T1

9897

96

Thermal

Overload

NO

T3T2

T1

NO

L3L2

L1

A2

A1Contacter

95

T3T2

T1

9897

96

Thermal

Overload

A2

1816

15B

1A

1Timer

Relay

A2

1816

15B

1A

1Timer

Relay

CB1/BLU

CB2/BLU

CB3/BLU

CB1/BLK

CB2/BLK

CB3/BLK

2T1/1

4T2/1

6T3/1

PE

TS2

TS3

CB1/BRN1

1

1

3

3

3

2

2

2

CB2/BRN

CB3/BRN

TS1

2T2/1

4T2/2

6T3/2

1L13L2

5L3

2T14T2

6T3

DCCurrentSensor

From

Grey M

12 Cab

les

To Tem

pSw

itch 1To

Temp

Switch 2

3 Phase

Disconect

DCCurrentSensor

NO

T3T2

T1

NO

L3L2

L1

A2

A1Contacter

95

T3T2

T1

9897

96

Thermal

Overload

NO

T3T2

T1

NO

L3L2

L1

A2

A1Contacter

95

T3T2

T1

9897

96

Thermal

Overload

A2

1816

15B

1A

1Timer

Relay

A2

1816

15B

1A

1Timer

RelayCB1/BLU

CB2/BLU

CB3/BLU

CB1/BLK

CB2/BLK

CB3/BLK

2T1/1

4T2/1

6T3/1

PE

TEMP1

TEMP2

CB1/BRN

CB2/BRN

CB3/BRN

2T2/1

4T2/2

6T3/2

1L13L2

5L3

2T14T2

6T3

DCCurrentSwitch

From

Breaker

To Pum

p Thro

ugh Po

wer Fast Q

uick Co

nnect

3 Phase

Disconect

DCCurrentSwitch

Jump

erJum

per

Jump

er

V-V-V-

V+

V-

Valve Signal

Valve Signal 2

Light

Relay 1

Switch 1

Light

Relay 2

Switch 2

3 PHA

SECO

NTRO

L VOLTA

GE

MULTI-SOURCE / DUAL PUMPHFI BOOSTER PUMP SECTION


FEED WATER CONNECTION**PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES

• Connectpre-runmainwatersupplylinetopumpinletwithhosesupplied.

• Singleoperatingpump:1”MNPT

• Dualoperatingpump:1-1/2”MNPT

START UP BOOSTER PUMPS

PUMP MUST BE PRIMED BEFORE OPERATION!WARNING!

1. FLUSHMakesurewatersupplytopumpisturnedon.Openball

valveanddirecttowardadrainorcontainertoremovethe

majorityoftheairfromthepumpuntilasteadystreamof

waterisflowing(approx. 1 min).Thenclosetheballvalve.

2. CHECK ROTATION OpenAqua-Lab™MotorControlUnit(MCU)andensure

3phasedisconnectison.(Note: Door will not open with

disconnect on. Use a 1/4” wrench or crescent wrench to turn

it back on after opening door.) (MCU with blue and black

Eaton disconnect can be opened without shutting off by

depressing button under switch handle. Press small button

with screw driver to bypass disconnect (Image 1).

!WARNING! - ELECTRIC SHOCK HAZARD. HIGH

VOLTAGE PRESENT INSIDE MOTOR CONTROL UNIT -

USE CAUTION!

Startthepumpmomentarilybydepressingthecenterofthecontactor(image 2).

a. Connect Powerfast Cordset on motor(s) to motor control unit.b. In the lower left of the enclosure, wire each leg of the incoming power to the terminals labeled 2T1, 4T2, and 6T3.

• Make sure to follow all applicable electrical codes.

c. Quick connect high temp shutdown switch.• Connect the high temp switch from the pump

assembly to MCU.

Image 1

Image 2



Image 5

Image 6Image 7

!WARNING! RUNNING THE PUMP BACKWARD WILL CAUSE CATASTROPHIC SYSTEM FAILURE! ENSURE THAT PUMP ROTATION IS CORRECT (image 3) asindicatedbythearrowonthecastingofthepumpandthat200psicanbereached.

• If pump cannot regulate to 200 psi, remove pump motor cover and look at shaft to confirm correct rotation.

• Verify pump inlet pressure remains positive when running.

3. CLOSE CABINET Turnon3phasedisconnect,ifhightempswitchispresent,pushtostart(Image 4).

4. PURGE BYPASSStartthepumpandslowlyopenballvalveuntilitiswideopen.Allowtorunfor60secondstoflushlinesandthenclosevalve.

5. CONNECT Connectthepumpoutletlinetothemanifoldandopenballvalve.

6. DOUBLE CHECKConfirmthatthepumpcanobtain200psiwhilefiringsolenoidsandthatthepumphousing(stainless steel tube)iscooltothetouchafteraminuteinoperation.

• If housing is hot or noisy, pump did not prime correctly.

• If pump does not prime, repeat steps 3-5.

• If not at 200 psi and the pump is correctly rotating you may need to adjust the bypass regulator to obtain 200 psi (Image 5).

Verifypumpprime24hoursafteroperationtoensureprimeheld.Paycloseattentiontothetemperatureofthepumpshaft,thewholestainlesssteelarea (Image 6)shouldbethesametemperature.Ifitstartsgettinghotterthanthesupplywaterorgreaterthan137°,thenitislikelythatthepumpdidnotprimecorrectlywhichWILL CAUSE DAMAGE TO PUMPS.Themotorhousing(paintedportion)willbehotduringoperation.

HFI BOOSTER PUMPHFI BOOSTER PUMP SECTION

******************(HFI supplied motor starter)******************

b. Connect the gray M12 cables hanging out of the motor starter box to port 8 “PUMP” on the black M12 junction boxes.

i. If you have more panels than gray wires from the MCU, connect the lose gray wires sent in the shipment into the same jumpers as the pre-wired gray cables. (This step must be completed for unit to function.)

c. Connect Powerfast Cordset on pump motor(s) to motor starter box.d. In the lower left of the enclosure, wire each leg of the incoming power to the terminals labeled 2T1, 4T2, and 6T3.

• Make sure to follow all applicable electrical codes.


HFI GRUNDFOS PUMP & VARIABLE FREQUENCY DRIVE (VFD)

Pump Power Cord, To Be Wired To VFD

Fan Fuses & Transformer

Fan Filter

Current Switch

VFD

M12 Connections To Junction Block

Gray Cord For Pressure Transducer

Motor Stool For Lifting

Pump Motor

Main Power Fuses

Fan

Incoming Power

ElectricDisconnect

Location For Pressure Transducer,

Temp Switch, Pressure Gauge.

