Dover HYDRO AquaBlend Xtreme User manual

user manual
AquaBlend Xtreme

index
1.OO overview page
1.01 Package Contents 4
1.02 General Description 5
1.03 Specifications 5
1.04 Safety Precautions & Warranty Compliance 6
1.05 General Tips 6
2.OO installation and operation
2.01 Installation & Start-up 7
2.02 Suggested Installation 7
2.03 Operation 8
3.OO maintenance
3.01 General Maintenance Tips & Schedule 9
3.02 Routine Maintenance Instructions 10
4.OO troubleshooting
4.01 New Install Troubleshooting Table 11
4.02 Injector in Operation or After Scheduled Maintenance Troubleshooting Table 11
5.OO injector repair parts
5.01 Body and Piston 12
5.02 Lower End Parts 0.2% - 2% 13
5.03 Lower End Parts 0.78% - 5% 14
6.OO warranty and contact
6.01 Limited Warranty 15
6.02 Limitation of Liability 15
6.03 Contact 15

4
1.OO overview
Safety Precautions
WARNING! Please read precautions thoroughly before operation. Meet all applicable local codes and regulations.
THANK YOU FOR YOUR INTEREST IN OUR PRODUCTS
Please use this equipment carefully and observe all warnings and cautions.
protective clothing and eyewear when dispensing chemicals or other materials or when working in the
vicinity of all chemicals, filling or emptying equipment, or changing metering tips.
observe safety and handling instructions of the chemical manufacturer.
direct discharge away from you or other persons or into approved containers.
dispense cleaners and chemicals in accordance with manufacturer’s instructions. Exercise CAUTION when
maintaining your equipment.
reassemble equipment according to instruction procedures. Be sure all components are firmly screwed or
latched into position.
equipment clean to maintain proper operation.
only to water tap outlets (5 PSI Minimum, 90 PSI Maximum and Maximum water temperature 100° F).
if the unit is used to fill a sink, or the discharge hose can be placed into a sink. The unit must be mounted
so that the bottom of the cabinet is above the overflow rim of the sink
WEAR
ALWAYS
KEEP
NOTE
ATTACH
1.O1 Package Contents
1) AquaBlend Xtreme Injector
HYD117947XT 2 % ADJ, NPT
HYD117948XT 5 % ADJ, NPT
HYD117957XT 2 % ADJ, BSP
HYD117958XT 5 % ADJ, BSP
2) Quick Start Guide (P/N HYD9006170)
3) Accessory Kit (Mounting brackets and hardware)
4) Dosage Gasket kit
(P/N HYD17210 2%)
(P/N HYD17220 5%)
5) Mounting Bracket (P/N HYD195008)
6) Mounting Pins (P/N HYD004014 x2)
7) Suction Tube with Filter
(P/N HYD10095359 2%)
(P/N HYD10095356 5%)

5
1.OO overview (continued)
1.O2 General Description
The AquaBlend Xtreme models are designed to inject liquid concentrate or soluble powder that recommended and approved
for injection into fluid systems. AquaBlend Xtreme has specifically been designed to handle various water treatment chemicals
and organic acids.
1.O3 Specifications
Category Specification
Operating Pressure Min: 5 PSI (0,4 Bar) Max: 90 PSI (6,2 Bar)
Flow Rate 0.04 - 11 GPM (10 - 2500 l/h)
Dilution Ratio Range Model 0.2% - 2% (1:500 - 1:50) Model 0.78% - 5% (1:128 - 1:20)
Pipe Coupling 3/4” npt/ght/bsp
Housing PVDF
Dosing Accuracy +/- 10% of ratio
Repeatability +/- 5%
Pressure Loss Available on request
Maximum Temperature 100°F/ 38°C
Minimum Temperature 34°F/ 1°C
Maximum vertical suction of concentrate 13 Feet/396 Centimeters
Maximum horizontal suction of concentrate 49 Feet/1493 Centimeters
Self Priming Yes
Seal Material Available: Engineered Flouroelastomer - organic acids and water treatment chemicals
Maximum Viscosity 2,000 cP (Ex. Honey)
Recommended Accessories 140+ mesh filter, check valve, pressure regulator, flow restrictor
Weight 4-Product: 3.2 lbs
Dimensions 4-Product: 8.7 inches High x 10.7 inches Wide x 6.4 inches Depth

