Hydra-Flex AQUA-LAB AX Bedienungsanleitung

AQUA-LAB™AX, BX, TX

CHEMICAL DISPENSING SYSTEM

User Manual

REV A

4000133 revA0717

TABLE OF CONTENTS

FOR ADDITIONAL SUPPORT CALL

952-808-3640

OR VISIT US ON THE WEB:

www.hydraexinc.com

Overview 1

Features 1

 Specications       1

InstallationInstructions       2

 InstallationSpecications      2

Unpacking 2

 LocationandMounting      3

 FeedWaterConnection      4

 ChemicalLineConnections     4

 PneumaticConnections      4

 ElectricalConnections      5

Operation         6

 PumpPrimingInstructions      6

 WaterFlowRateandChemicalDilutionSetUp   6

PostInstallationVacuum&BackPressureCheck    7

 Chem-FlexInjectorVacuumCheck    7

 Chem-FlexBackPressureCheck     7

 IndividualInjectorFlowRateMeasurement   8

Troubleshooting        8

Appendix 10

 ChemicalMetering&DilutionCharts    10

 TerminalBoxWiringInstructions(Optional)   11

 ReplacementPanel,Pump,&MCUPartsList   12

OVERVIEW

Page | 1

FEATURES

• Consistentandaccuratechemicalapplication

• Flexiblepumpdesign—owratesFROM10to40GPM

• Compactdesignreducesfootprint

• Pre-wiredandpre-plumbedforfastinstallation

• EasyPlug-and-Playutilityandchemicalconnections

• Modulardesign—customizedtoyourneedsforupto15chemicalsplusTri-Foam

• UsesHydra-CannonChemicalManifoldSystemsforeasyandquickservice

• Color-codedChem-FlexInjectorsusingQuick-Changeconnections

• Fornewinstallationsorretrotinanycarwash

TheAQUA-LABwillsimplifythedeliveryofliquidchemicalstoyourcarwasharch.Itsplug-andplay

systemiscompactandpre-assembledforquickinstallation.

ToensurethattheAQUA-LABwillinterfaceproperlywithyourcarwashfacility,youmustrstverifythat

yourfacilityhasalloftheproperspaceandconnectionrequirementsaccordingtothespecications

below.YoumustalsoverifythatyouhaveorderedtheproperpartnumberforyourAQUA-LABtomatch

therequirementsneededbyyourfacility.

SPECIFICATIONS

• UPto15ChemicalPorts

• Upto15PneumaticPorts

• Hydraulicsoperatingpressure:200psi(Factoryset)

• Pneumaticsoperatingpressure:100psi(Factoryset)

• OperatingAmbientTemperature:40-120DegF

• Operatepumpswith208/230or480Voltages(3-phase)

• OperateSolenoidValveswith24VAC,24VDC,120VAC

• 1-1/2”watersupplyline(TXModel)

• 1”watersupplyline(AX&BXModels)

• Inletpressure:2-80psi

• SpaceRequirements:

 a.AquaLabSystems

 i.TXFModel–3’x3’footprintwith5’Clearance

  ii.TXWModel–2’widex4.5’highofwallspaceforsystem

  iii.AXModel–3’widex2’highofwallspaceforsystem

  iv.BXModel–1.5’widex2’highofwallspaceforsystem

 b.PumpAssemblies–Pumpsneedtobewithin3’ofthesystemtoallowconnectionofthe

  twowithjusttheincludedconnectionhose

  i.SinglePump–4’x1’wallspace

  ii.DualPumpWallmount–4’x3’ofwallspace

  iii.DualPumpFloorskid–4’widex1.5’deepfootprintwith4’ofClearance

 c.ElectricalEnclosures

  i.MotorStarter(AXandBXModels)–1’widex1.5’highofwallspace

  ii.VFDMotorController–1.5’widex2’highofwallspace

  iii.TerminalBox(Accessory)–1’widex1’highofwallspace

INSTALLATION INSTRUCTIONS

INSTALLATION SPECIFICATIONS

TheAQUA-LABchemicaldeliverysystemhasbeendesignedforafastandhasslefreeinstallation.It

comesfullyassembledwithallofthecomponentspre-wiredandplumbed,leavingonlythesettingof

equipment,andconnectionoftheincomingandoutgoinghosesandwires.Asfollowsaretheinstallation

specicationsfortheAQUA-LAB:

GENERAL:

