Istobal User Manual - Hydra
Contents
1. Z PHYDRA FLEX INNOVATION AGUA LAB EVO Chemical Dispensing System Istobal User Manual REV B O Hydra Flex Inc 2014 Table of Contents Contents e A Pr IE ee eee IE MM e l SOS a eo obde 2 EE 4 SE AA O Ue O o E 5 Puno PES SUCIOS caia 5 IER ER Was Ee E 6 ODA ARS SS SO D oc wes Me o eae 6 Che Moa UE ae 7 o oo In 9 Injector Vacuum Check for troubleshooting injectors ccccccccnnnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 9 A CO E a A EE E 9 Ar Op rated Valve Replacement EE 10 Para TS SU a e A 11 PEC S61 e o PE ME RE RS PENE 12 PO A EA evecare taene AEAEE 12 E A RE 13 Chemical D AO RAUOS a ao ra a ao A A ea a ee k 14 a E E E TEE AA 15 Repke ment Part Larra 16 KEE 17 Hydra Flex Inc 2014 Specifications Operating water pressure 180 200 psi Do Not Operate Pump Above 225psi Pneumatics operating pressure 80 100 psi Do Not Operate Valves Above 100psi Maximum water source temperature 140 F Operating ambient temperature 40 120 F Electrical supply a 208 230 or 480 volts 3 phase b 2hp pump 7 4 amps A 230 volts or 3 7 amps 480 volts c Overload Setting 8 0 230 volts or 4 0 480 volts 6 Operate solenoid valves with 24VAC 24VDC 120VAC a 3 5 watts per port Water supply a 3 4 ID line pump feed b Inlet pressure 2 80 psi i If pumps are fed from tank water level must be 54 above pumps oS IS 8 Air supply a 3 8 feed per system b 20CFM 80 100 psi2. Pump Leaks AAA AA O Hydra Flex Inc 2014 Page 11 Pressure Regulator Issues Pump not primed Follow priming instructions Debris in regulator Remove regulator and clean out debris Motor rotation incorrect Verify rotation Opening too many valves at once System is limited by size of pump and size of psi injectors increase flow by adding secondary pumps or reduce size number of injectors open Defective check valve if applicable Replace check valve Defective Regulator Replace regulator Defective Pump Replace Pump System won t regulate up to 200 Flow Arch Issues Incorrect injector flow rate selection Replace with larger injector System pressure too low Ensure system pressure is set at 200psi Flow at arch is too Foam Generator Plugged Ensure cleaned and clear Downstream plumbing restrictive Increase size of plumbing tubing ensure check valves are cleaned or new reduce elbows in line or other turns that would restrict Valve Issues Air pressure too low Ensure primary air regulator reading at least 60 psi turn up to 80 90psi if possible and check again Internal valve o ring jammed twisted Remove valve from manifold Carefully remove top of valve caution under high spring pressure push white piston up with small allen wrench from opposite end and check o ring condition Replace and lubricate if needed Valve won t open Internal o ring seal damaged worn Remove valve from manifold Careful
3. Under Spray Flow Thru 3000173 As Shipped Wax Super Wax 618096 3 25gpm 2x 632 676 2x0880 Optimizing the System Consistently achieve the desired cleaning and presentation performance using the least amount of chemical and water Injectors vs Metering Tips vs Nozzles The key to optimizing the system is through trial and error Don t be afraid to try these steps to achieve your ideal performance a ig Pahr Tube What do injectors do Metering Tip i o Increases or decreases the amount of water in the solution What do metering tips do o Increases or decreases the amount of chemical in the solution 200 psi dal pesa GE psi max What do nozzles do o Determines the pattern and backpressure of the solution Fr n Chemical Hydra Flex Inc 2014 Page 6 Application Optimization repeat for each application e Application too wet o Increase air o Reduce injector size decreases water o Increase metering tip increases chemical e Application too dry o Decrease air o Increase injector size increases water o Decrease metering tip decreases chemical e Nozzle sputters o Decrease air o Decrease nozzle s and or size used on arch o Increase injector size increases water e Too much chemical used o Decrease metering tip o Decrease metering tip and injector size to maintain desired ratio e No chemical o Check vacuum of injector see instructions on page 9 o Check foot valve o Check metering tip e No