6
1.OO overview (continued)
1.O4 Safety Precautions & Warranty Compliance
WARNING! Please read precautions thoroughly before operation. Must meet all applicable local codes and regulations.
Remove Red Caps Prior to Installation
Your injector is 100% factory tested before delivery and
may contain a small amount of water. The three red plastic
caps are fitted after testing to ensure cleanliness of
the injector.
Before Applying Aggressive Chemicals
Please consult your distributor, chemical manufacturer
or contact Hydro Systems customer service to confirm
compatibility with your injector. Always wear proper safety
protection as recommended by chemical supplier.
Label all Fluid Lines, Valves and Connections
If the solution that is being injected is not suitable for
drinking, all fluid lines should be labelled, "Warning: Not for
human consumption!"
Monitor Outlet Flow
It is the user's responsibility to monitor the output of
chemical injected.
A Filter is Recommended and Required
Install a filter of 140 mesh (104 micron) or finer depending
on your fluid quality to prolong the working life of the
injector and for the warranty to be valid. A filter is imperative
since most fluid contains impurities or particles, especially if
the fluid source comes from a well, pond or lake.
Avoid a Potentially Hazardous Chemical Accident
Select a safe location. Chemical container should be kept
away from children and/or high usage areas and the location
must also not be susceptible to freezing temperatures.
Avoid Solution Contamination
Use only clean FILTERED fluid. Do not allow contaminants
to enter the solution container. Dirt, debris and other
contaminants in the solution container may cause excessive
wear to the unit.
Fluid Temperature
Min: 34° F (1°C) Max: 100° F (38°C)
Maximum Fluid Pressure 90 psi (6,2 bar)
Install a pressure regulator and/or pressure relief valve
to ensure operating pressure does not exceed the
maximum specification.
Before Removing An Injector From The System
Release fluid pressure. While the system is in operation, turn
off the incoming fluid valve. Leave the out going valve open
this will relieve the pressure at the injector and all parts of the
system after the injector. Injector is now safe to remove.
1.O5 General Tips
For A Long Service Life
Start with clean fluid by using an inline filter to reduce
impurities. Keep the solution container covered and clean.
Keep the suction tube filter 2" (5 cm) from the bottom of the
container. Perform maintenance procedures as
recommended (see Maintenance page 9).
Soluble Powder Use
Ensure the chemical is completely dissolved before starting
the injector. If necessary, dissolve the chemical in hot
water and allow to cool before using. Failure to thoroughly
dissolve the chemical will cause premature wear to the
dosage piston/gasket and the inner cylinder.
Please read this instruction manual thoroughly. Following the procedures, will increase the life of your injector.
Keep From Extreme Temperature
Protect the injector from freezing temperatures or
excessive heat.
Rinse Injector After Each Use
Additive allowed to remain in injector can dry out, foul or
damage the lower end at the next start-up (see Maintenance
page 9).
Injector Not in Use for an Extended Period
If the injector has not been stored properly deposits may
have dried onto the motor (see Maintenance page 9). Before
operation, soak entire unit into room temperature water
approx.. 72° F (22° C) for a 24 hour period.

7
2.OO installation & operation
2.O1 Installation & Start-up
Fluid Filter (Required)
Install a filter of 140 mesh (104 micron) or finer depending
on your fluid quality to prolong the working life of the
injector and for the warranty to be valid. Hydro Systems
recommends a Twist II Clean®filter that can be ordered with
your injector.
Mounting Injector
Securely fasten your injector to a solid object such as a wall or
in a cold fluid line. Note arrow on injector indicates fluid flow.
Backflow Preventor (Recommended)
Install one that meets local code requirements.
Pressure Safety Release Device (Recommended)
Prevents pressure from exceeding specifications of the unit.
Bypass Valve Set-up (Recommended)
Allows the injector to be taken off-line for maintenance
or storage when not in use.
Fluid-Hammer Arrester (Recommended)
Prevents fluid-hammer damage to the injector when
operating quick closing solenoid, pneumatic or hand-
operated ball valves on the fluid system.
Anti-Siphon Valve (Optional)
To prevent solution from being siphoned out (from the
solution container) into the feed lines when the upstream
valve is shut off. The anti-siphon valve must be installed on
the downstream outlet.
Additional Siphoning Prevention
Place solution container on a level below the injector suction
tube fitting. Using the inlet side as a shut-off valve could cause
full strength solution to siphon into the feed line.
Solution Container
Use any size container. A lid or cover is recommended.
To connect your solution container, gently push the end of
the suction tube onto the bottom of the suction tube fitting
assembly. Place the filter into the solution container at least
2" (5 cm) from the bottom and fill with at least 2" (5 cm) of
chemical solution.
Never Use Petroleum Based Lubricants
The injector is shipped with a thin coat of silicone around
the seals for ease-of-assembly. Petroleum based lubricants
such as Vaseline©, baby oil, WD40©, or motor oil on
the O-rings or any part of the injector should never be
used as this can cause particles to adhere and clog or
damage the injector.
Check System for Leaks and Start-Up Procedures
Open the bypass valve (A), close inlet valve (B) and outlet valve
(C) to prevent fluid flow into the injector. SLOWLY turn on the
main fluid line. Run fluid flows between 5 -10 gpm (1100-2200
l/hr) through the plumbing system. Turn on all of the valves
located downstream from your injector to release trapped air.
SLOWLY turn on the inlet valve (B). Open the outlet valve (C)
and close valve (A). As fluid travels through the injector, you
will hear a “clicking” sound. Check for leaks and correct
if necessary.
2.O2 Suggested Installation
A
B
C