(QTY 3: 1/4” FNPT)

Vent Cap To Prime pump

Embossed Arrow For Motor Direction

Pump Inlet (1.25” ID Hose For 20 GPM, 2” ID Hose For 40 GPM)

Pump Outlet (1/2” FNPT for 20 GPM, 1”

FNPT For 40 GPM)

Wye Strainer Screen (Inside Manifold,

Remove Plug To Clean Strainer Screen)

HFI GRUNDFOS PUMP SECTION

FOR PART NUMBERS & DIAGRAMS - SEE PAGES 34-35


S+S-

S+S+

S-S-

Jum

per

Jum

per

NCNCNC

OVOV

24V24V

204217

Jum

per

Ground

Jum

per

Curre

ntSw

itch

MAI

NSU1

W1

V1M

OTO

RU2

W2

V21

23

45

67

8

910

1112

1314

1516

Bloc

k 1Bl

ock 2

Powe

rFr

om F

uses

24 -

12 =

Cur

rent

Swi

tch

24 -

217

= Pr

essu

re T

rans

duce

r

24 -

204

= Te

mp

Switc

h or

Jum

per

Pum

p

Cap

Brow

n W

ire

Tran

sduc

er: B

rown

= 2

4VBl

ue =

217

Shiel

d =

Gree

n

Aqua

-Lab

Pane

l 1Aq

ua-L

abPa

nel 2

Opt

iona

lTe

mp

Switc

h

AC

WIR

ING

Shield

217

202204

OVOV

24V

VFD WIRING DIAGRAM(FOR FLOOR MOUNTED GRUNDFOS PUMP)


S+S-

S+S+

S-S-

Jum

per

Jum

per

NCNCNC

OVOV

24V24V

OVOV

24V

204217

Jum

per

Ground

Jum

per

Curre

ntSw

itch

MAI

NSU1

W1

V1M

OTO

RU2

W2

V21

23

45

67

8

910

1112

1314

1516

Bloc

k 1Bl

ock 2

Powe

rFr

om F

uses

24 -

12 =

Cur

rent

Swi

tch

24 -

217

= Pr

essu

re T

rans

duce

r

24 -

204

= Te

mp

Switc

h or

Jum

per

Pum

p

Cap

Brow

n W

ire

Tran

sduc

er: B

rown

= 2

4VBl

ue =

217

Shiel

d =

Gree

n

Aqua

-Lab

Pane

l 1Aq

ua-L

abPa

nel 2

Opt

iona

lTe

mp

Switc

h

217

Shield

204202

54

32

1

DC

WIR

ING


GREY M12 CABLE DIAGRAM TWO PANELS(SINGLE FLOOR MOUNT GRUNDFOS PUMP & VFD)

Gra

y W

ire

Hom

e Ru

n Ca

ble

Gra

y W

ire

VFD

To Car Wash Controller

To Power 3PH

Pressure Sensor Wire

Note: Not all gray wireswill be used.

Water InletWater Outlet

Pressure Sensor

Grundfos Pump

LOCREM ?

STOPS START



1. Slideinhexnutsfromplumbingoutletmanifoldintoslotsonpumphousing

2. Fastenoutletmanifoldtopumphousing.Torqueboltsto~40footpounds.Ensuregasketislocatedcorrectly.

3. Verifythatthepumpvoltagematchesthesitevoltagethatwillbesuppliedtopowerthepump.Thereisavoltagelabelonthepumpcordindicatingwhichvoltagethepumpiswiredfor.Motorsareratedfor+10%oftheratedvoltageonthemotornameplate.

4. RoutepowerfromsitetoVFDbox.MakesurethatthesitepowerbeingsuppliedmatchestheVFDvoltage. Note: Do not run pump power cord within 6 ft of sensitive electronics. Route in independent conduit to prevent signal interference.

5. RoutepumppowercordtoVFD.

6. Routewatertopump.

a. Note: for 40 GPM pump, do not plumb any elbows or bends within 20 inches of the pump inlet. b.Note: for 20 GPM pumps, do not plumb any elbows or bends within 13 inches of pump inlet.

7. RoutepumpoutlettoAqua-LabHD/XDpanel.

8. Primethepumpbylooseningtheventpluglocatedatthetopofthepump.Airwillpurgethroughtheventhole.Pumpisprimedoncewaterbeginstoflowoutofthevent.Tightenventcapplug. a. Disconnect closed ball valve at Hydra-Cannon inlet and point towards drain or into bucket and slowly open ball valve to flush water and any air that might be trapped in line. Close and re-connect.

Fasten outlet manifold to pump housing

Slide Nuts Into Frame

CAUTION: DO NOT APPLY 480V TO A 230VAC VFD.

Main Site Supply PowerWhite to L1, Red to L2, Black to L3

Pump Power CordWhite to U2, Red to V2, Black to W2,

Ground to Grounding screw

Loosen Priming Vent To Purge Air

Pump Is Primed Once Water Begins To Come Out. Close Vent By Tightening Plug

9. Attachgraypressuretransducercabletopressuretransducer.

10. AttachremaininggraysignalcordstoAqua-LabHD/XDM12junctionblockspositionssixand8B. a. Note: The VFD control box has 3 M12 junction block signal cables attached. If the system does not require all three cords, leave cords coiled up and ensure cable ends are capped.

(Threads Into outlet of Pump)

START UP(SYSTEMS WITH VFD & GRUNDFOS PUMPS):



11. EnsureVFDisintheREMModebyusingthekeypadonthefrontfaceoftheVFD.

12. SEE PAGE 13 FOR INSTRUCTIONS ON WIRING YOUR VFD. YOUR VFD MUST BE WIRED IN ORDER FOR YOU TO VERIFY ROTATION. Verify Correct Rotation (in REM MODE):Pulsethepumponandoffbysendingasignalfromthecarwashcontrollerforachemicalfunctiontoturnon.Examinethefanbylookingdownwardontothepump.Verifythatthefanisspinninginthesamedirectionasindicatedonthemotorcasting.

a. Look downward onto motor to verify fan is rotating in the correct direction.

b. Turn signal off when complete. If pump is rotating backwards, switch any two lines that connect VFD power to the pump, ie: Switch U2 with V2 as shown in the image above in section 5. CAUTION: DO NOT WORK INSIDE VFD BOX UNTIL 10 MINUTES AFTER POWER DOWN.

13. SendsignalfromcarwashcontrollertoAqua-Labpaneltoturnonpump,verifythat180-200PSIwaterissuppliedtotheAqua-Labpanel.Usetheupanddownarrowsonthekeypadtoincrease/decreasepressure.

Press loc/REM Button Until REM Is Shown In The Top Left Of Screen

Direction On Motor Casting Indicating Correct Direction

FAULTSTheVFDhasthefollowingfaultprotectionstokeepthepumpandsystemsafe.Seetablebelow.

FAULT TYPE FAULT CAUSE SCREEN READ OUT

Low Inlet Pressure(FAULT 42)

1. No water supplied to pump inlet.2. Blown fuse on incoming power supply.3. Panel flow set up exceeds pump

performance curve (reduce injector sizes).4. Hose rupture.5. Pump running at low pressure for more

than 1 minute.

High Temperature(FAULT 14)

1. If temperature switch is wired in and the temperature exceeds switch set point, the temperature switch will fault out.

2. If the temperature switch is not installed make sure that there is a solid jumper between terminal block 24V and terminal block 204.

LOCREM ?

STOPS TART

LOC FAULT

INLET LOWRESET EXIT

FAULT 42

LOCREM ?

STOPS TART

REM FAULT

EXT FAULT 1RESET EXIT

FAULT 14

VFD MODESRemote Mode:ThistakesasignalfromacarwashcontrollertoturnonachemicalfunctionwhichtheninitiatestheVFDtostartthepump.TouseREMmode,presstheloc/rembuttonontheleftofthekeypaduntilREMappearsonthetopleftofthescreen.Sendasignalfromthecarwashcontrollertoactivatethepump.Usetheupanddownarrowsonthekeypadtoincrease/decreasepressure.

SAFETYCAUTION: WAIT 10 MINUTES AFTER POWERING DOWN THE VFD BEFORE

WORKING INSIDE THE BOX. THE VFD CONTAINS LARGE CAPACITORS AND 10 MINUTES IS NEEDED TO ALLOW THE CAPACITORS TO SAFELY DISCHARGE.



(Based on field experience this is HFI’s recommended starting point)1. Usingtherecommendedstartingpoint(Page28)orthetargetflowrateandthechemicaldilutions

chart(appendixPage27)installtheappropriateinjectorintoeachport.

2. Connectpre-runsolutionlinestoeachinjectorwiththesuppliedcouplerandpushconnectfitting.

a. Be sure to use Teflon tape when connecting the injector to the coupler and push connect fitting to ensure there are no leaks.

b. Do not over tighten poly fittings or they may crack.

