Hydro HydroMinder HP User manual

user manual
HydroMinderTM HP

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Index
1.00 Overview .................................................................................................................................................................5
1.01 Safety Precautions .....................................................................................................................................................................................................................................5
1.02 Description of the System.......................................................................................................................................................................................................................5
1.03 Panel Components ....................................................................................................................................................................................................................................6
1.04 Panel Dimensions.......................................................................................................................................................................................................................................7
2.00 Specication ...........................................................................................................................................................8
3.00 Panel Installation ...................................................................................................................................................9
3.01 Site Survey ...................................................................................................................................................................................................................................................9
3.02 Required Skills and Tools ...................................................................................................................................................................................................................... 10
3.03 Mounting the Panel................................................................................................................................................................................................................................ 11
3.04 Signal Wiring ............................................................................................................................................................................................................................................ 11
3.05 Air Supply .................................................................................................................................................................................................................................................. 11
3.06 Foaming Outlets...................................................................................................................................................................................................................................... 12
3.07 Solution Lines........................................................................................................................................................................................................................................... 12
3.08 Chemical Supply Lines .......................................................................................................................................................................................................................... 13
4.00 Pump Installation.................................................................................................................................................14
4.01 Pump Overview ....................................................................................................................................................................................................................................... 14
4.02 Floor Mount............................................................................................................................................................................................................................................... 14
4.03 Gaskets Installation ................................................................................................................................................................................................................................ 15
4.04 Pump Inlet ................................................................................................................................................................................................................................................. 16
4.05 Pump Outlet.............................................................................................................................................................................................................................................. 16
4.06 Hoses ........................................................................................................................................................................................................................................................... 17
4.07 Prime Pump............................................................................................................................................................................................................................................... 17
5.00 VFD Installation....................................................................................................................................................18
5.01 VFD overview............................................................................................................................................................................................................................................ 18
5.02 Mounting the VFD .................................................................................................................................................................................................................................. 18
5.03 Wiring the VFD ........................................................................................................................................................................................................................................ 18
5.04 VFD and Pump Operation Check ...................................................................................................................................................................................................... 19
5.05 Operating the VFD ................................................................................................................................................................................................................................. 20
5.06 System Start UP........................................................................................................................................................................................................................................ 20
6.00 Maintenance and Troubleshooting..................................................................................................................21
6.01 Maintenance ............................................................................................................................................................................................................................................. 21
6.02 Troubleshooting ...................................................................................................................................................................................................................................... 21
Index

7.00 Spare Parts ...........................................................................................................................................................23
7.01 Panel Spare Parts - 1 of 2 ...................................................................................................................................................................................................................... 23
7.02 Panel Spare Parts - 2 of 2 ...................................................................................................................................................................................................................... 24
7.03 Pump Spare Parts.................................................................................................................................................................................................................................... 25
8.00 Warranty ............. ..................................................................................................................................................26
8.01 Limited Warranty..................................................................................................................................................................................................................................... 26
8.02 Limitation of Liability............................................................................................................................................................................................................................. 26
Index

5
1.01 Safety Precautions
WARNING! Please read precautions thoroughly before operation. Must 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.
protective footware, such as steel toed shoes, when installing the unit and its peripherals.
Disconnect all electrical power during installation, service, and/or any time electrical connections are
exposed.
Installation of the system must be performed according to the instructions of this manual. It is the
responsibility of the installer to ensure that the equipment or system into which the product is incorporated
complies with all relevant legislation and codes of practice which apply in the country of use.
Regularly inspect equipment and keep equipment clean and properly maintained.
Warranty is voided if the user modifies, adds, or suppresses any feature of the unit.
All components involved in maintenance tasks must be the ones registered in the spare parts list supplied by
the manufacturer. Otherwise the Warranty is void.
1.00 Overview
WEAR
NOTE
1.02 Description of the System
The HydroMinder HP is a high pressure, venturi injector-based, multi-channel chemical dilution system for use in bay and
tunnel car washes.
The panel works in conjunction with a pump to provide pressurized water and a VFD to regulate the pump’s output at a
constant 200 psi.
HydroMinder HP is available in two sizes, 5 or 7 product configurations.
Product Features
• Valve Injector flow rates of 0.75 to 12 GPM per application.
• Individually controlled foaming pressure lines for each application.
• Triple foaming supported tied to three individually controlled foaming pressure lines.
• Quick disconnects and shutoffs for each valve for ease of installation and maintenance.
• Stainless steel componentry for superior longevity.