8
2.OO installation & operation (continued)
2.O3 Operation
Clicking Sound is Normal
Fluid flowing through the injector will automatically cause
the injector to “click” and inject a set amount of solution
into the fluid line. The higher the flow rate the more frequent
the “clicking.” The injector is designed to inject solution
proportionally (at the same set ratio) regardless of fluid flow.
Maximum number of clicks per 15 seconds is 50.
Service Fluid Flow
Fluid flow and pressure must be within the established
specifications (see Specifications on page 5) for your model.
Change Feed (Injection) Rate
The feed rate on the injector is adjustable EVEN WHILE
OPERATING AND UNDER PRESSURE. To change feed rate
see (Fig. 1 and Fig. 2).
1. Lift lock ring (Fig. 1).
2. Rotate Ratio Adjuster Sleeve (Fig. 2) up or down to the
desired setting. Use arrows at top of the Ratio Adjuster
Sleeve to line up with the desired feed rate on the sleeve.
3. Return ring to lock position by pushing down on ring.
NOTE: Do not screw Ratio Adjuster Sleeve below lowest
setting line. Measure outlet fluid to assure desired feed rate
is being delivered.
Bleed Port
Ensure all air is out of the unit by pressing the bleeder
button, on the lid, in until water comes out. Release bleeder
button to stop water from flowing out of bleed port.
%
Fig. 1
Fig. 2

9
3.OO maintenance
NOTE: Maintenance intervals may vary depending on conditons of use
and the chemicals being injected.
3.O1 General Maintenance Tips & Schedule
Rinse Injector After Each Use
Additive allowed to remain in injector can dry, foul or damage
the lower end at the next start-up. Place suction tube
into a 1 qt. (0.95 liters) or more container of fresh filtered
water. Flow fresh water through the injector by operating
until container is empty. This procedure is not needed for
continuous operation.
Clean Solution Container
Keep covered to prevent dirt, and other debris from entering
the container. Rinse container thoroughly and often. Do
not mix chemicals together that might react and cause a
precipitate. Use FILTERED fluid when filling container.
Clean Suction Tube Filter Screen
Inspect each time new solution is added. Clean filter
screen and suction tube as necessary by rinsing in fresh
water. Replace if necessary. Keep filter screen off bottom
of solution container to prevent dirt and precipitate from
clogging filter.
Clean Inlet Filter
Clean or replace inlet filter as required to increase the life of
the unit as well as reduce pressure loss.
Bypass Injector
When not in use place the injector in bypass mode by using
the three valve bypass.
Storage
For extended storage, rinse injector using a minimum of 1/2
gallon. (See “Rinse Injector After Each Use”) Drain water
from unit. Inspect lower end seals. Apply thin coat of silicone
to seals and reassemble unit. Place plugs back into inlet/
outlet & suction tube fitting. KEEP FROM FREEZING.
Perform these maintenance
procedures to extend the life of your unit.
Every 3 - 6
Months
Every 6 - 12
Months
Replace as
Necessary
1. Clean Seal areas of
Dosage gasket.
2. Clean & Check
Seal, Cylinder, clean
and/or replace as
necessary.
3. Clean Filters
1. Replace Dosage
gasket.
2. Clean and/ or
replace Check
Poppet, inside Suction
Tube Fitting.
1. Cylinder
2. O-ring/Gasket
3. Motor Piston
4. Shaft Assembly
Dosage gasket
5. Check Valve Assy
and Tubing