• PeopleRequired:2people

• MechanicalSkillLevel:Basic-Mountingequipment

• ElectricalSkillLevel:Advanced-Threephasepowerandknowledgeoflocalcodesisrequired

• PneumaticSkillLevel:Basic-pneumaticutilityconnectionrequired

• FluidSkillLevel:Basic-Waterutilityconnectionrequired

• ChemicalKnowledge:Advanced-Chemicaltitrationsrequired

TOOLS AND EQUIPMENT NEEDED:

• Unpacking:Normalhandtools

• Assembly:Normalhandtools

• Wiring:Normalelectricalwiringtools

• Startup:Electricalmeterhelpfulbutnotrequired

ESTIMATED TIMELINE:

• Unpacking:15–30minutes

• FrameMounting:0.5–2.0hours

• FluidConnections:0.5–2.0hours

• Motor&ValveWiring:1–4.0hours

• Startup&adjustment:1.5–6.0hours

UNPACKING

TheAQUA-LABisshippedinawoodencrateforthepurposeofprotection.Beforeunpacking,besure

thattheAQUA-LABisonalevel-atsurface.Tounpack,performthesesteps:

1. OpenthecrateusingadrillwithPhillipsbitorPhillipsheadscrewdriver

2. CutthecellophaneoffoftheAQUA-LABbyusingautilityknife.Besuretocuteitheratthe

cornersorinanareawheretheknifewillnotdamagetheAQUA-LAB.

3. Usinganadjustablewrench,un-bolttheAQUA-LABfromthepallet.

4. LifttheAQUA-LABfromthepallet.Useassistanceifnecessary.

5. Disposeofpallet,cellophaneandadditionalpackagingmaterials.

LOCATION AND MOUNTING

**WhenselectingalocationforanyAqua-Labsystemmakesuretoconsidertheproximitytofeedwater,

powersupply,andthecontrolcabinetthatthevalvesignalswillneedtobewiredfrom(orajunctionbox

withtheappropriatesignalswires)aswellasspacenearthesystemtostorechemicalcontainers.

SPACE REQUIREMENTS:

• Aqua-Lab Systems

• TXFModel–3’x3’footprintwith5’Clearance

• TXWModel–2’widex4.5’highofwallspace

• AXModel–3’widex2’highofwallspace

• BXModel–1.5’widex2’highofwallspace

Pump Assemblies(ForTXW,AX,andBXModels)–Pumpsneedtobewithin3’ofthesystemtoallow

connectionofthetwowithjusttheincludedconnectionhose

• SinglePump–4’x1’walloroorspace

• DualPumpWallmount–4’x2.5’ofwallspace

• DualPumpFloorskid–4’widex1.5’deepfootprintwith4’ofClearance

Electrical Enclosures

• MotorStarter(TXW,AX,andBXwithWallmountpumpassembly)–1’widex1.5’highofwall

space

• VFDMotorController(TXW,AX,orBXwithWallmountpumpassembly)–1.5’widex2’high

ofwallspace

• TerminalBox(OptionalItem–usedif30’signalcablesdonotreachcarwashcontrolcabinet)

–1’widex1’highofwallspace

MOUNTING OF COMPONENTS:

• Aqua-Lab Systems

• TXF–Positionontheoorinoptimallocation,canbeanchoredwithincludedanchorfeet

• TXW–Mounttoconcreteorcinderblockwallwith4concreteanchors

• AX–Mounttoconcreteorcinderblockwallwith4concreteanchors

• BX–Mountsturdywallwith4appropriateanchors

Pump Assemblies–DoesnotapplytoTXF

• SinglePump–Mountpumpangetoconcreteorcinderblockwallorconcreteoorwith4

concreteanchors–**Needstobewithin3’oftheAqua-Labsystemtoconnectthemwiththe

includedconnectionhose

• DualPumpWallmount–Mounttoconcreteorcinderblockwallwith4concreteanchors

–**Needstobewithin3’oftheAqua-Labsystemtoconnectthemwiththeincluded

connectionhose

• DualPumpFloorskid–Positionontheoornearthefeedwaterconnection–**Needstobe

within3’oftheAqua-Labsystemtoconnectthemwiththeincludedconnectionhose

Electrical Enclosures

• MotorStarter–(PremountedtotheFrameforTXF)forothersystemsmounttothewallwith

4appropriateanchors

• VFDMotorController–(PremountedtotheFrameforTXF)forothersystemsmounttothe

wallwith4appropriateanchors

• TerminalBox(Accessory)–Mounttowallwith4appropriateanchors–**Locationwilldepend

onthepositionoftheAqua-Labsystemanditsproximitytothecarwashcontrolcabinet

FEED WATER CONNECTION

**Priortoconnection,pleaseensurethatthefeedlinesarefreeofconstructiondebrisbyushingoutthe

piping.

