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)

© Hydra-Flex, Inc. 2017 Page | 9
PROBLEM POTENTIAL CAUSED SOLUTIONS
Injector is not drawing chemical - Fails
Vacuum Pressure check test
Too much back pressure on injector
Perform back pressure check test out-
lined in Section IV if this manual. If the
result is higher than 66 psi then Increase
arch nozzle size or quantity, use larger
tubing, or use a smaller ow injector
Clogged injector check valve
Blow compressed air through the chem-
ical hose barb on the injector to remove
debris
Clogged injector nozzle Remove injector and blow out any debris
with compressed air
Defective Injector If Vacuum check fails but Back Pressure is
less than 66 psi, replace the injector
System won’t regulate up to 200 psi
Debris in regulator Remove regulator and clean out debris
Opening to many valves at once
System is limited to opening up to 8
valves at once or pressure will be greatly
affected by so much demand
Pump not primed Follow priming instructions
Defective Check Valve Replace check valve if broken
Defective Regulator Replace Regulator
Defective Pump Replace Pump
Flow at arch is too low
Incorrect Injector Flow Rate Selection Replace with desired injector size
System pressure too low Ensure system pressure is set at 200 psi
Downstream pluming restrictive
Perform Back pressure test outlined in
Section IV of this manual, if over 66 psi,
increase tube size and reduce elbows,
turns or other restrictive plumbing
No ow from injector
Solenoid valve malfunction
Ensure valve is receiving the correct
electrical signal and voltage
Disassemble valve and clean out debris
(See valve replacement instructions)
Clogged Injector Remove injector and blow out debris
with compressed air
No water supply Check that the system has a supply of
water
Valve stuck open – Staying open when
signal is off Debris in valve seat Remove and clean valve (See valve replacement instructions)
VALVE REPLACEMENT INSTRUCTIONS
Removemalfunctioningvalvesfromthemanifoldmakingsuretounscrewitfromthelargersteelhex
closesttotheplasticbody.Onacleanworksurfacedisassemblethevalveassembly.Becautiouswiththe
smallcomponentsandnotinghowitisassembled.Inspectfordebristhatcouldinterferewiththevalves
operation,payingparticularattentiontoanythingblockingthetwosmallholesthroughthevalvepiston
(2ndpartfromtheleftintheimagebelow).Forandcorrectassemblyreferencetheimagebelow.