4. command from the controller Ensure that pump rotation is correct as indicated by the arrow on the bottom of the pump and that 200 psi can be reached o If pump cannot regulate to 200 psi remove pump motor cover and look at shaft to confirm correct rotation Start the pump and slowly open ball valve until it is wide open Allow to run for 60 seconds to flush lines and then close valve Reconnect the high pressure line to the Hydra Cannon Manifold and open valve Confirm that the pump can obtain 200 psi while firing solenoids and that the pump housing stainless steel tube is cool to the touch after a minute in operation o If housing is hot or noisy then pump did not prime correctly If pump does not prime repeat steps 3 5 Verify pump prime 24 hours after operation to ensure prime held Pay close attention to the temperature of the pump housing stainless steel area lf it starts getting hotter than the supply water or greater than 140 then it is likely that the pump did not prime correctly which will cause damage to pumps The motor housing painted portion will be hot during operation O Hydra Flex Inc 2014 Page 5 Istobal M22 M24 Initial Set Up Application Injector Nozzles Pre Spray 2 step 618098 3 25gpm 10x 0880 4x 632 676 618086 2 25gpm 2x 0880 10x 0680 Shampoo Rinse Flow Thru 3000173 Triple Foam 3x 618070 1 5gpm each As Shipped Horns Rinse Flow Thru 3000173 See Wax Low Pressure
5. hammer accident third party damage fluid impurities such as sand or minerals acts of God or acts of war Nor does it apply to any equipment which has been repaired or altered by anyone not so authorized by Hydra Flex Inc All equipment must be properly installed in accordance with specified plumbing electrical and mechanical requirements The warranty does not apply to normal wear and tear or routine maintenance components as described in the equipment manual Except as expressly stated herein Hydra Flex Inc shall not be liable for damages of any kind in connection with the purchase maintenance or use of this equipment including loss of profits and all claims for consequential damages This limited warranty is in lieu of all other warranties expressed or implied Hydra Flex Inc neither assumes nor authorizes any person to assume for it any other obligation or liability in connection herewith This warranty is neither assignable nor transferable Transportation damage claims are to be submitted to the carrier of the damaged material Hydra Flex Inc 2014 Page 16
6. supply 9 Solution lines a 3 8 ID poly lines for 3 25GPM and below D ID poly line for 3 25 to 5 5 GPM c 63 ID poly line for 5 5 8 GPM 10 Space requirements a 38 W x 44 H with pump assembly For additional support call 952 808 3640 O Hydra Flex Inc 2014 Page 1 Air Solenoid Valves Air Actuated Hydra Cannon Illustrations Vis starting at the top H20 Inlet left hand side and Pressure Gauge working clockwise Mounting Slots 2 top 2 bottom Integrated Electrical Control Box L ES 4 j dardi DI e 10 GPM Quick y o fF cl Change Pump s Primary Air Regulator Inlet Water Le Selection Valve d 52 Optional n Bypass Pressure Regulator Foaming Air or Frost Protection Air Valves Regulators Optional Wye Strainer Thermal Relief Valve Multi Conductor Three Phase Three Phase Signal Cable Power to Pump Power In Hydra Flex Inc 2014 1 16 starting at the top left hand side and working clock wise Air Pilot Solenoid Valves 1 4 Air Pilot Solenoid Valves 5 8 Air Pilot Solenoid Valves 9 12 Foaming Air Solenoid Valves 13 15 Air Pilot Solenoid Valve 16 For Inlet Water Selector optional Page 2 Diode Terminal Block Timer Contactor NN Integrated Motor Starter fo Wire Color 1 White 1 IL 2 White 2 lesi 3 White 3 23 4 White SS 5 White x 6 White 7 White L H
7. 629083 2 2 00 629086 2 2 30 2 3 20 2 5 40 O Hydra Flex Inc 2014 Page 14 Replacement Parts List Agua Lab EVO A B C D HFI Part Number Contactor 3000864 Thermal Overload 3000862 Diode Terminal Block Timer 3000664 Time Foaming Air Regulator 3000808 Foaming Air Valve 1001429 Primary Air Regulator 3001160 Tri Foam Manifold Thermal Relief Valve 3000323 Hydra Flex Inc 2014 Page 15 JRA FLUI OVATION AQUA LAB WARRANTY Factory Limited Hydra Flex Inc warrants its equipment to be free from defect in material or workmanship under proper normal proper use for a period of one 1 year beginning the date of purchase The Hydra Flex Inc s liability shall be limited to repair or replacement of parts found to be defective within the warranty period and following Hydra Flex Inc s inspection Hydra Flex Inc shall have the option requiring the return of defective material to establish the purchaser s claim In the event of repair or replacement this limited warranty is non cumulative Neither labor nor transportation charges are included in this warranty This warranty is based upon the proper care and maintenance of the warranted equipment Warranty does not apply if the merchandise is altered or modified in any way Warranty does not apply to any equipment which has been subject to misuse inappropriate use of tools including exposure to harsh chemicals neglect lack of maintenance freezing fluid