Main Water Supply Line Size:

• AXandBXModels:1”FemaleNPT;

• TXFandTXWModels:1-1/2”FemaleNPT

• Keepatleast2PSIinsupplylinewhenpumpisinoperation

• Maximuminletpressureis80PSI

• Ifthepumpsarefedfromatank,thewaterlevelmustbeatleast54”abovepumpatalltimes

CHEMICAL LINE CONNECTIONS

Chemical Inlet Connections

• Chemicaltuberecommendation:1/4”IDFlexiblePVCTubing(ChemicalLineTubing)

• Runchemicallinefromstoragecontainerthroughthechemicalaccessholes(Smallerdiameter

holes)andconnectdirectlytothehosebarbontheinjector–ensurethatafootvalveorsimilar

checkvalve/screenisattachedattheendofthelineinthestoragecontainer.

Chemical Solution Connections

• Solutiontuberecommendation:1/2”ODPolyTubing

• Adapthosetochemicalinjectorusingcustomerpreferredconnectiontype

• 3/8”&1/2”ODTubePushFittingsareprovided

• Feedhosethroughsolutionoutletholes(Largerdiameterholes)

• Meteringtipswillneedtobeinstalledtosetdilutionratio-seeOperationsectionbelow

PNEUMATIC CONNECTIONS

**IF AIR IS NOT REQUIRED FOR YOUR AQUA-LAB, PLEASE SKIP THIS SECTION

Pneumatic Utility Connections:

• FlowandPressure:20CFM,100PSIMax(PrimaryRegulatorFactorySet,donotadjust)

• IncomingConnectionTypeandSize:3/8”ODHosePushFitting

• FilterIncluded:Yes

• RegulatorIncluded:Yes(PrimaryRegulatorFactorySet,donotadjust)

• LubricatorIncluded:No

• OutgoingConnectionTypeandSize:1/4”ODHose–PushtoConnect

• AirPressureControl:IndividualAdjustableRegulators

• AirFlowControl:No

**Ifthereareunusedairports,eitherscrewouttheindividuallineregulatoruntilairnolongerowsor

insert supplied plugs

ELECTRICAL CONNECTIONS

**Use appropriate table below based on if your system has a Current Sensing and Timer Relays – See

Figure below to determine type of system.

Solenoid Valve Signal Connection – **WITH CURRENT SENSING AND TIMER RELAYS

Solenoid Valve Signal Connection – Without Current Sensing and Timer Relays

STATION OR USE M12 LABEL ON

BOX LABEL

MAIN TRUCK

CABLE WIRE COLOR

MANIFOLD

POSITION*

Ground N/A Green/Yellow N/A

DO NOT USE N/A Blue N/A

Hot / + N/A Brown N/A

Station 1 1 White 1

Station 2 2 Green 2

Station 3 3 Yellow 3

Station 4 4 Grey 4

Station 5 5 Pink 5

Neutral / Common 6 Red N/A

STATION OR USE M12 LABEL ON

BOX LABEL

MAIN TRUCK

CABLE WIRE COLOR

MANIFOLD

POSITION*

Ground N/A Green/Yellow N/A

Neutral / Common N/A Blue N/A

DO NOT USE N/A Brown N/A

Station 1 1 White 1

Station 2 2 Green 2

Station 3 3 Yellow 3

Station 4 4 Grey 4

Station 5 5 Pink 5

DO NOT USE 6 Red N/A

Timer Relay

Current Sensing Relay

**Manifold Positions Numbered from Left to Right

Pump Power Connection and Signal Connection

**208/230V or 480V 3-Phase Power required

Motor Starter Version

• Ifreceptacleplugaccessoryisincluded,simplyplugthesystemintothe

walloutlet

• WireeachlegoftheincomingpowertotheterminalslabeledL1in,

L2in,andL3ininthelowerleftoftheenclosure.Makesuretofollowall

applicableelectricalcodes.