10
3.OO maintenance (continued)
3.O2 Routine Maintenance Instructions
Step 1.
Unscrew and remove
lower end from assembly.
Step 2.
Pull down on shaft, rotate shaft
90° and remove.
Step 3.
Remove shaft with gasket and
install new. If damage on sealing
surface of shaft, replace shaft.
Step 6.
Place new motor piston
carefully into pump body and
replace lid.
Step 5.
Remove motor piston from
pump body.
Step 7.
Place shaft into the motor piston.
Step 9.
Replace lower end assembly and lid
onto the pump body. Ensure o-ring is
still in the lid before putting it back on.
Step 4.
Hold body firmly and unscrew
the lid. If lid is tight, use 1' (25
mm) socket to loosen.
Step 8.
Rotate shaft 90° to lock into place.
Gently pull down to ensure shaft
is locked.
↓
↓

11
4.OO troubleshooting
4.O1 New Install Troubleshooting
Problem Cause Solution
1. No Clicking Sound
a. Fluid not flowing through unit
• Are the red plugs at the inlet, outlet and suction tube fitting
openings removed?
• Is the unit installed backward? The arrow on the unit must
point in the direction of the fluid flow.
• If still not clicking, do not open the upper body. Call Hydro
Systems customer service.
b. Fluid flowing through unit
• Fluid rate is below or exceeds rated service flow of injector.
(See Specifications for maximum flow rate page 5). Maximum
number clicks = 28 per 15 seconds.
• Ensure all air is out of the unit by pressing the bleeder button
in, on the lid, until water comes out.
• If below increase flow rate, if above, reduce flow rate.
• Operating pressure exceeds maximum limit. Install a pressure
reducer valve.
(See Specifications for maximum flow rate page 5).
4.O2 Injector in Operation or After Scheduled Maintenance Troubleshooting
Problem Cause Solution
1. No Clicking Sound
a. Air trapped in unit
b. By-pass valve not open
c. Broken springs
d. Dirty or plugged inlet filter
e. Main piston assembly worn
f. Main body worn or scored
• Release trapped air by pressing the bleeder button in until
water comes out.
• Set valve to the closed position.
• Replace Motor Piston assembly, Clean fluid filter.
• Ensure mesh size is correct for proper filtration. Clean filter.
• Replace Motor Piston assembly. Clean fluid filter.
• Replace body and piston.
2. Clicking sound. No suction of solution
a. Cracked or loose suction hose
b. Dosage gasket worn or
installed incorrectly
c. Suction tube or suction tube fitting
cracked, leaking or clogged suction
tube filter
d. Check valve #11 leaking
• Check for proper fit and/or replace.
• Replace. Ensure during maintenance replacement that dosage
gasket was installed correctly.
• Replace and/or clean as necessary.
• Clean and/or replace as necessary.
3. Clicking Sound. Under Injecting or Unit Operates
at High-flow and not at Low Flow.
a. Dosage gasket worn
b. Inner cylinder worn
c. Broken springs
d. Main piston assembly worn
e. Main body worn or scored
• Replace.
• Replace inner cylinder and gasket.
• Replace Motor Piston assembly, Clean fluid filter.
• Replace Motor Piston assembly. Clean fluid filter.
• Replace Body & Piston.
4. Fluid Re-filling Solution Tank
a. Check valve leaking or dirty
b. Washer seal on check valve is
swollen or chemical attack
• Check seat area on suction tube fitting. Check valve and seal
must fit loose in the suction tube fitting. Clean seal and inside
fitting for debris.
• Replace with new check valve assembly.