6
1.00 Overview (continued)
1.03 Panel Components
The diagram below list the componentry of a 7 valve system. The 5 valve system differs in number of valves and supporting
componentry.
See A
Pneumatic
Solenoid Valves Signal Box
Mounting Key
Hole
Foaming Air
Regulators
Water Distribution
Manifold
Individual Output
Ball Valve
Foaming Output
Angled Seat
Valve
Hose from
Pump
Operating Water
Pressure Gauge
Main Air Supply
Regulator
Solution Output
A
Quick Connect
Quick Connect
Injector
Check Valve
Chemical Inlet
Triple Foam
Manifold

7
1.00 Overview (continued)
1.04 Panel Dimensions
Note: Dimensions are same for both 5 valves and 7 valves system.
28.01 in.
29.76 in.
31.47 in.
18 in.
23 in. 31.07 in.

8
HydroMinder HP Panel
Wall Mount
Provided Hardware No. 8 Screw and Anchor kit
Air Supply
Min. Pressure Required
Tubing Size
Recommended Material
Connection Type
80 psi Dry
3/8” OD - to be supplied on site
Polyethylene
Push-To-Connect
Control Signals
Signal Voltage
Cable length
Specified at purchase
30 meters
Chemical Supply
Tubing Size
Recommended Material
Connection Type
1/4” ID - to be supplied on site
Vinyl
Barb
Solution Outlets
Tubing Size
Recommended Material
Connection Type
1/2” OD - to be supplied on site
Polyethylene
Push-To-Connect
Foaming Outlets
Tubing Size
Recommended Material
Connection Type
3/8” OD - to be supplied on site
Polyethylene/Polyurethane
Push-To-Connect
Injectors
Available Flow Rates
0.75, 1, 1.5, 2, 2.25, 3.25, 4, 5.5,
7, 8, 9, 10, and 12 gpm
Weights and Dimensions
Weight
Height
Width
Depth
75 lbs
31.07”
31.47”
6”
Pump
Floor Mount
Hardware Anchors for 1/2” Bolt Holes - to be
supplied onsite
Pump Inlet (From City)
Min. Pressure
Provided Hose Length
Provided Hose Size
Provided Connection Type
40 psi
6 ft.
1” ID
1” Barb
Pump Outlet (To Panel)
Working Pressure
Provided Hose Length
Provided Hose Size
Provided Connection Type
(Pump Outlet)
Provided Connection Type
(Panel Inlet)
200 psi (Factory Set)
6 ft.
1” ID
1” NPT
Quick Connect
Electric
Input Voltage
Specified at purchase (Check VFD
Name plate)
480 VAC 3-Phase
240 VAC 3-Phase
Weights and Dimensions
Weight
Height
Width
Depth
127 lbs
41”
10”
9”
Max. Pump Capacity 20 gpm
VFD
Wall Mount
Provided Hardware
No. 8 Screw and Anchor kit
Electric
Input/ Output Voltage
Max Rated Power
Max Frequency
Specified at purchase (Check VFD
Name plate)
480 VAC 3-Phase
240 VAC 3-Phase
6.4 Amps at 480 VAC
12.9 Amps at 240 VAC
60 Hz
Pressure Transducer
Cable
Provided cable Length 6 ft.
Weights and Dimensions
Height
Width
Depth
11”
7.5”
8”
2.00 Specification

9
3.00 Panel Installation
3.01 Site Survey
When determining where to install the panel, consider the distance to the pump stand, air supply, car wash control panel,
and chemical containers. Incoming/outgoing connections will need to accommodate the distance. Also consider how the
solution, chemical, and air lines will be routed, and what hardware will be required to accomplish that scheme.
Refer the below diagram to locate the panel and peripheral components.
3Phase
Power
Panel
VFD
Pump
To VFD*
3 Phase Power Cord
to Pump*
Pressure Transducer Cable (6 ft.)
Water Inlet
200 psi Pressure
Transducer & Cable
Ground Mount
Signal Box
Main Air Supply
Regulator
Air Solenoid
Valves
Panel Water
Inlet Hose (6 ft.)
Flange Fittings & Seals
Flange Fittings & Seals
80-120 psi Air Inlet
Pressure & Tubing*
Recirculation Hose
Cable to Car Wash
Controller
HydroMinder HP Panel
* To be supplied onsite.
To Chemical
To Chemical To Chemical To Chemical
To Chemical
To Chemical To Chemical
Filter
Chemical ow lines
Water ow lines
Air ow lines
Electrical lines