© Hydra-Flex, Inc. 2017 Page | 10
APPENDIX: CHEM-FLEX INJECTORS - CHEMICAL DILUTION RATIOS
3.00” 1: 251 1: 503 1: 754 1: 1006 1: 1509 1: 2012 1: 2263 1: 2416 1: 2460 1: 2628 1: 4526 1: 5532 1: 8047 1: 10059 1: 12070 1: 15088 2.00” 1: 181 1: 363 1: 544 1: 726 1: 1089 1: 1451 1: 1633 1: 1402 1: 1337 1: 1510 1: 3266 1: 3991 1: 5806 1: 7257 1: 8708 1: 10885 1.00” 1: 104 1: 208 1: 311 1: 415 1: 623 1: 831 1: 934 1: 835 1: 778 1: 898 1: 1869 1: 2284 1: 3322 1: 4153 1: 4983 1: 6229 0.75” 1: 82 1: 165 1: 247 1: 329 1: 494 1: 659 1: 741 1: 642 1: 668 1: 755 1: 1483 1: 1812 1: 2636 1: 3295 1: 3954 1: 4942 0.50” 1: 59 1: 119 1: 178 1: 238 1: 357 1: 475 1: 535 1: 487 1: 496 1: 558 1: 1069 1: 1307 1: 1901 1: 2376 1: 2852 1: 3564 0.25” 1: 34 1: 68 1: 102 1: 136 1: 204 1: 272 1: 306 1: 282 1: 304 1: 344 1: 612 1: 748 1: 1088 1: 1360 1: 1632 1: 2040
#8-32 METERING TIPS
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 8.0 10.0 12.0 15.0
Injector Color White Yellow Tan Red Orange Gray Blue Light
Blue
Light
Green Pink Purple Dark
Green Black Black Black Black
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”
(2.4 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)
COPPER 1: 57 1: 104 1: 155 1: 195 1: 281 1: 406 1: 468 1: 598 1: 629 1: 739 1: 881 1: 1074 1: 2019 1: 2318 1: 3324 1: 4259 PUMPKIN 1: 43 1: 82 1: 119 1: 126 1: 238 1: 348 1: 398 1: 519 1: 554 1: 647 1: 774 1: 946 1: 1465 1: 1832 1: 2310 1: 3042 BURGUNDY
1: 34 1: 67 1: 97 1: 111 1: 207 1: 304 1: 347 1: 461 1: 495 1: 575 1: 690 1: 845 1: 1244 1: 1670 1: 1975 1: 2469
LIME 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 414 1: 447 1: 518 1: 622 1: 764 1: 988 1: 1262 1: 1481 1: 1958 TAN 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 414 1: 447 1: 518 1: 622 1: 764 1: 826 1: 1042 1: 1286 1: 1557 ORANGE 1: 23 1: 44 1: 64 1: 78 1: 137 1: 196 1: 215 1: 293 1: 314 1: 365 1: 437 1: 536 1: 751 1: 874 1: 1136 1: 1262 TURQUOISE
1: 17 1: 31 1: 45 1: 55 1: 91 1: 126 1: 134 1: 185 1: 197 1: 230 1: 274 1: 336 1: 561 1: 752 1: 885 1: 1099
PINK 1: 14 1: 24 1: 35 1: 42 1: 68 1: 93 1: 98 1: 130 1: 143 1: 159 1: 188 1: 224 1: 372 1: 473 1: 570 1: 728 LIGHT BLUE
1: 11 1: 17 1: 24 1: 31 1: 47 1: 64 1: 66 1: 93 1: 98 1: 114 1: 136 1: 166 1: 318 1: 406 1: 483 1: 572
BROWN 1: 10 1: 15 1: 22 1: 28 1: 43 1: 58 1: 59 1: 84 1: 88 1: 103 1: 122 1: 150 1: 270 1: 338 1: 408 1: 507 RED 1: 12 1: 17 1: 23 1: 34 1: 45 1: 46 1: 65 1: 69 1: 80 1: 95 1: 116 1: 202 1: 254 1: 306 1: 375 WHITE 1: 12 1: 16 1: 22 1: 31 1: 42 1: 43 1: 61 1: 64 1: 74 1: 88 1: 108 1: 180 1: 226 1: 272 1: 343 GREEN 1: 11 1: 14 1: 20 1: 28 1: 37 1: 38 1: 53 1: 55 1: 65 1: 76 1: 94 1: 160 1: 201 1: 241 1: 300 BLUE 1: 10 1: 12 1: 17 1: 23 1: 30 1: 31 1: 44 1: 46 1: 53 1: 63 1: 77 1: 122 1: 152 1: 185 1: 224 YELLOW 1: 9 1: 12 1: 16 1: 20 1: 22 1: 30 1: 31 1: 36 1: 42 1: 52 1: 80 1: 100 1: 120 1: 148 BLACK 1: 10 1: 13 1: 16 1: 17 1: 23 1: 24 1: 28 1: 33 1: 40 1: 61 1: 77 1: 92 1: 115 PURPLE 1: 6.6 1: 8.3 1: 9 1: 10 1: 13 1: 13 1: 15 1: 17 1: 21 1: 31 1: 39 1: 46 1: 57 GRAY 1: 5.3 1: 6.7 1: 6.9 1: 7.6 1: 9.9 1: 10 1: 11.6 1: 13 1: 16 1: 24 1: 30 1: 35 1: 44 OPEN 1: 4.9 1: 5.3 1: 5.2 1: 6.0 1: 6.1 1: 6.1 1: 7.6 1: 8.3 1: 10 1: 12 1: 15 1: 18 1: 23
3/7” polyow (LLDPE) tubing is required to ensure a seal between the tube wall and the spiral plug.
(Assumes feed pressure of 200 PSI (14 bar))
NOTE: Dilution ratios given are based on drawing water through the metering tips and are meant as a starting point for system conguration. Results are expected to vary when drawing chemicals due to differences in viscosity and temperature. There may be slight variations of performance in injectors and metering tips that are unavoidable due to manufacture tolerances. Using the same tip color from site to site is a good starting point. However, with the potential for variation from part, to part it is reasonable to still need to do some adjustments from there.

