Hydra-Flex AQUA-LAB AX User manual

© Hydra-Flex, Inc. 2017
AQUA-LAB™AX, BX, TX
CHEMICAL DISPENSING SYSTEM
User Manual
REV A
4000133 revA0717
© Hydra-Flex, Inc. 2017

© Hydra-Flex, Inc. 2017
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

© Hydra-Flex, Inc. 2017
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

© Hydra-Flex, Inc. 2017 Page | 2
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.

© Hydra-Flex, Inc. 2017 Page | 3
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

© Hydra-Flex, Inc. 2017 Page | 4
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

© Hydra-Flex, Inc. 2017 Page | 5
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

© Hydra-Flex, Inc. 2017 Page | 6
**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.

© Hydra-Flex, Inc. 2017 Page | 7
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.

© Hydra-Flex, Inc. 2017 Page | 8
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)