10
3.00 Panel Installation (continued)
3.02 Required Skills and Tools
Skills
Mechanical Mounting the panel and assembling injectors
Electrical Knowledge of 3 phase systems and local electrical code for VFD/Pump
Familiar with car wash controller trigger signals
Plumbing Assembling pump flanges, threaded connections, and hose connections
Connecting solution lines
Air Connecting air lines
Chemical Connecting chemical pick up lines
Process Knowledge of car wash applications
Tools
Mechanical Hammer Drill
Masonry Bits
Impact Driver
Bubble Level
Tape Measure
Pencil/Marker
Wrench Set
Screwdriver Set
Electrical Cable – length determined by pump/VFD location
Cable Stripper
Wire Stripper
Multimeter
Flexible Watertight Conduit
Ring Terminals and Crimper
Plumbing Pipe Wrench
Teflon tape/Pipe dope
Tube Cutters
1” Hose Clamps

11
3.00 Panel Installation (continued)
3.04 Signal Wiring
Warning! - Ensure the voltage from the car wash trigger signals matches the voltage stated on the air solenoids.
Run the signal box cable to the car wash control panel and connect the trigger wires to the appropriate terminals.
Refer the below table and the car wash control panel schematics to identify the appropriate wiring locations.
Signal Box Wiring
Connections Wire Color
Supply VAC Brown (Not Used)
Neutral Blue
Valve 1 White
Valve 2 Green
Valve 3 Yellow
Valve 4 Grey
Valve 5 Pink
Valve 6 Red
Valve 7 Black
Valve 8 Violet (Not Used)
Ground Green/Yellow
3.05 Air Supply
Run tubing from the compressed air supply to the main air regulator on the panel. Adjust the panel’s regulator to 80-120 psi.
3.03 Mounting the Panel
Warning! - Wear protective PPE, such as steel toed shoes and safety glasses, when installing the unit and its
peripherals.
Note: Two people will be required to mount the panel.
1. Determine where the panel will be mounted. The surface must be vertical and able to withstand the weight of the panel.
Refer to the site survey diagram for location.
2. A paper template with bolt hole locations is included for ease of installation. Tape the template to the mounting surface.
The template must be tight for accurate placement of the bolts.
3. Drill pilot holes and insert the anchors into the holes. Drive the bolts approximately 1/4 in. from the wall to allow the panel
to drop in the key slot.
4. Align the panel over the bolts and drop it into place. After dropping the panel into position, drive the bolts hand tight.
5. Install the angled seat valves to the quick connect fittings on the ball valves. Insert each corresponding air tube to the seat
valve.

12
3.00 Panel Installation (continued)
3.06 Foaming Outlets
Run tubing from the foaming applications to the panel’s foaming outlets. The order of the valves corresponds to the order of
the foaming outlets. If an application doesn’t require a foaming connection, leave the outlet empty.
Triple Foaming Application
The first three foaming outputs are for triple foaming applications on solution valve 1. If a single foaming application is
used on valve 1, only one foaming output needs connected
3.07 Solution Lines
1. Choose the injector size for each application. Refer to each application’s flow recommendation for a starting size. The
injector flow rates are specified by the color and have the flow rate stamped on the body.
2. Insert the injector into the angled seat valve’s quick connect.
3. Run solution lines to the Push-In connections
Single flow application: Triple flow application:
7 Valve Foaming Outlet 5 Valve Foaming Outlet

13
3.00 Panel Installation (continued)
3.08 Chemical Supply Lines
1. The chart below should be used as a guideline for selecting the metering tip but is based on water-thin products.
Performing a titration will guarantee desired dilutions are achieved.
2. Insert the metering tip into the hose barb.
3. Slide the chemical pick-up tubing completely over the barb.
4. Install a footvalve/check valve and/or filter (not provided) on the other end of supply tube and place in the chemical
container.
Nominal
Tips 0.75 1 1.5 2 2.25 3.25 4 4.5 5.5 7 8 9 10 12
Grey 5 6 7 7 7 9 10 11 13 15 16 18 20 24
Black 5 7 7 7 7 9 11 12 14 16 17 19 21 26
Beige 5 7 8 8 8 11 12 13 18 20 21 24 27 32
Red 5 7 9 9 9 15 17 19 29 32 34 38 42 51
White 6 8 11 12 14 23 26 29 43 47 51 57 63 76
Blue 7 9 12 16 17 27 30 33 50 54 58 65 73 87
Tan 8 11 17 19 21 36 40 45 66 72 78 88 98 118
Green 12 16 22 29 31 57 63 69 111 115 118 133 147 177
Orange 14 19 28 37 40 68 77 86 131 137 143 161 179 215
Brown 17 23 33 42 47 85 97 109 157 162 167 188 209 250
Yellow 24 33 43 56 68 111 126 141 209 227 245 275 306 367
Aqua 27 36 52 68 77 124 149 173 255 265 274 308 342 411
Purple 48 64 53 69 119 190 212 234 395 429 463 521 579 695
Pink 83 110 140 182 218 378 451 523 686 727 768 864 960 1152