3. Connect¼”polylinesfromeachchemicalcontainertothehosebarbontheappropriateinjector. a. Ensure a foot valve or similar check valve/filter is installed on each line.

i. These must be present or metering tips may clog.4. Meteringtipswillneedtobeinstalledtosetdilutionratio(seeappendixPage27forratiochartsto

determinetip.)

INITIAL INJECTOR SETUP

YourAqua-LabHD/XDpanelwasdesignwith Tri-Foamcapabilitythebelowinstructionswill showyouhowtosetupyourtriplefoam.

• Yourtriplefoamhasbeensetupfromthe factorytobeinthelastport(furthestright).

• Insertyourtriplefoammanifoldintothatpositionwithyourselectedinjectorsalreadyinserted.

• Onthetopsideofthepaneltheregulatorswillcontroltheairtoeachofyourtriplefoamcolors.

• Insertyourairlinestothearchintothe bulkheadfittingsonthesideofthepanel.Thebulkheadwillbetheairlinesforeachcolor.

Note: Occasionally if all three regulators are pre-set too high, you may need to lower all three regulators to their lowest setting and then turn them up to the desired pressure.

TRIPLE FOAM SETUP

APPENDIX

AB

C

AB

C


What do metering tips do?• Increasesordecreasestheamountof

chemicalinthesolution.

What do nozzles do?• Determinesthepatternandbackpressure

ofthesolution.

APPLICATION OPTIMIZATION(REPEAT FOR EACH APPLICATION)• Application too wet

• Increase foaming air pressure• Reduce injector size (decreases water)• Increase metering tip (increases

chemical)

• Application too dry• Decrease foaming air pressure• Increase injector size (increases water)• Decrease metering tip (decreases

chemical)

• Nozzle sputters• Decrease foaming air pressure• Decrease number of nozzle(s) and/or

size used on arch• Increase injector size (increases water)

• Too much chemical used• Decrease metering tip• Decrease metering tip and injector

size (to maintain desired ratio)

OPTIMIZING THE SYSTEMCONSISTENTLY ACHIEVE THE DESIRED CLEANING AND PRESENTATION/PERFORMANCE USING THE LEAST AMOUNT OF CHEMICAL AND WATERINJECTORS VS. METERING TIPS VS. NOZZLESTHE KEY TO OPTIMIZING THE SYSTEM IS THROUGH TRIAL AND ERROR. DON’T BE AFRAID TO TRY THESE STEPS TO ACHIEVE YOUR IDEAL PERFORMANCEWhat do injectors do?

• Increasesordecreasestheamountofwaterinthesolution.

• No chemical • Check vacuum/back-pressure of

injector for clogging (see page 26 for Injector Vacuum Check Instructions or page 23 for troubleshooting)

• Check foot valve• Check metering tip

• Nozzle fan pattern not filled• Reduce nozzle size• Increase injector size (increases water)

• Water not present at all nozzles on arch• Verify check valves are functioning• Verify nozzles are not plugged• Reduce number of nozzles• Reduce nozzle size• Increase injector size (increases water)

NOZZLE SETUP(Optional For Maximized Optimization)

• Usingtherecommendedstartingpoint(appendixpage28)installtherecommendednozzles.• Thismayinvolveremovingandpluggingsomeports.• DuetothelowerwaterusagedeterminedbytheinjectoroftheAqua-Labyouwillneedto

matchtheflowoftheapplicationdevicetotheinjector.• Setupthenozzlespraypatternsto“paint”thecar-slightlyoverlappingeachother.


MINIMUM NUMBER OF NOZZLES NECESSARY WITH FOAMING AIR(Assuming <10 PSI line loss and ~ 40 PSI at the nozzle)

SPRAY NOZZLE SIZE# 2.0 # 3.0 # 4.0 # 5.0 # 6.0 # 7.0 # 8.0 # 9.0 # 10.0

0.25 4 2 2 1 1 1 1 1 10.50 8 5 4 3 2 2 2 1 10.75 13 8 6 5 4 3 3 2 21.0 17 11 8 7 5 5 4 3 31.5 26 17 13 10 8 7 6 5 52.0 35 23 17 14 11 10 8 7 7

2.25 39 26 19 15 13 11 9 8 73.25 56 37 28 22 18 16 14 12 115.5 96 64 48 38 32 27 24 21 198.0 140 93 70 55 47 39 35 31 2810 175 116 87 69 58 49 44 38 3512 209 140 105 83 70 59 52 46 4115 262 175 131 104 87 74 65 57 52

INJE

CTO

R FL

OW

RAT

E @

200

PSI

(GPM

)

MINIMUM NUMBER OF NOZZLES NECESSARY WITHOUT FOAMING AIR(Assuming <10 PSI line loss and ~ 40 PSI at the nozzle)

SPRAY NOZZLE SIZE# 2.0 # 3.0 # 4.0 # 5.0 # 6.0 # 7.0 # 8.0 # 9.0 # 10.0

0.25 1 1 1 1 1 1 1 1 10.50 2 1 1 1 1 1 1 1 10.75 3 2 1 1 1 1 1 1 11.0 5 3 2 2 1 1 1 1 11.5 7 5 3 3 2 2 1 1 12.0 10 6 5 4 3 2 2 2 22.25 11 7 5 4 3 3 2 2 23.25 16 10 8 6 5 4 4 3 35.5 27 18 13 11 9 7 6 6 58.0 39 26 19 16 13 10 9 9 7

10.0 49 33 24 20 16 13 11 11 912.0 59 39 28 24 20 15 13 13 1115.0 74 49 35 30 25 19 16 16 14

INJE

CTO

R FL

OW

RAT

E @

200

PSI

(GPM

)

Elbows/Pipe Fittings• Elbowsandotherpipefittingsaddbackpressurebycausingthefluidtochangedirectionand

thuschangingthefluid’smomentum.Trytofindsimplerwaystorouteyourfluidwithoutelbows.

Line Length• Longerlinesaddbackpressureduetotheinherentresistancecausedbyfriction.Seeifyoucan

reducethelinelengthorincreasetheinsidediameter.

CHEMICAL USAGE MEASURINGVERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING1. Setuplabscalewithsmallbucketofchemicaltobemeasured.

2. Putthesuctionlineintothebucket.

3. Runtheapplicationbeingtestedto“prime”theline.(Allairbubblesmustberemovedforaccuracy.)

4. RecordtheInitial Weight fromthescale.(Taringthescalewithweightonthescalecanaffectaccuracy.)5. Runtheapplicationfor1vehicle(ormanuallyforthesameamountoftimeitwouldbeonfor1

vehicle).

6. RecordtheFinal Weightfromthescale.7. SubtracttheInitialWeightfromtheFinalWeighttodeterminetheweightofusedproduct.

8. DividethePer Car Weightingramsbythespecificgravityofthechemicaltodeterminethemillilitersofchemicalusedpervehicle.

9. Repeatforeachchemicalapplication.

0

8

16

24


RECOMMENDED MAINTENANCETHE RECOMMENDED SERVICE AND MAINTENANCE ON THE AQUA-LAB SYSTEM ARE AS FOLLOWS. Monthly

• Check/drainprimaryairregulator/filterseparator.• Checkwaterfilterandreplaceasneeded(ifinstalled).• Checkandcleanwyestrainer.

Semi-Annually• Checkandreplaceinjectormeteringtips.• Inspectandreplacechemicallinesasneeded.• Ensurelinesaretightlysecuredtoinjectorhosebarbs,clip1”offoldhoseasneededthatwas

stretchedbyhosebarb.

