Hydra-Flex Sonny's CarWash Backroom Aqua-Lab 3 User manual

CHEMICAL DISPENSING SYSTEM
User Manual
REV G
4000240 revG0422
© Sonny’s Backroom
by Hydra-Flex 2022
3/4/9 2/3/7
2/5/9

TABLE OF CONTENTS
For additional tech support call 952-808-3640 or visit www.hydraflexinc.com
Shop Parts & Accessories now: www.hydraexinc.com/chemical-dispensing-parts-accessories/
View Catalog: www.hydraexinc.com/literature/
SPECIFICATIONS 4
INSTALLATION INSTRUCTIONS 5
Estimated Installation Timeline 5
Unpacking 6
Location Layouts & Mounting 7
Layout Drawings 7
Grundfos Pump Installation 9
20 GPM Grundfos With Integrated VFD Installation Instructions 10
40 GPM Grundfos With Integrated VFD Installation Instructions 12
Aqua-Lab 3™Panel Installation 15
Pneumatic Connections 15
Alfred Gateway and Disconnect Box Mounting 15
Electrical Connections 16
Wiring Diagrams 17
Solutions Connections 20
Initial Injector Setup 20
Triple Foam Setup 20
Optimizing the System 21
Alfred™Gateway Installation 22
Aqua-Lab 3™Parts & Diagram List 25
Grundfos Pump with Integrated VFD Parts & Diagram List 26
Grundfos Fault Finding 27
Troubleshooting 30
APPENDIX 32
Injector Optimization Tool 33
Injector Vacuum Check 34
Nozzle Setup 34
Chemical Usage Measuring 35
Recommended Maintenance 36
MAM & BAM Valves 36
Recommended Setup Starting Points 37
Composite Chem-Flex Injector Part Numbers 38
VersaDial™Chem-Flex Injector Part Numbers 40
Pressure Loss In Run Length 41
Aqua-Lab 3™Warranty 42

4 | © Sonny’s CarWash Backroom by Hydra-Flex, Inc. 2022
SPECIFICATIONS
AQUALAB 3 SYSTEM SPECIFICATIONS
POWER REQUIREMENTS
20 GPM (75 LPM) 5 HP Grundfos pump 40 GPM (150 LPM) 7.5 HP Grundfos pump Air-actuated valves
230V / 3PH / 60Hz / 13.2A
460V / 3PH / 60Hz / 6.2A
230V / 3PH / 60Hz / 20A
460V / 3PH / 60Hz / 9.1A
24 VDC
Node converts all voltage signals, but only one
control voltage type can be used per node
230V: Recommended for use
with 20A breaker
460V: Recommended for use
with 15A breaker
230V: Recommended for use
with 30A breaker
460V: Recommended for use
with 30A breaker
WATER INLET LINES
20 GPM (75 LPM) Grundfos pump 40 GPM (150 LPM) Grundfos pump
1” ID 2” ID
SPACE REQUIREMENTS (DEPTH X WIDTH X HEIGHT)
Main Disconnect Box Additional Small Disconnect Box Alfred Gateway
7.5” x 14” x 12” (19.1 x 35.6 x 30.5 cm) 4” x 5” x 8” (10.2 x 12.7 x 20.3 cm) 4” x 7” x 7” (10.2 x 17.8 x 17.8 cm)
SPACE REQUIREMENTS (DEPTH X WIDTH X HEIGHT)
40 GPM Grundfos pump 20 GPM Grundfos pump Aqua-Lab 3 panel (w/o VersaDial) Aqua-Lab 3 panel (w/ VersaDial)
26” x 18” x 39”
(66.0 x 45.7 x 99.1 cm)
14” x 24” x 48”
(35.6 x 60.9 x 121.9 cm)
8” x 32” x 24”
(20.3 x 81.3 x 60.9cm)
8” x 32” x 41.39”
(20.3 x 81.3 x 105.1cm)
OPERATING WATER PRESSURE
200 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.) 180°F (82.2°C)
AIR INLET LINE
3/8” OD Poly Tube per panel
WATER FILTRATION
(SUGGESTED)
50 Micron
AIR OUTLET LINE
3/8” OD Poly Tube per application
AIR INLET PRESSURE
20 CFM @ 80-120 PSI (5.5-8.3 bar) Dry Air
BACK ROOM AMBIENT AIR TEMP
MAX: 130°F (54°C)
SOLUTION OUTLET LINES
Up to 2.25 GPM (8.5 LPM) 3.25 - 4.5 GPM (13.3 - 17 LPM) 5.5 GPM (20.8 LPM) 8.0 - 15.0 GPM (37.9 - 56.8 LPM)
3/8” ID (1/2” OD Poly Tube*) 1/2” ID* 5/8” ID* 3/4” ID
*Assuming line length is 50’ (15 m) or less. Refer to page 42 for recommended size chart for other lengths of tubing.
OUTLET CONNECTION FROM MANIFOLD
20 GPM pump 40 GPM Grundfos pump
1” FNPT 1” FNPT
WATER SUPPLYMAX FLOW PER PORT
Max flow per MAM
valve port 6 GPM
Max flow per BAM
valve port 15 GPM
FLANGE TORQUE
40 GPM Grundfos pump
40 ft-lbs (Min.)
PRESSURE TRANSDUCER (VFD)
Pressure range (20
GPM) 0-300 PSI
Pressure range (40
GPM) 0-363 PSI
Set point 200 PSI
Cord length 23 feet / 7 meters