14
4.00 Pump Installation
4.01 Pump Overview
Warning! Do not run the without water. The pump needs primed before operation.
Note: Only qualified personnel should perform the installation.
1. Use pipe dope or teflon tape for threaded connections.
2. Consider the proximity of the panel and VFD when choosing the pump location. A 6 ft. hose is
provided that connects from the pump outlet to the panel. A 6 ft transducer cable will need to
connect from the VFD to pressure inducer at the pump outlet.
3. Consider the pump inlet and outlet locations. The orientation will determine the distance it can
be installed from the wall. The water hammer arrestor extends approximately 9 in. and the pressure
transducer extends approximately 6 in.
4. Ensure the correct orientation of tee connector, cross connector and water arrestor while installing
the hardware.
5. A water filter is provided that can either be installed on the pump’s inlet plumbing or at the source of
the water supply. If installed on the pump’s inlet plumbing, it will require installing before the pump is mounted as it will
require tilting the pump up to prevent interference when screwing the filter on
4.02 Floor Mount
1. The pump should be installed on cement base, or other similar base. The pump should be located in a well ventilated but
frost-free area. Refer to Section Site Survey diagram for location.
2. Align the pump into position and create pilot holes using the stand’s bolt holes as guides. Drive the four anchors to secure
the pump base to the floor.
Pump Connection
Pump Installation Consideration
Recirculation Hose
Input
Outlet
Water Hammer
Arrestor
Tee Connector
Pressure Transducer
Cross Connector

15
4.03 Gaskets Installation
Sealing gaskets and the following hardware needs to be installed on both the inlet and outlet of the pump.
1. 2. 3.
4. 5.
4.00 Pump Installation (continued)
Remove the cover sticker. Rotate
the flange to protrude slightly.
Place and hold the gasket on the
black flange.
Align the flange on the gasket with
shortest face towards the gasket.
Secure the flange with bolts,
washers and nuts. Tighten with
star method. Install the 1” Female
reducer bushing.
Flange slightly
Protruding
Longer Face away
from Gasket
Shorter Face
towards Gasket
Install the straight connector.

16
4.00 Pump Installation (continued)
4.04 Pump Inlet
Note: Follow step 2a if the filter will not be installed on the pump inlet plumbing. Follow step 2b if the filter will be installed on
the pump inlet plumbing.
1. 2.
2.
Install the Tee Connector. The branch
of the tee must face towards the
water hammer arrestor.
Install the Metal Barb fitting at the
center branch and the plastic barb
fitting in the remaining open branch.
a.
Install the filter before the pump
plumbing. Arrows on the filter indicate
the flow of water
b.
Add a straight connector and plastic
barb fitting to the filter. Arrows on the
filter indicate the flow of water. The
filter will interfere with the ground
when installing so the pump will need
tilted up.
4.05 Pump Outlet
1. 2. 3.
Install the cross fitting into the
straight connector. The cross’s
branches should be approximately
horizontal to the floor.
Install the water hammer arrestor
and ensure the arrestor’s opening
is facing towards the pump inlet.
Towards
Inlet
Install the barb fitting on the
arrestor and reducer bushing on
the cross fitting.

17
4.05 Pump Outlet (Continue)
4.00 Pump Installation (continued)
4.07 Prime Pump
1. Ensure the pump’s water supply is on and the pump’s outlet hose is connected to the panel with the ball valve in the ON
position
2. Slowly open the vent plug on the pump to bleed air in the system. Once water starts spraying out the valve, ensure that all
air pockets have escaped by leaving the valve open until no air is observed for at least one minute. Close the vent plug.
Note: Water will spray out of the vent plug when performing this step.
3. Ensure minimum 40 psi pressure is maintained on the panel water pressure gauge.
Venting Plug
4.06 Hoses
1. Install the incoming water supply and recirculation hose on the barb fittings using hose clamps.
2. Connect outlet hose to the pump inlet and attach the opposite end to the quick connect on the panel. Turn the ball valve
on the hose to ON position.
Thread the pressure transducer
inside the Bushing.
4.
Recirculation Hose
Input
Outlet