Annually• Cleanwaterregulator.• Inspectmotorstarterforcorrosion,ifidentifiedorderreplacement/spareparts.

1-3 Years• Inspectandreplaceinjectors.• Replacewatervalves.• Replacemainpressureregulator.

AIR OPERATED VALVE REPLACEMENT1. ShutofftheballvalvetoHydra-Cannonmanifold.2. Disconnectairlinefromfrontofvalve.3. Unscrewquickconnectfittingbyhand(DO NOT LOSE BLACK WASHER).4. UnscrewvalveassemblyfromtheHydra-Cannonmanifold.5. Screwnewvalveintomanifolduntilhandtightandthreadedpilotportis

facingforward.6. Removethecapfrompilotportandthreadinquick

connectfittingtofrontofvalve–HAND TIGHT ONLY.7. Pushairlinebackintofitting.8. OpentheballvalvetotheHydra-Cannonmanifold.

BAM VALVE REPLACEMENT1. ShutoffthewatersupplyballvalvetotheBAMmanifold.2. Disconnectairlinefromfrontofmanifold.3. Removespringclipsfromassemblythatareadjacenttovalvebeingreplaced.4. Unboltvalveassemblyfromthepanel.5. Removevalvefromassembly.6. Installnewvalveintoassemblyensuringcorrectorientation.7. Reinstallspringclipsandboltvalveassemblytopanel.8. Pushairlinebackintofitting.9. OpenthewatersupplyballvalvetotheBAMmanifold.

Unscrew from manifold using this portion of valve


INJECTOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONSInjector Is Not Drawing Chemical - Passes Vacuum Pressure Check Cloggedchemicalfeed

Checkchemicalhose,footvalve,meteringtip,andhosebarbfordebrisorclogs.

No Flow From InjectorValvemalfunction,valvenotopening

Ensureminimum60psionprimaryairregulator,ensurevalvereceivingsignal.

Cloggedinjector Removeinjectorandblowoutdebriswithcompressedair.

Nowatersupply Checkthatthesystemhasasupplyofwater.

Injector Is Not Drawing Chemical - Fails Vacuum Pressure Check

ToomuchbackpressureoninjectorCleanorreplacedownstreamcheckvalves,increasenozzlesizeorquantity,uselargertubing,orusesmallerflowinjectors.

CloggedinjectorcheckvalveBlowcompressedairthroughthechemicalhosebarbontheinjectortoremovedebris.

Cloggedinjectornozzle Removeinjectorandblowoutanydebriswithcompressedair.

Defectiveinjector Replaceinjector.

Productspecific-Sonny’sRainBar Removeelbowatinlettofoamgeneratorandremovenozzle.

Manifoldinletclogged(rare)Removeendfittingsandretentionrod.Cleanoutinletholestoallowfullflow.

Injector stainless steel disintegrating Stronghydrofluoricacid CallHydra-Flexandordercompositeversionofinjectors.

PUMP ISSUESTROUBLESHOOTING

PROBLEM POTENTIAL CAUSES SOLUTIONS

Pump Operates, But Only Delivering 100-150 Psi Incorrectmotorrotation Reverserotationbyinterchangingtwoleads.

Pump Operates, But Delivers Little Or No Water

Pumpnotprimed Seepriminginstructions.

Missing1of3phases Wireaccordingtodiagram/checkbreaker(turnoffonback).

InadequatewatersupplyCheckpressureoninletsideofpumptobesurepositivepressureismaintained.

Undersizedpiping Replacewithlargerpiping.

Leakontheinletside Makesureconnectionsaretight.

Wornordefectivepumpparts Replacewornpartsorentirepump,cleanpartsifrequired.

Overheat Light OnInlettemptoohigh

Reduceinlettempto110°FMax,injectorflowto10GPMmax.

Injectorflowtoolow Increasecontinuousflowtoatleast3/4GPM.

Pump Will Not Start Or Run AtFull Speed

ConstanthotnotconnectedMakesureconstantcontrolvoltageissuppliedincarwashcontroller.

Blownfuseorcircuitbreaker

Couldbeduetoblownpumpmotor.Trytoturnbreakerbackonorreplacefuse.Ifbreakertripsaftertryingtofiremotoritismostlikelyburnedout.Replacewithnewmotorandpump.

Defectivemotorstartercontactor Replacemotorstartercontactor.

Thermaloverloadsettoolow/tripped Adjustsettingonthermaloverloadtomatchvoltage.

IncorrectmotorvoltageVoltagemustbewithin10%ofmotorratedvoltage.(Checkthatpumpiswiredforcorrectvoltage.)

Defectivemotor Replacemotor.

3phasedisconnectturnedoff Turndisconnecton.

Pumpcomponentsdamaged Replacewornpartorentirepump.

CurrentSensornotseeinganycurrent

Turnononevalveandverifyredlightblinksfast,verifyatleast10wrapsofwirearoundcurrentsensor.


FLOW / ARCH ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS

Flow At Arch Is Too Low

Incorrectinjectorflowrateselection

Replacewithlargerinjector

Systempressuretoolow Ensuresystempressureissetat200psi

Foamgeneratorplugged Ensurecleanedandclear

DownstreamplumbingrestrictiveIncreasesizeofplumbing/tubing,ensurecheckvalvesarecleanedornew,reduceelbowsinlineorotherturnsthatwouldrestrict

VALVE ISSUES

VFD ISSUES


Valve Will Not Open

AirpressuretoolowEnsureprimaryairregulatorreadingatleast60psi,turnupto80-90psiifpossibleandcheckagain.

Internalvalveo-ringjammed/twisted

Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallallenwrenchfromoppositeendandchecko-ringcondition.Replaceandlubricateifneeded.

Valve Leaks Air Or Water Out Top

Internalo-ringsealdamaged/worn

Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallscrewdriverfromoppositeendandchecko-ringcondition.Replacewith018&008VitonO-ringandlubricatewithDow111valvelube.

Valve Remains Open After Signal Is Off

Manifoldpressureisabove230psi Reducepressuretomanifoldto200psioperatingpressure.

Airexhaustmufflerisclogged Replaceexhaustmuffler.


Low Inlet Pressure (FAULT 42)Valve Leaks Air Or Water Out Top

Nowatersuppliedtopumpinlet. Verifywatersuppliedtopumpissufficient.

Blownfuseonincomingpowersupply.

Confirmcorrectelectricalsupplyandconnections.

Panelflowsetupexceedspumpperformancecurve.

Ensuretotalinjectorflowislessthanpumpsystemcanprovide.Reduceinjectorsize(s)ifneeded.

Waterpressureislessthan100psiforlongerthan1minute.

Checksystemforleaksorrupturedhoses.

High Temperature (FAULT 14)

Iftemperatureswitchiswiredinandthetemperatureexceeds180°F,thetemperatureswitchwillfaultout.

Ensureinletwatertemperatureislessthan140°F.

Ifatemperatureswitchisnotinstalled,falsesignaltoVFD.

Ensureasolidjumperbetweenterminalblock24Vandterminalblock204inthecontrolbox.

PRESSURE REGULATOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS

System Won’t Regulate Up To 200 Psi

Pumpnotprimed Followpriminginstructions.

Debrisinregulator Removeregulatorandcleanoutdebris.

Motorrotationincorrect Verifyrotation/switch2leads.

OpeningtoomanyvalvesatonceSystemislimitedbysizeofpumpandsizeofinjectors,increaseflowbyaddingsecondarypumpsorreducesize/numberofinjectorsopen.

Defectivecheckvalve(ifapplicable) Replacecheckvalve.

DefectiveRegulator Replaceregulator.

DefectivePump ReplacePump.

PressureTransducerissetincorrectlyorisbroken

RefertoPumpManualtoverifytransducersettingorreplacetransducer.