VFD Version

• Ifreceptacleplugaccessoryisincluded,simplyplugthesystemintothewalloutlet

• WireeachlegoftheincomingpowertotheMainpowerswitchinthetoprightoftheenclosure,

screwterminalslabeledL1,L2,andL3.Makesuretofollowallapplicableelectricalcodes.

OPERATION

PUMP PRIMING INSTRUCTIONS

1. RefertosectionII-gtoensureallelectricalconnectionsarecomplete.

2. Connectsupplywaterwitha1”(AXandBXModels)or1-1/2”(TXModel)InletLineandopenfeed

line(Minimum2psirequired)

3. Pulleachpumpdischargequick-connectuntilasteadystreamofisowing,andthenreconnect.

4. Startthepumpsoneatatimeusingthemotorstarter.Ensurethatpumprotationiscorrectas

indicatedonpumpandthat200psicanbereached.

5. TXModel:Slowlyopentheprimingballvalvelocatedofftheendofthedistributionblockandallow

watertoowuntilsteady,thenclosethevalve(ahosecouldbeconnectedtothevalvetothedrainto

avoidexcessivewaterontheoor)

6. AXandBXModels:WiththepumpoffdisconnectthehighpressurelinetotheAquaLabatthequick

disconnectandpointinasafedirection,whileholdingthelinetocontrolitstartthepumpandallow

watertoowuntilsteady.

7. Closetheballvalve(TXModel)orreconnectthehighpressurelineatthequickdisconnect(AXand

BXModels)

8. Conrmthatthepumpscanobtain200psiandthatthepumphousingiscooltothetouchaftera

minuteinoperation.

9. Ifpumpdoesnotprime,repeatsteps3-6

• !!Paycloseattentiontothetemperatureofthepumphousing,ifitstartsgettinghotterthanthe

supplywaterthenitislikelythatthepumpdidnotprimecorrectly!!

• *WARNING*Ifthepumpsdonotprimecorrectlytheywillheatupanditwillcausedamageto

the pumps.

WATER FLOW RATE AND CHEMICAL DILUTION SET UP

ForeachofthechemicalsthattheAqua-Labisdeliveringtothecarwashbayfollowthestepsoutlined

belowtosettheoverallowrateandchemicaldilution.NOTE:youwillneedtoknowthetargetowrate

andchemicaldilution(concentration)priortosettingupeachchemical.

1. UsingtheNozzleSizechartintheAppendixofthismanual,followthe‘FeedPressure’columndown

to‘200’(theoperatingpressureoftheAqua-LabSystem).

2. Findtheowratetotherightof‘200’thatisclosesttothedesiredtargetowrate;fromtherefollow

thatcolumnbacktothetopofthecharttondtheappropriateNozzlesize.

3. UsingtheChemicalMeteringRatechartintheAppendixofthismanual,ndtheowratealongthe

topthatisclosesttotheowrateyoujustdeterminedinstep2above.

4. Followthatcolumndownuntilyoundthedilutionratio(concentration)thatisclosesttothetarget

value,thenlooktotheLeftofthecharttoseewhichmeteringtipitcorrespondsto.

NOTE:Itmaybenecessarytochangetoadifferentinjector’ssizebasedonthespraypatternand

deliveryofchemicaltothevehicle.InthatsituationusetheNozzlesizecharttodeterminethenewow

rateat200psiandrepeatsteps3and4abovetosetthechemicalusage.

NOTE:Thedilutionratios(concentrations)givenintheChemicalMeteringRateChartarebasedon

drawingwaterthroughthetips.Someadjustmentstoatiplargerorsmallermayberequiredduetothe

differentofviscositiesofthechemicalsandwater.

POST INSTALLATION VACUUM & BACK

PRESSURE CHECK

If the spray nozzles on the arch are too small for the injector chosen, the back pressure put on the

injector may cause the vacuum to not function and chemical will not be pulled

The checks below are intended to help identify any potential issues that would cause the injector

not to function correctly

CHEM-FLEX INJECTOR VACUUM CHECK

1. AttheChem-FlexInjector,removethechemicalfeedlinefromtheinjectorhosebarb.

2. AttachedthetubingofthevacuumgaugetotheChem-Flexhosebarb.

3. Withthepump(s)on,manuallyactivatethechemicalthatistobetestedatthemaincarwashcontrol

cabinet.Aninjectorthatisworkingproperlywillhaveareadinggreaterthanorequalto(≥)18inHg

4. Repeatsteps2-4foreachchemicallanethatavacuumreadingisneededfor.

5. Oncetestingiscomplete,turnofftheAqua-Labpumpfromthemaincarwashcontrolcabinet.

CHEM-FLEX INJECTOR VACUUM CHECK

Back Pressure is dened as the pressure that is created between the injector and the arch nozzles.