www.SonnysDirect.com | 5
INSTALLATION INSTRUCTIONS
WHO TASK EST. TIME
DISTRIBUTOR MONITOR & RECORD PERFORMANCE 2 HR / WK
DISTRIBUTOR MAINTENANCE PER SCHEDULE OR AS NEEDED
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
WHO TASK EST. TIME
DISTRIBUTOR & CUSTOMER DETERMINE LOCATION TO INSTALL EQUIPMENT 1 HR
PLUMBER INSTALL WATER SUPPLY LINE 4 HR
ELECTRICIAN INSTALL ELECTRICAL SUPPLY LINE 4 HR
TECHNICIAN LABEL ALL CONTROLLER RELAYS AT CONTROLLER 1 HR
TECHNICIAN RUN SOLUTION AND AIR LINES (IF NECESSARY) 5 HR
TECHNICIAN INSTALL AIR SUPPLY LINE 1 HR
TOTAL LABOR HOURS 16 HRS
WHO TASK EST. TIME
DISTRIBUTOR / TECHNICIAN HANG EQUIPMENT 1 HR
TECHNICIAN CONNECT WATER, AIR AND SOLUTION LINES 1 HR
TECHNICIAN CONNECT CONTROL LEADS TO MAIN CONTROLLER OR JUNCTION BOX 2 HR
DISTRIBUTOR/TECHNICIAN STARTUP (INJECTOR, METERING TIP AND NOZZLE SELECTION) 3 HR
DISTRIBUTOR/TECHNICIAN DOCUMENT CONFIGURATION 1 HR
TOTAL LABOR HOURS 8 HRS
Installation takes approximately ONE day. An
electrician and a plumber are needed for half a day.
General Skill Level
• Mechanical: Basic - mounting equipment
• Electrical: Advanced - three-phase power and controls knowledge (local codes knowledge required)
• Plumbing: Moderate - principal supply line required
• Pneumatic: Basic - pneumatic utility connection required
• Chemical Knowledge: Moderate - chemical titrations required
ESTIMATED INSTALLATION TIMELINE

6 | © Sonny’s CarWash Backroom by Hydra-Flex, Inc. 2022
INSTALLATION INSTRUCTIONS
STEPBYSTEP INSTALLATION INSTRUCTIONS
NOW ON YOUTUBE!
Scan the QR code to watch our team walk you through
step-by-step instructions.
• Drill with Phillips head
• Concrete drill bit 1/2”
• Concrete drill bit 3/16”
• Hammer
• Hammer Drill
• Utility knife
• Wire stripper
• Socket set
• Tape measure
• Utility knife
USEFUL TOOLS:
• Multi Meter
1. UNPACKING
• First, do NOT discard your manual. We recommend
keeping it in the blue envelope we have provided for you
and store it safely in your wash’s office for troubleshooting
and future references on system maintenance.
• KEEP all accessories shipped in a central and safe
location for installation, after the panel and pump
have been mounted.
• Unpack your system and pump from their
respective boxes.
• Inspect the shipment for any damage or missing
components. Please call us immediately at 952-808-3640 if
either occurs.
• If pumps are included with order, utilize proper lifting
technique and mechanical assistance if necessary.
TOOLS & EQUIPMENT NEEDED:
STEP-BY-STEP FULL INSTALLATION
INSTRUCTIONS
The following pages include all necessary steps to ensure your new Aqua-Lab 3
system and Alfred platform are fully installed for your wash.