18
5.00 VFD Installation
5.02 Mounting the VFD
1. Refer to section Site Survey diagram for mounting VFD.
Note: Mount the VFD away from areas subjected to steam or chemicals.
2. Place the VFD on the wall and mark the screw locations.
3. Drill 1/4” pilot holes and insert anchors. Drive the bolts approximately 1/8” from the wall.
4. Place the VFD key holes on the bolts and push down to lock into position. Tighten the bolts on the VFD frame.
5.03 Wiring the VFD
1. Remove the two bolts on the VFD cover for terminal locations. Also remove the pump cover
2. Wire the following:
a. Three phase cable from the power source to the VFD
b. Three Phase Power cable from VFD to the pump
c. Pressure Transducer cable from VFD to the pressure transducer
Note: Do not turn ON power to VFD until the next step.
5.01 VFD overview
WARNING!: The Pump must be primed before installing the VFD to prevent dry running.
WARNING!: Please follow safe electrical precautions.
Follow the directions below for installing the VFD. Only qualified personnel should perform the
installation.
VFD Installation Considerations
1. Determine how to connect the electrical cables from power source to the VFD and from VFD
to the pump.
2. The VFD mounting height needs to be considered for ease of access to operate the unit.
Refer to section Site survey.
3. The VFD is preset so that once power is received, it will drive the pump to 200 psi. The
pump must be primed before this step and connected to the panel so that pressure can be
checked on the panel’s gauge.
Types of VFD
Part Number Description
HYD10100457 200-240 VAC VFD ASSY with Pressure
Transducer Cable
HYD10100458 380V-480 VAC VFD ASSY with Pressure
Transducer Cable

19
5.00 VFD Installation (continued)
5.04 VFD and Pump Operation Check
On the pump motor, rotating direction is critical. Rotation will need to be checked in tandem
when the power is released to the VFD. The rotating direction is indicated on the fan cover.
1. Before releasing power to the VFD, Confirm the following:
a. The pump is primed.
b. The water supply is on.
c. The pump’s outlet hose is connected to the panel with the ball valve open
and pressure atleast 40 psi.
d. The pressure transducer is plugged in.
e. You are prepared to quickly turn power off if the motor rotation is wrong. Two people may be required; one to control
the power and one to watch the motor rotation.
2. Turn the VFD’s power source on while checking the motor rotation in tandem. Immediately stop power to the VFD if the
rotation is wrong. Interchanging any two leads with power off can reverse the pump rotation.
3. Verify the pressure gage reads approximately 200 psi.
VFD o Pressure:
≥40 psi
VFD on Pressure:
200 psi
Ball Valve
Open Position
Connect pressure transducer cable.
W
V
U
Connect pump motor cable.
From: Pressure Transducer
Connect Brown +24 VDC wire to T1 and Blue Input wire to T10 on the connector.
From: Power Source From: Pump Motor
From: Power Source
From: Pressure Transducer
To: Pump Motor
Connect three phase power to L1, L2,
L3, and ground
Connect motor cable to
U,V,W and ground
Connect red wire to T1 and black wire to T6 on the terminal connector.

20
5.05 Operating the VFD
Automatic ON/OFF operation
If desired, the installer can preserve pump life by automating the VFD so that is only on during the car wash’s operating hours.
T1 is tied to the VFD’s internal (isolated) 24V supply. T2 has the function of ‘Run Enable’, meaning the VFD will operate only
when it receives the 24V signal from T1. When these connections are bridged, run is always enabled. To enable run only
during operating hours, remove the bridge and wire T1 and T2 to a relay or contactor that is only energized during operating
hours.
Manual ON/OFF Operation
To preserve pump life, the VFD will need to be turned off during non operating hours.
5.00 VFD Installation (continued)
5.06 System Start UP
After installing the panel, pump and VFD the operating variables will needs to be optimized. Perform the following steps
1. Ensure incoming air pressure is at 80 psi and water pressure at 200 psi.
2. Prime the chemical lines by manually engaging each air solenoid button.
3. Set the foaming pressure for each application.
4. Verify Injector Flow rates and chemical dilutions to the car wash application. Injectors and metering tips initially chosen may
needs to be exchanged to achieve desired results. Performing a titration will guarantee desired dilutions are achieved.
A chemical scale may be used to verify amount of chemical used per car.
Buttons