PressureTransducercableislooseordamaged

Ensuregoodconnectionsorreplacecable.


STEPS:1. Plugtheoptimizationtoolintothe

outletlineofinjectorandconnectsolutionoutputline.

2. TurnonfunctionfromcarwashcontrollertoactuateHydra-Cannonvalvesuchthatfluidisflowingthroughboththeinjectorandinjectoroptimizationtoolandouttotheapplicator.

3. Readinjectoroptimizationtool.

4. Ifthegaugeisinthe“RED ZONE”thebackpressureoftheoutletlineiseithertoolowortoohigh.Seestepsbelowtocorrect. Solution

Output Line

Hydra-Cannon Valve

Injector Optimization Tool

Injector

Chemical Draw Line

Chemical Bucket

BACKGROUND:ThistoolisforinitialsetupandtroubleshootingofChem-Flex™InjectorsandanAqua-LabHD/XDChemicalDispensingSystem.Inorderfortheinjectortoworkproperlyanddrawchemicalthisgaugemustbeinthe“GREEN”sectionwheninstalledimmediatelyafteraninjectorthatisrunning.Ifthegaugeisintheredyouwilleithersee:intermittentchemical,nochemicaldraw,orchemicalbeingappliedataverylowpressure.

Backpressurereferstothepressureinthesolutionoutputline.Excessivebackpressureisthemainreasonthatinjectorswillnotdraw.Ifthereiseveranyconcerntowhyaninjectorisnotdrawingchemical,thebestandeasiestwaytodiagnosetheproblemistocheckthebackpressure.Seeinstructionsbelow:

INJECTOR OPTIMIZATION TOOL

BACK PRESSURE TOO HIGH (UPPER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)

1. Foamgeneratorsareclogged/degraded.Cleanorreplacemediaingenerator.2. Injectorflowsizeistoolarge.Godownaninjectorsize(lessGPM).3. Nozzlesizeonthearchistoosmall.Goupinnozzlesize.4. Checkvalvesaredirtyandorfailing.Cleanorreplacecheckvalves.5. Thereisakinkinthelineorexcessfittings(elbowsandreducersincreasethebackpressure).

Checklineandreplaceanykinkedsections.Trytoreducefittings.6. IDoftubinggoingouttothetunnelistoosmall.Goupasizeininsidediameter.7. Checkvalveshavetoohighofcrackingpressure.Replacecheckvalvewithlowerpressurecheckvalve.8. Cleanfootvalve.

BACK PRESSURE TOO LOW (LOWER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)

1. Injectorflowtoolow.Increaseinjectorsize.2. Nozzlesizetoolarge.Reducenozzlesize.


INJECTOR VACUUM CHECK

C

B

(FOR TROUBLESHOOTING INJECTORS) 1. AttheChem-Flexinjector,removethechemicalfeedlinefrom

theinjectorhosebarb.

2. AttachthetubingofthevacuumgaugetotheChem-Flexhosebarb(ImageA).

3. Withthepump(s)on,manuallyactivatethechemicalthatistobetestedatthemaincarwashcontrolcabinet.Aninjectorthatisworkingproperlywillhaveareadinggreaterthanorequalto(≥) 20inHg.

4. Ifvacuumreads<20in/Hg(imageB),removesolutionmetering tip(imageC)andretest. a. If retest vacuum reads >20 in/Hg (image D), The solution metering tip is clogged. Replace the metering tip. b. If Retest vacuum reads <20 in/Hg, continue to STEP 5

5. Removeanozzleonthearchorthechemicalfeedlinefromthefoamgeneratorandretestvacuum. a. If retest vacuum reads >20 in/Hg, back pressure is being created. Continue to STEP 6. b. If back pressure is not still not being created try these steps and retest after each:

1. Clean nozzle tips. 2. Loosely replace media in foam generator. Do not over pack. 3. Decrease air pressure for foaming. 4. Try smaller injector (this will produce less flow and thus less back pressure).

c. If retest vacuum reads <20 in/Hg, replace injector and retest. If vacuum continues to read <20 in/ Hg, call your service provider.

6. Repeatsteps2-5foreachchemicallanethatavacuumreadingisneededfor.

7. Oncetestingiscomplete,turnofftheAqua-LabHD/XDpumpfromthemaincarwashcontrolcabinet.

A

D

HFI MCU HIGH TEMP SHUTDOWN RESTART INSTRUCTIONS1. Closeballvalveonpanelandquickdisconnecthigh

pressurewaterline.

*** Purge pressure before disconnecting (pressure gauge to read 0 PSI before disconnecting).2. Pointhosetodrainandopenballvalvetopurgehotwater

andcoolpumpforseveralminutes(USECAUTION).

3. Whenpumpissufficientlycooledcloseballvalve,reconnecthose,openballvalveandpressredbuttononMCUtorestart.

4. Determinewhysystemoverheated.Seemanualfortroubleshooting(page22Overheat Light On)

1.

2.

3.


CHEM-FLEX INJECTORS - CHEMICAL DILUTION RATIOS

3.00

”1:

251

1: 5

031:

754

1: 1

006

1: 1

509

1: 2

012

1: 2

263

1: 2

416

1: 2

460

1: 2

628

1: 4

526

1: 5

532

1: 8

047

1: 1

0059

1: 1

2070

1: 1

5088

2.00

”1:

181

1: 3

631:

544

1: 7

261:

108

91:

145

11:

163

31:

140

21:

133

71:

151

01:

326

61:

399

11:

580

61:

725

71:

870

81:

108

85

1.00

”1:

104

1: 2

081:

311

1: 4

151:

623

1: 8

311:

934

1: 8

351:

778

1: 8

981:

186

91:

228

41:

332

21:

415

31:

498

31:

622

9

0.75

”1:

82

1: 1

651:

247

1: 3

291:

494

1: 6

591:

741

1: 6

421:

668

1: 7

551:

148

31:

181

21:

263

61:

329

51:

395

41:

494

2

0.50

”1:

59

1: 1

191:

178

1: 2

381:

357

1: 4

751:

535

1: 4

871:

496

1: 5

581:

106

91:

130

71:

190

11:

237

61:

285

21:

356

4

0.25

”1:

34

1: 6

81:

102

1: 1

361:

204

1: 2

721:

306

1: 2

821:

304

1: 3

441:

612

1: 7

481:

108

81:

136

01:

163

21:

204

0

Spiral Plug Length

#8

-32

MET

ERIN

G T

IPS

Flow

Rat

e(G

PM) a

t 200

PSI

0.25

0.50

0.75

1.00

1.50

2.00

2.25

3.00

3.25

3.75

4.50

5.50

8.0

10.0

12.0

15.0

Inje

ctor

Col

orW

hite

Yello

wTa

nRe

dO

rang

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ray

Blue

Ligh

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ght

Gre

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k G

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Blac

kBl

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Blac

kBl

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Noz

zle

Size

0.02

9”

(0.7

mm

)0.

040”

(1.0

mm

)0.

051”

(1.3

mm

)0.

057”

(1.4

mm

)0.

070”

(1.8

mm

)0.

083”

(2.1

mm

)0.

086”

(2.2

mm

)0.

095”

(2.4

mm

)0.

098”

(2.5

mm

)0.

106”

(2.7

mm

)0.

117”

(2.9

mm

)0.

125”

(3.2

mm

)0.

161”

(4.1

mm

)0.

117”

(4.5

mm

)0.

186”

(4.7

mm

)0.