www.SonnysDirect.com | 7
INSTALLATION INSTRUCTIONS
2. LOCATION LAYOUTS & MOUNTING
• If location has not been identified during the Pre-Installation Process, make sure to consider the
system’s proximity to feed water, power supply, and the control cabinet, as well as space near the system
to store chemical containers.
*Please note: hoses off the pump are only 6 feet and mounting locations should be planned
for accordingly.
• The following layout options include different ways to install your selection of pumps and panel systems.
2 PANELS, 1 20GPM GRUNDFOS PUMP
** The same layout
can be used with a
40 GPM Grundfos
pump.
***Pump congura-
tion will vary de-
pending on specic
order options.
10
28
41
28
41
14
12
85 Total Width
5
8
6
6
15
8
8
10
3
17
28
27
52
44
4/1/2021
Disconnect
Box
Alfred
Gateway
Aqua-Lab 3
Panel
Primary Air
Regulator
MAM
Position
20 GPM
Wall Mount
20 GPM
Pump
BAM
Position
14”
12”
3” 6”
8”
5”
6” 8” 28”
41”
52”
8”
17”
15”
28”
44”
10”10”
85” Total Width
28”
41”
27”

8 | © Sonny’s CarWash Backroom by Hydra-Flex, Inc. 2022
INSTALLATION INSTRUCTIONS
10 14 10
28
41
28
41
14
12
108 Total Width
5
8
6
6 15
8
4
5
52
44
3/30/2021
28
41
28
41
14
12
85 Total Width
5
8
6
6
8
8
3
17
28
27
9
13
5
7
27 10 10
52
4/1/2021
2 PANELS, 1 40GPM GRUNDFOS PUMP
2 PANELS, 2 20GPM GRUNDFOS PUMPS
41”
27” 10”
10” 14” 10”
28”
17”
12”
3”
9”
10” 52”
52”
44”
41”41”
28”28”
41”
28”
28”
27”
13”
14”
5” 5”
6”
6”
8” 8”
8”
7”
85” Total Width
108” Total Width
8”
15”
12” 8”
6”
5”
4”
5”
6”

www.SonnysDirect.com | 9
INSTALLATION INSTRUCTIONS
28
41
28
41
14
12
5
8
6
6
8
3
17
28
27
9
13
5
7
27
10 10
10
10
142
52
4/1/2021
Additional
Disconnect
Box
3. PUMP INSTALLATION
• There are two types of pumps you can install with your system.
• The Grundfos 20 GPM is wall-mounted. Position it on the wall between 10” and 6’ from your
system to the water supply, using the supplied hose. If needed, purchase our hose extension kit
(part number 1003233) to allow further distance.
• The Grundfos 40 GPM is floor-mounted. Position it on the floor between 10” and 6’ from your
system to the water supply, using the supplied hose. If needed, purchase our hose extension kit
(part number 1003233) to allow further distance.
• The following pages include step-by-step instructions for your specific Grundfos pump installation.
PUMP PRIMING INSTRUCTIONS FOR THE 40GPM GRUNDFOS PUMP
WARNING: FAILURE TO PRIME PUMP WILL VOID WARRANTY
1. Confirm the inlet water source is turned on and the ball valve to the panel
inlet is closed.
2. Loosen the vent plug on the pump head to allow any air that may be trapped in
the pump to escape.
3. Turn on any function from Motor Control Unit to activate pump and run for 2
minutes, then close vent cap (DO NOT OVERTIGHTEN) and turn off pump.
4. Check for any leaks in the plumbing during this time.
NOTE: Some water will spray out of vent cap, so we recommend having a
bucket handy.
5. Open ball valve to Aqua-Lab 3 manifold inlet.
3 PANELS, 2 20GPM GRUNDFOS PUMPS
142” Total Width
28”
10” 10” 10”
10”
52”
8”
28”
27”
27”
12”
3”
9”
13”
14”
5” 5”
4”
6”
6”
8”
8”
7”
41” 28”
17”

10 | © Sonny’s CarWash Backroom by Hydra-Flex, Inc. 2022
INSTALLATION INSTRUCTIONS
20 GPM GRUNDFOS WITH INTEGRATED VFD CONT.
952-808-3640 • www.hydraexinc.com
20 GPM GRUNDFOS WITH INTEGRATED VFD
INSTALLATION INSTRUCTIONS
33”
29”
44”
44”
26”
11”
Top Of Pump
Mount
Main Water Inlet
RevD0422_4000230