It is caused by the chemical solution from the injector trying to push its way through the nozzle, the

smaller the nozzles the harder it is to push through and consequently higher back pressure

1. DisconnecttheoutlethosefromtheChem-Flexinjectorthatabackpressurereadingwillbetakenfor.

2. ConnectthebackpressuregaugeassemblytotheoutletoftheChem-Flexinjector.

3. Connectthehosetothearchtotheotherendofthebackpressuregaugeassembly.**Makesureall

hosebarbttingsaresecuredwithhoseclamps.

4. TurnontheAqua-LabpumpandthesolenoidvalvefortheChem-Flexbeingtestedfromthemain

carwashcontrolcabinet–Thebackpressureshouldnotexceed33%ofthefeedpressure(forthe

Aqua-Labwiththefeedpressuresetto200psithebackpressureshouldnotexceed66psi).

5. TurnofftheAqua-Labpumpandsolenoidvalveatthemaincarwashcontrolcabinet.

6. Removethebackpressuregaugeassemblyfromtheinjectorandreconnectthehosetothearch.

**Makesureallhosebarbttingsaresecuredwithhoseclamps.

7. Repeatsteps1-5foreachinjectorthatabackpressurereadingisneededfor.

TROUBLESHOOTING

The AQUA-LAB is supplied with the following tools to assist in set up and troubleshooting:

• Vacuum gauge for checking the vacuum at the chemical injector hose barb,

• Back Pressure Gauge for measuring back pressure downstream of the injector.

PROBLEM POTENTIAL CAUSED SOLUTIONS

Pump Operates, but delivers little or no

water

Inlet Restriction Check all in-line lters and inlet plumbing

for restrictions

Low line voltage

Inadequate water supply Check pressure on inlet side of pump to

be sure positive pressure is maintained

Undersized piping Replace with larger piping

Leak on the Inlet side Make sure connections are tight

Worn or defective pump parts Replace worn parts or entire pump,

Clean parts if required

Pump not primed See priming instructions

Incorrect Motor rotation Reverse motor rotation by interchanging

any two leads

Pump won’t start or run at full speed

Blown fuse or circuit breaker Replaced fuses or close circuit breaker

Defective Motor Starter contactor Replaced motor starter contactor

Incorrect Motor Voltage Voltage must be within 10% of motor

rated voltage

Defective motor Replace motor

Pump components damaged Replace worn part or entire pump

Excessive Noise from Pump

Pump not secured rmly Secure properly

Restricted Inlet Clean or correct restriction

Cavitation (Sounds like marbles in pump) Increase inlet size

Pump Leaks Worn mechanical seal Replace shaft seal

Worn o-ring seals Replace

Injector is not drawing chemical - Passes

Vacuum Pressure check test Clogged chemical feed Check chemical hose, foot valve, meter-

ing tip and hose barb for debris or clogs

INDIVIDUAL INJECTOR FLOW RATE MEASUREMENT

1. Attachashortsectionoftubing(3-5ft)totheoutletoftheinjectorthatyouwanttomeasuretheow

rateof.

2. TurnontheAqua-LabpumpandthesolenoidvalvefortheInjectorbeingtested.Ifpossiblehave

someoneassistbyturningthemonwhileyoukeepthewaterfromtheshortsectionofhosepointed

inasafedirection.

3. Usinga2litergraduatedcylinder(orotherlargegraduatedcylinder)andastopwatch(watchorcell

phonewithastopwatch)

• Makesurethegraduatedcylinderisemptyandthatthestopwatchiscleared.

• Directtheowofwaterfromthetubeintothegraduatedcylinderandstartthestopwatchthe

instantyoustartaddingwatertothecylinder.

• Stopthetimerwhenthecylinderisatleasthalffull,preferablyatawholenumberlevel(ie.1liter,

2liters)

• Dividethenumberoflitersbythetimeinsecondsthenmultiplyby15.85–thiswillresultinhow

manyGallonsperminute(GPM)

Dieses Handbuch passt für folgende Modelle

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