207”

(5.3

mm

)

CO

PPER

1: 5

71:

104

1: 1

551:

195

1: 2

811:

406

1: 4

681:

598

1: 6

291:

739

1: 8

811:

107

41:

201

91:

231

81:

332

41:

425

9

PUM

PKIN

1: 4

31:

82

1: 1

191:

126

1: 2

381:

348

1: 3

981:

519

1: 5

541:

647

1: 7

741:

946

1: 1

465

1: 1

832

1: 2

310

1: 3

042

BURG

UN

DY

1: 3

41:

67

1: 9

71:

111

1: 2

071:

304

1: 3

471:

461

1: 4

951:

575

1: 6

901:

845

1: 1

244

1: 1

670

1: 1

975

1: 2

469

LIM

E1:

28

1: 5

71:

81

1: 1

001:

183

1: 2

701:

307

1: 4

141:

447

1: 5

181:

622

1: 7

641:

988

1: 1

262

1: 1

481

1: 1

958

TAN

1: 2

81:

57

1: 8

11:

100

1: 1

831:

270

1: 3

071:

414

1: 4

471:

518

1: 6

221:

764

1: 8

261:

104

21:

128

61:

155

7

ORA

NG

E1:

23

1: 4

41:

64

1: 7

81:

137

1: 1

961:

215

1: 2

931:

314

1: 3

651:

437

1: 5

361:

751

1: 8

741:

113

61:

126

2

TURQ

UO

ISE

1: 1

71:

31

1: 4

51:

55

1: 9

11:

126

1: 1

341:

185

1: 1

971:

230

1: 2

741:

336

1: 5

611:

752

1: 8

851:

109

9

PIN

K1:

14

1: 2

41:

35

1: 4

21:

68

1: 9

31:

98

1: 1

301:

143

1: 1

591:

188

1: 2

241:

372

1: 4

731:

570

1: 7

28

LIG

HT

BLU

E1:

11

1: 1

71:

24

1: 3

11:

47

1: 6

41:

66

1: 9

31:

98

1: 1

141:

136

1: 1

661:

318

1: 4

061:

483

1: 5

72

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1: 1

01:

15

1: 2

21:

28

1: 4

31:

58

1: 5

91:

84

1: 8

81:

103

1: 1

221:

150

1: 2

701:

338

1: 4

081:

507

RED

1: 1

21:

17

1: 2

31:

34

1: 4

51:

46

1: 6

51:

69

1: 8

01:

95

1: 1

161:

202

1: 2

541:

306

1: 3

75

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ITE

1: 1

21:

16

1: 2

21:

31

1: 4

21:

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1: 6

11:

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1: 7

41:

88

1: 1

081:

180

1: 2

261:

272

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43

GRE

EN1:

11

1: 1

41:

20

1: 2

81:

37

1: 3

81:

53

1: 5

51:

65

1: 7

61:

94

1: 1

601:

201

1: 2

411:

300

BLU

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10

1: 1

21:

17

1: 2

31:

30

1: 3

11:

44

1: 4

61:

53

1: 6

31:

77

1: 1

221:

152

1: 1

851:

224

YELL

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1: 9

1: 1

21:

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1: 2

01:

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1: 3

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1: 3

61:

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1: 5

21:

80

1: 1

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120

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1: 1

01:

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1: 1

61:

17

1: 2

31:

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1: 2

81:

33

1: 4

01:

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1: 7

71:

92

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15

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91:

10

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31:

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51:

17

1: 2

11:

31

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91:

46

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1: 6

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7.6

1: 8

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10

1: 1

21:

15

1: 1

81:

23

Metering TipNO

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)


RECOMMENDED SETUP STARTING POINTS

FoamingAir:Startat25PSI(adjustbasedonuniqueapplication)

PC2 INJECTOR PART NUMBERS

Foroptimalperformance,matchtheflowoftheinjectortotheflowofthenozzlesorapplicator.Thismayinvolvechangingnozzlesand/orremovingorpluggingsomeports.Seebelowforrecommendedsetupstartingpoints.

APPLICATOR INJECTOR(S) PART NUMBER/COLORScentDispenser (1.0 GPM) (3.8 LPM)

CTANozzles(ForShowerhead,SeeBelow) (1.0 GPM) (3.8 LPM)

FoamStick (1.5 GPM) (5.7 LPM)

Mitter/WrapNozzles (1.5 GPM) (5.7 LPM)

Undercarriage/RustInhibitor (2.0 GPM) (7.6 LPM)

VJetOrFlatFanNozzleArch (2.25 GPM) (8.5 LPM)

K12NozzleArch (2.25 GPM) (8.5 LPM)

K15NozzleArch (3.25 GPM) (12.3 LPM)

HockeyPuck1 Row Of Holes

(0.75 GPM) (2.8 LPM)2 Rows Of Holes


(1.5 GPM) (5.7 LPM)

Showerhead1 Row Of Holes



(2.0 GPM) (7.6 LPM)

Rain Bar1 Row Of Holes



(5.5 GPM) (20.8 LPM)

LowFlowFoamCurtain-ChooseFoamAccessoryBasedOn#OfInputs/FoamGenerators

Duo-Foam With (2X)(3.25 GPM) (12.3 LPM)

Triple-Foam With (3X)(2.25 GPM) (8.5 LPM)

HighFlowFoamCurtainApplication-WorksWithUpTo4Inputs/FoamGenerators

(8.0 GPM) (8.5 LPM) With Distribution Manifold

(XD, HD)


(XD, HD)


(XD, HD)

INLET CONNECTION PC2* (QUICK-CONNECT)

OUTLET CONNECTION 3/8” MNPT

FOR USE WITH AQUA-LAB MODEL(S) MD, XD, HD

COLOR FLOW ORIFICE FLOW RATE @ 200 PSI (14 bar) SINGLE BARB DUAL BARB

White 0.029” (0.74 mm) 0.25 GPM (1.0 LPM) 618029 -

Yellow 0.040” (1.02 mm) 0.50 GPM (1.9 LPM) 618040 629040

Tan 0.051” (1.39 mm) 0.75 GPM (2.8 LPM) 618051 629051

Red 0.057” (1.45 mm) 1.00 GPM (3.8 LPM) 618057 629057

Orange 0.070” (1.78 mm) 1.50 GPM (5.7 LPM) 618070 629070

Gray 0.083” (2.11 mm) 2.00 GPM (7.6 LPM) 618083 629083

Dark Blue 0.086” (2.18 mm) 2.25 GPM (8.5 LPM) 618086 629086

Light Blue 0.095” (2.41 mm) 3.00 GPM (11.3 LPM) 618095 629095

Light Green 0.098” (2.49 mm) 3.25 GPM (12.3 LPM) 618098 629098

Pink 0.106” (2.69 mm) 3.75 GPM (14.2 LPM) 618106 629106

Purple 0.117” (2.98 mm) 4.50 GPM (17.0 LPM) 618117 629117

Dark Green 0.125” (3.18 mm) 5.50 GPM (20.8 LPM) 618125 629125


Max Pressure Inlet / Outlet Up to 250 PSI (17 bar)

Temperature Range 33°F - 140°F (.5°C - 60°C)

Maximum Wrench Torque (PC2) Hand Tighten Only (30 in-lbs)

Maximum Wrench Torque (PC3) Hand Tighten Only (60 in-lbs)

INLET CONNECTION PC3*

OUTLET CONNECTION 3/4” MNPT

FOR USE WITH AQUA-LAB MODEL(S) XD, HD

COLOR FLOW ORIFICE FLOW RATE @ 200 PSI (14 bar) SINGLE BARB

Black 0.161” (4.09 mm) 8.00 GPM (30.3 LPM) 818161

Black 0.177” (4.50 mm) 10.0 GPM (37.9 LPM) 818177

Black 0.186” (4.72 mm) 12.0 GPM (45.2 LPM) 818186

Black 0.207” (5.30 mm) 15.0 GPM (56.8 LPM) 818207

SPECIFICATIONS

*For exclusive use with Aqua-Lab Chemical Dispensing Systems.