© Hydra-Flex, Inc. 2017 Page | 11
TERMINAL BOX WIRING INSTRUCTIONS
(OPTIONAL)
The terminal box offers a simple way to locate the solenoid
signal wires. Typically used when an existing system is removed,
their signals can be brought to this box and terminated with the
Aqua-Lab.
INSTALLATION INSTRUCTIONS
1. Determinelocationandhangterminalbox.Notethatthesideof
theboxwiththreeholesisfortheAqua-Labcontrolcables(yellow
cables),andthesideoftheboxwith5holesisfortheincoming
activationsignalsfromthewashcontroller.Orientateboxaccordingly
andwithinreachofAqua-Labyellowcables
2. RemoveCoverandnoticethelabelingoftheterminals(Figure2).
EachchemicalbankoftheAqua-Labislabeledas1,2,&3.ForTX
modelthiscorrespondstotop(1),middle(2),andbottom(3).ForAX
modelthiscorrespondstoleft(1)andright(2)
3. Bringtheyellowcablefromthecorrespondingchemicalbanktothe
boxandinsertthroughcableglandasshown.(Figure3)
4. Usingasmallscrewdriver,pressintothespringterminalandpull
awayfromthewireterminaltoopenthespringclamps.Insertthe
wirethatcorrespondstothelabeledcolorthenreleasethespringby
removingthescrewdriver(Figure4)
5. Repeatforallcolorslabeled.(brownandredarenotused)
6. BlueandGreen/Yellowaretobewiredtothecommonandground
terminalswhicharesegmentedasshown(Figure5)
7. RepeatforallyellowAqua-Labcables
8. Individuallyinsertchemicalactivationsignalsthroughcableglands
andwiretodesiredchemicalposition(seewiringchartinoperations
manual)(Figure6).
9. Repeatforallchemicalsignals,onlyoneofthecommon(blue)and
ground(Green/yellow)wiresforthesignalsneedtobewiredtothe
correspondingsegmentedterminalssincetheyshouldbepreviously
connectedatthewashcontroller.Youcanwireuptothreeofthe
commonsandgroundstoensurearedundantconnection.
10. Lightlytugonallwirestoensureagoodconnection.
11. ReplaceCoverandtightenscrews
Figure 1
Figure 4
Figure 2
Figure 5
Figure 3
Figure 6
Figure 7

© Hydra-Flex, Inc. 2017 Page | 12
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REPLACEMENT PANEL, PUMP, & MCU PARTS LIST - AQUA-LAB AX/BX/TX

© Hydra-Flex, Inc. 2017
PART NAME PART NUMBER
1ElectricSolenoidValveReplacement
24 VAC 1001072
24 VDC 1001073
120 VAC 1001074
2(ShownOnPage4) Hydra-CannonValveO-RingReplacementKit 1001155
3SingleBlackHydra-CannonReplacementAssembly 1001384
41/2”NPTHydra-CannonManifoldEndFittingAssembly 1001556
5 Hydra-CannonInterfaceFittingAssembly 1001557
6 M12JunctionBlock-6Port,With30’HomerunCable 3000412
7M12JunctionBlock-6Port,With100’HomerunCable 3000750
8 M12XDinAXDinISplitterCable 3000406
9M12XDinAXDinISplitterCableMedium 3000407
10 M12XDinAXDinISplitterCableLong 3000408
11 M12XDinACable 3000350
12 OutletPressureGauge0-400PSIBottomMount 3000491
13 1/4”HoseBarbFoamingAirCheckValve 3000819
14 PneumaticReplacementValveWithRegulator
24 VAC 1001274
24VDC1001275
120VAC1001276
15 PiscoRegulatorReplacement 3000543
16 PrimaryAirRegulator (BXOnly) 1001161
17 PrimaryAirRegulator (AX&TX) 1001184
18 PrimaryairregulatorReplacementBowl-Aluminum 3000952
19 PrimaryairregulatorReplacementBowl-Plastic 3000870
20 1”MaleQuickConnect-Brass 3000205
21 1”FemaleQuickConnect-Brass 3000206
22 3/4“MaleQuickConnect-Brass 3000196
23 3/4”FemaleQuickConnect-Brass 3000197
24 1/2”MaleQuickConnect-Brass 3000500
25 1/2”FemaleQuickConnect-Brass 3000502
26 1”WyeStrainer-20Mesh 3000490
27 1”NPTT16WyeStrainerScreen&GasketKit 1001938
28 1/2”BallValve-Brass 3000565
29 ThermalReliefValve-1/2”NPT 3000323
30 40GPMBypassPressureRegulator-StainlessSteel 3000464
31 ManifoldInlet1/2”IDHoseX1/2”NPTEnds-72”Long 3000579
32 20GPMQuickConnectRegulatorPlumbingAssembly 1001775
33 Replacement/Backup20GPMPump 1001362
34 OutletManifold 3000662
35 1”CheckValve-Brass 3000250
36 QuickConnect9’CordsetForPump 3000782
37 QuickConnectPumpPlug-Female 3000783
38 ThermalOverload-Sprecher&Schuh 3000862
39 Timer Relay 3000664
40 CurrentSensor-AC 3000666
41 CurrentSensor-DC 3000866
42 Contactor-Sprecher&Schuh
24VAC3000863
24VDC3000864
120VAC3000865
43 M12Cordset(Grey) 3000347
44 3/4”x72”Hose 3000659
Page | 13

© Hydra-Flex, Inc. 2017 Page | 14
T:952-808-3640•F:952-808-3650•www.hydraexinc.com•sales@hydraexinc.com
4000133 revA0717