12
Key Part No. Description
1 HYD011732 Kit M - Mounting bracket kit
2 HYD017200XT Kit H - Motor piston replacement
3HYD102601NPT
HYD102601BSP
Body, NPT, PVDF, AquaBlend Xtreme
Body, BSP, PVDF, AquaBlend Xtreme
1
2
3
5.O1 Body and Piston Exploded Parts Diagram
Service Parts List
5.OO injector repair parts

13
Key Part No. Description
1 HYD017210XT Kit A: Dosage gasket kit
2 HYD017211XT Kit B: Wear kit
3 HYD017213XT Kit D: Check valve kit
4 HYD017214XT Kit E: Wear parts maintenance kit
5 HYD017216XT Kit G: Complete lower end kit
1 2 3
5.O2 lower end parts O.2% - 2% exploded parts diagram
Service Parts List
5.OO injector repair parts (continued)
1
2
3
4
5

14
5.O3 lower end parts O.78% - 5% exploded parts diagram
Key Part No. Description
1 HYD017220XT Kit A: Dosage gasket kit
2 HYD017221XT Kit B: Wear kit
3 HYD017223XT Kit D: Check valve kit
4 HYD017224XT Kit E: Wear parts maintenance kit
5 HYD17226XT Kit G: Complete lower end kit
Service Parts List
5.OO injector repair parts (continued)
1 2 3
4
5

15
6.O1 Limited Warranty
Seller warrants solely to Buyer the Products will be free from defects in material and workmanship under normal use and
service for a period of one year from the date of completion of manufacture. This limited warranty does not apply to (a) hoses;
(b) and products that have a normal life shorter than one year; or (c) failure in performance or damage caused by chemicals,
abrasive materials, corrosion, lightning, improper voltage supply, physical abuse, mishandling or misapplication. In the event
the Products are altered or repaired by Buyer without Seller’s prior written approval, all warranties will be void.
No other warranty, oral, express or implied, including any warranty of merchantability or fitness for any particular
purpose, is made for these products, and all other warranties are hereby expressly excluded.
Seller’s sole obligation under this warranty will be, at Seller’s option, to repair or replace F.O.B. Seller’s facility in Cincinnati,
Ohio any Products found to be other than as warranted.
6.O2 Limitation of Liability
Seller’s warranty obligations and Buyer’s remedies are solely and exclusively as stated herein. Seller shall have no other
liability, direct or indirect, of any kind, including liability for special, incidental, or consequential damages or for any other claims
for damage or loss resulting from any cause whatsoever, whether based on negligence, strict liability, breach of contract or
breach of warranty.
6.OO warranty
Hydro Systems
3798 Round Bottom Road
Cincinnati, OH 45244
Phone [phone]OO
Toll Free 8OO.543.7184
Fax 513.271.O16O
Web hydrosystemsco.com HYD10099002 Rev A 9/18
Congratulations on Your Purchase!
We make the best and most reliable fluid-driven injectors available.
Hydro Systems will provide for replacement of all parts proven to
be defective in material or workmanship from the date of purchase
for the following periods:
1Year
Covers your unit from manufacturing
and material
defects only.
Hydro Systems products are warranted to be free from defects
in materials and workmanship for the above time frames. Hydro
Systems will at its sole option repair or replace any component
that fails in normal use. Any repairs made under warranty shall not
extend the initial warranty period.
To Maintain Your Warranty
Your only responsibility is ordinary maintenance - filtering incoming
fluid, replacing the O-ring and dosage piston/gasket when worn.
Seals and O-rings are not covered under the warranty.
To Return an injector for Warranty or Non-Warranty repair:
Contact Hydro Systems Company or your local distributor for return information.
This warranty is not valid if the defects are found to be due to the
product’s misuse, lack of maintenance, fluid impurities such as
sand or iron, defective installation, freezing, fluid hammer, abuse,
unwanted side effects due to the chemicals you choose to inject
or service provided by anyone who is not an authorized service
provider. Hydro Systems declines any responsibility if the product
is not used in compliance with the operating instructions and
specifications as indicated in this owner’s manual.
IN NO EVENT SHALL HYDRO SYSTEMS BE LIABLE FOR ANY
INCIDENTAL, SPECIAL; INDIRECT, OR CONSEQUENTIAL DAMAGES,
WHETHER RESULTING FROM THE USE, MISUSE OR INABILITY TO
USE THIS PRODUCT OR FROM DEFECTS IN THE PRODUCT.
There is no warranty expressed or implied relating in any way to
products used in conjunction with Hydro Systems.
Hydro Systems or authorized distributor shall not be liable for
incidental or consequential damage, such as any economic loss.
Hydro Systems retains the exclusive right to repair or replace the
product. Such remedy shall be your sole and exclusive remedy for any
breach of warranty. There are no warranties, expressed or implied,
which extend beyond those described above.
6.O2 Contact