PC3 CHEM-FLEX INJECTOR PART NUMBERS

*For exclusive use with Aqua-Lab Chemical Dispensing Systems.

Max Pressure InletNPT up to 1000 PSI (69 bar)

PC2 up to 500 PSI (34 bar)

Max Pressure Outlet 333 PSI (23 bar)

Temperature Range 33°F - 175°F (.5°C - 79°C)

Maximum Wrench Torque 30 ft-lbs (41 N-m)

SPECIFICATIONS

PRESSURE LOSS IN RUN LENGTH

All solution line tubing should be selected for 10 PSI or less of pressure loss.*20 PSI pressure loss may be acceptable depending upon nozzle sizing, foamers, check valves and other line restrictions present in application.All numbers represent pressure loss in PSI for selected solution line tubing.

GREEN = GOOD YELLOW= USE CAUTION RED = NOT RECOMMENDED

5/8” ID BRAIDEDINJECTOR

Flow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50

Injector Color White Yellow Tan Red Orange Gray DarkBlue

LightBlue

Light Green Pink Purple Dark

Green

Nozzle Size 0.029”(0.7 mm)

0.040”(1.0 mm)

0.051”(1.3 mm)

0.057”(1.4 mm)

0.070”(1.8 mm)

0.083”(2.1 mm)

0.086”(2.2 mm)

0.095” (2.41 mm)

0.098”(2.5 mm)

0.106” (2.69 mm)

0.117”(2.9 mm)

0.125”(3.2 mm)

150’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 6 PSI 7 PSI 9 PSI 13 PSI* 18 PSI*125’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 8 PSI 11 PSI* 16 PSI*100’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 9 PSI 13 PSI*75’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 3 PSI 4 PSI 5 PSI 7 PSI 9 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 3 PSI 5 PSI 6 PSI25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI

Run

Leng

th


INJECTORFlow Rate (GPM) at 200 PSI 8.0 10.0 12.0 15.0

Injector Color Black Black Black Black


0.177”(4.50 mm)

0.186”(4.72 mm)

0.207”(5.26 mm)

100’ 10 PSI 15 PSI* 21 PSI 32 PSI75’ 8 PSI 11 PSI* 16 PSI* 24 PSI50’ 5 PSI 8 PSI 11 PSI* 16 PSI*25’ 3 PSI 4 PSI 6 PSI 8 PSIRu

n Le

ngth

3/4” ID BRAIDED

INJECTORFlow Rate (GPM) at 200 PSI 8.0 10.0 12.0 15.0

Injector Color Black Black Black Black


0.177”(4.50 mm)

0.186”(4.72 mm)

0.207”(5.26 mm)

100’ 3 PSI 4 PSI 5 PSI 8 PSI75’ 2 PSI 3 PSI 4 PSI 6 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI25’ 1 PSI 1 PSI 2 PSI 2 PSIRu

n Le

ngth

1” ID BRAIDED

1/2” ID BRAIDED

3/8” ID, 1/2” OD POLY TUBE

INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50

Injector Color White Yellow Tan Red Orange Gray Blue LightBlue

LightGreen Pink Purple Dark

Green


0.040”(1.0 mm)

0.051”(1.3 mm)

0.057”(1.4 mm)

0.070”(1.8 mm)

0.083”(2.1 mm)

0.086”(2.2 mm)

0.095” (2.41 mm)

0.098”(2.5 mm)

0.106” (2.69 mm)

0.117”(2.9 mm)

0.125”(3.2 mm)

150’ 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 9 PSI 11 PSI* 18 PSI* 21 PSI 27 PSI 36 PSI 56 PSI125’ 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 8 PSI 9 PSI 15 PSI* 18 PSI* 23 PSI 30 PSI 47 PSI100’ 1 PSI 1 PSI 2 PSI 2 PSI 4 PSI 7 PSI 8 PSI 12 PSI* 14 PSI* 18 PSI* 24 PSI 36 PSI75’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI 9 PSI 11 PSI* 14 PSI* 18 PSI* 26 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 4 PSI 4 PSI 6 PSI 8 PSI 9 PSI 12 PSI* 18 PSI*25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 4 PSI 5 PSI 6 PSI 9 PSI

Run

Leng

th

INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.00 3.25 3.75 4.50 5.50

Injector Color White Yellow Tan Red Orange Gray Blue LightBlue

LightGreen Pink Purple Dark

Green


0.040”(1.0 mm)

0.051”(1.3 mm)

0.057”(1.4 mm)

0.070”(1.8 mm)

0.083”(2.1 mm)

0.086”(2.2 mm)

0.095” (2.41 mm)

0.098”(2.5 mm)

0.106” (2.69 mm)

0.117”(2.9 mm)

0.125”(3.2 mm)

150’ 1 PSI 5 PSI 7 PSI 11 PSI* 22 PSI 36 PSI 44 PSI 76 PSI 88 PSI 115 PSI 154 PSI 239 PSI125’ 1 PSI 4 PSI 6 PSI 9 PSI 18 PSI* 30 PSI 37 PSI 63 PSI 73 PSI 101 PSI 129 PSI 200 PSI100’ 1 PSI 3 PSI 5 PSI 7 PSI 14 PSI* 23 PSI 28 PSI 50 PSI 54 PSI 77 PSI 103 PSI 142 PSI75’ 1 PSI 2 PSI 4 PSI 6 PSI 12 PSI* 18 PSI* 22 PSI 37 PSI 42 PSI 53 PSI 77 PSI 106 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI 8 PSI 12 PSI* 15 PSI* 25 PSI 28 PSI 39 PSI 52 PSI 73 PSI25’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 7 PSI 12 PSI* 13 PSI* 19 PSI* 26 PSI 34 PSI

Run

Leng

th


PART NAME PART NUMBERDuo-Foam Kit (HD/XD) 1002267

Triple-Foam Kit (HD/XD) 1002268

Distribution Manifold (HD/XD) 1002289

High-Flow Rinse Kit (PC2) 1001230

Anti-Siphon Kit (PC3) 1002230

PC3 To PC2 Adapter (HD/XD) 1002094

Injector Optimization Tool 1002018

Vacuum Tester Kit 1001104

Water Filtration System - Cold 1001431

Water Filtration System - Cold Replacement Filter 3000855

PC2 Plug - Stainless Steel 3000022

Flow-Through Adapter 3000173

Bug Prep Foam Generator For Prep Gun Replacement 1001750

Bug Prep Foaming Prep Gun Replacement 1001751

Bug Prep Foaming Prep Gun,Hose, & Injector Replacement 1001754

Bug Prep Dual Lumen 3/8” Spiral Hoe 30’ (9 m) 1002254

Aqua-Lab Rack Mounting Kit (Motor Control Unit Mounted Rack) 1002090

Aqua-Lab Rack Mounting Kit (Variable Frequency Drive Mounted Rack) 1002146

Aqua-Lab Rack Mounting Kit (Rack Tray Option) 1002080

Stainless Steel Motor Drip Shield (Wall Mounted Booster Pumps Only) 3001347

Kick Plate Cover (Floor Mounted Grundfos Pump Only) 1002159

Vinyl Hose Barb Cap 3000745

Remote Metering Device/Check Hub 1001756

3/8” Coupler 3000522

3/8” Elbow 3000523

3/8” x 1/2” Push-To-Connect 3000526

3/8” Check Valve (PC2) 3000970

3/4” Check Valve (PC3) 3002091

3/4” to 3/4”” Hose Barb & Check Valve Kit (PC3) 1002384

3/4” to 1” Hose Barb & Check Valve Kit (PC3) 1002386

AQUA-LAB HD/XD - ACCESSORIES


113

2

3

17

5

14

15

27/28

25

26

46

1216

2310

789

11

13

2

184

15

627/28

12

23or24

10

78

9

11

AQUA-LAB PANEL PARTS DIAGRAM

2526


NUMBER PART NAME PART NUMBER1 Air Actuated Hydra-Cannon Valve Replacement Kit - Stainless 3000925

2 Single BAM Valve Replacement 1002216

3 10-32” x 1/4” Push-To-Connect Air Fitting For Air Actuated Valve 3000987

4 BAM Valve Repair Kit 1002223

5 Hydra-Cannon Valve O-Ring Repair Kit 1001155

6 BAM O-Ring Repair Kit 1002222

7 Solenoid Actuated Air Valve - Foaming

24VAC - 1001428

24VDC - 1001429

120VAC - 1001430

8 Solenoid Coil Replacement For Air Actuated Valve

24 VAC - 3001149

24 VDC - 3001150

120 VAC - 3001151

9 M12 X Din I Cordset24 VAC/VDC - 3001957

120 VAC - 3001958

10 Primary Air Regulator 1001184

11 Primary Air Regulator Replacement Bowl 3002410

12 Foaming Small Air Regulator & 60 PSI Gauge 3001762

13 Outlet Pressure Gauge 0-400 PSI Bottom Mount 3000491

14 Inter Face Fitting Assembly 3001815

15 BAM Inlet Kit 1002396

16 Hydra-Cannon To BAM Coupler 3001956

17 Hydra-Cannon End Plug Assembly 3000561

18 BAM End Cap Kit 1002395

19 (Not Shown) 1/4” Push To Connect Tee 3000815

20 (Not Shown) 1/4” Push To Connect To 1/8” NPT Elbow 3000803

21 (Not Shown) 1/4” Push To Connect To 1/8” NPT Elbow - Plastic 3002033

22 (Not Shown) 1/4” Hose Barb Foaming Air Check Valve 3000819

23 M12 Junction Block - 8 Port, With Homerun Cable30’ (10 m) - 3001366-03

100’ (30 m) - 3001366-100

24 M12 Junction Block - 6 Port, With Homerun Cable30’ (10 m) - 3001301

100’ (30 m) - 3001302

25 Ball Valve 1” - 3000509

26 Manifold Inlet 1” ID Hose X 1” NPT Ends - 72” (1.8 m) Long 3001732

27 Male Quick Connect - Brass 1” - 3000205

28 Female Quick Connect - Brass 1” - 3000206


33 38

37

36

31

41

28

39

27282930 or 31

34

35

32

NUMBER PART NAME PART NUMBER27 Male Quick Connect - Brass 1” - 3000205

28 Female Quick Connect - Brass 1” - 3000206

29 1” Wye Strainer - 30 Mesh 3000490

30 1” NPT T16 Wye Strainer Screen & Gasket Kit 1001938

31 1” NPT T15 Wye Strainer Screen & Gasket Kit 1001939

32 40 GPM (150 LPM) Bypass Pressure Regulator - Stainless Steel 3000464

33 Quick Connect 9’ (3 m) Cordset For Booster Pump 3000782

34 Temperature Switch Assembly 3000507

35 20 GPM (75 LPM) Quick Connect Regulator Plumbing Assembly 1002340

36 40 GPM (150 LPM) Grundfos Plumbing Assembly 1002130

37 Grundfos Pump System Manifold O-Ring 3001878

38 Replacement/Backup 40 GPM (150 LPM) Grundfos Pump 3001618

39 Replacement/Backup 20 GPM (75 LPM) Booster Pump 1001362

40 (Not Shown) Booster Pump Floor Stand 1002250

41 Dual Booster Pump Wall Mount Bracket 3000921

42 (Not Shown) Triple Booster Pump Wall Mount Bracket 3000950

AQUA-LAB PUMP PARTS DIAGRAM


48 or 4944 47 45 46 55

59

48or49

58

53

50or51

54

NUMBER PART NAME PART NUMBER43 (Not Shown) M12 Cordset (Gray) 3000347

44 High-Temp Light 3002512

45 Quick Connect Pump Plug - Female 3000783

46 Thermal Overload - Eaton 1002757

47 Timer Relay 1002758

48 Current Sensor - AC 3000666

49 Current Sensor - DC 3000866

50 VFD Replacement - 5HP230V - 1002664

480V - 1002666

51 VFD Replacement - 7.5HP230V - 1002665

480V - 1002667

52 (Not Shown) VFD MCU Keypad 3002373

53 VFD MCU Exhaust Fan 3001869

54 VFD MCU Exhaust Filter 3001868

55 Contactor - Eaton

24 VAC - 3001336

24 VDC - 3001337

120 VAC - 3001338

56 (Not Shown) VFD MCU Pressure Transducer 3001705

57 (Not Shown) Pressure Transducer Cable 3001867

58 VFD MCU Primary Fuse 1/2 AMP 3001870

59 VFD MCU Fuse30A - 3001871

60A - 3001872

AQUA-LAB CONTROL PARTS DIAGRAM


T:952-808-3640•www.hydraflexinc.com•[email protected]

4000087 revF0917

FACTORY LIMITEDHydra-Flex,Incwarrantsitsequipmenttobefreefromdefectinmaterialorworkmanshipunderproper

normaluseforaperiodofone(1)yearbeginningthedateofpurchase.

Hydra-Flex,Inc’sliabilityshallbelimitedtorepairorreplacementofpartsfoundtobedefectivewithinthe

warrantyperiodandfollowingHydra-Flex,Inc’sinspection.Hydra-Flex,Incshallhavetheoptionrequiring

thereturnofdefectivematerialtoestablishthepurchaser’sclaim.Intheeventofrepairorreplacement

thislimitedwarrantyisnon-cumulative.Neitherlabornortransportationchargesareincludedinthis

warranty.

Thiswarrantyisbaseduponthepropercareandmaintenanceofthewarrantedequipment.Warranty

doesnotapplyifthemerchandiseisalteredormodifiedinanyway.Warrantydoesnotapplytoany

equipmentwhichhasbeensubjecttomisuse,inappropriateuseoftools,includingexposuretoharsh

chemicals,neglect,lackofmaintenance,freezing,fluidhammer,accident,thirdpartydamage,fluid

impuritiessuchassandorminerals,actsofGodoractsofwar.Nordoesitapplytoanyequipmentwhich

hasbeenrepairedoralteredbyanyonenotsoauthorizedbyHydra-Flex,Inc.Allequipmentmustbe

properlyinstalledinaccordancewithspecifiedplumbing,electrical,andmechanicalrequirements.The

warrantydoesnotapplytonormalwearandtearorroutinemaintenancecomponentsasdescribedinthe

equipmentmanual.

Exceptasexpresslystatedherein,Hydra-Flex,Incshallnotbeliablefordamagesofanykindin

connectionwiththepurchase,maintenance,oruseofthisequipmentincludinglossofprofitsandall

claimsforconsequentialdamages.Thislimitedwarrantyisinlieuofallotherwarrantiesexpressedor

implied.Hydra-Flex,Incneitherassumesnorauthorizesanypersontoassumeforitanyotherobligation

orliabilityinconnectionherewith.Thiswarrantyisneitherassignablenortransferable.

Transportationdamageclaimsaretobesubmittedtothecarrierofthedamagedmaterial.

AQUA-LAB HD/XD™ WARRANTY

Documents

AQUA-LAB HD/XD - Hydra-Flex, Inc....AQUA-LAB HD/XD (WALL MOUNT) 1. Drill (4) 5/32” holes on the wall. 16 3/8” wide, 27 5/8” tall. 2. Press Aqua-Lab HD/XD board tight against