8. 8 White 9 White 1 Le 10 White APOLO TE 11 White Le 12 White 13 White sy j 14 White 14 14 H15 White C 15 16 White O16 1 Black 2 Black 3 Black 4 Black 5 Black 6 Black 7 Black 8 Black 9 Black 10 Black 11 Black 12 Black 13 Black 14 Black 15 Black 16 Black O Lem Thermal Overload Hydra Flex Inc 2014 Page 3 Principles of Operation The Aqua Lab EVO was designed to meet the application requirements of the standard roll over automatic car wash with an available pump room to store chemical and equipment The system is set up so that all that is required from the car wash controller is an output signal for each valve The EVO electrical control box uses that signal to open both the 3 5 watt air solenoid valves and to start the pump The standard 10 GPM pump produces up to 225 psi of pressure which is regulated down to 200psi by the bypass regulator The pump should never run above 225 psi The 200 psi water flows into the Hydra Cannon manifold which is fitted with 12 air actuated valves that are controlled by air solenoid valves The water valves control the flow of water to each injector or flow thru rinse fitting The Chem Flex injectors are color coded based on the water flow needed for each individual application and combine with color coded chemical metering tips to proportion the precise chemical mix ratio As water flows into the Chem Flex injector the veloci
9. K WASHER Unscrew valve assembly from the Hydra Cannon manifold Screw new valve into manifold until hand tight and threaded pilot port is facing forward ae SY s Remove the cap from pilot port and thread in quick connect fitting to front of valve Hand Tight ONLY Push air line back into fitting Open the ball valve to the Hydra Cannon manifold Unscrew from manifold using this portion of valve out em y LA Hydra Flex Inc 2014 Page 10 Pump Issues Reverse rotation by interchanging two leads Pump Operates but Incorrect Motor Rotation only delivering 100 150 psi Pump not Primed See Priming Instructions Missing 1 of 3 phases Wire according to diagram Pump Operates but Inadequate water supply Check pressure on inlet side of pump to be sure positive pressure is maintained delivers little or no S Water Undersized piping Replace with larger piping Leak on the Inlet side Make sure connections are tight Replace worn parts or entire pump clean parts if required car wash controller Blown fuse or circuit breaker Could be due to blown pump motor Try to turn breaker back on or replace fuse lf breaker trips after trying to fire motor motor is most likely burned out Replace with new motor and pump RE DE Water regulator fluttering chattering Try to adjust regulator down and then back up or Excessive Noise from Pump replace regulator pump Worn mechanical seal Replace Pump
10. ly remove top of valve caution under high spring pressure Valve leaks air or push white piston up with small screwdriver from water out top opposite end and check o ring condition Replace with 018 Viton O ring and lubricate with Dow 111 valve lube Valve remains open Manifold pressure is above 230 psi Reduce pressure to manifold to 200 psi operating after signal is off pressure O Hydra Flex Inc 2014 Page 12 Appendix Chem Flex Injectors Chemical Dilution Ratios Assumes feed pressure of 200 PSI 0744 SB 74 GPM at 0 25 0 50 0 75 3 25 200 PSI das Tip v 0 7 mm 1 0 mm 1 3 mm rs ra jamo omw o o cren a ME me oe ES DR KN E Green 0 098 2 5 mm 1 629 1 554 1 495 1 447 1 447 1 314 Ek 1 143 1 8 88 1 69 1 64 15255 A O 1261 1924 Kai 00 NOTE Dilution ratios given above are based on drawing water through the metering tips and are meant as a starting point for system configuration Results are expected to vary when drawing chemicals due to differences in viscosity and temperature zobi O Hydra Flex Inc 2014 Page 13 Chem Flex Injector Part Numbers 24 HYDRA FLEX FLUID INNOVATION Chem Flex Injector Part Numbers Part Number Barbs GPM 618029 1 0 25 1 0 50 618051 1 0 75 1 1 00 1 1 50 618083 1 2 00 618086 1 2 30 1 3 20 1 5 40 629029 2 0 25 2 0 50 629051 2 0 75 2 1 50
11. ring tips e Check and clean wye strainer e Inspect and replace chemical lines as needed e Ensure lines are tightly secured to injector hose barbs clip 1 off old hose as needed that was stretched by hose barb Annually e Clean water regulator e Inspect motor starter for corrosion if identified order replacement spare parts 1 3 Years e Inspect and replace injectors e Replace water valves e Replace main pressure regulator Hydra Flex Inc 2014 Page 8 Troubleshooting Injector Vacuum Check for troubleshooting injectors At the Chem Flex injector remove the chemical feed line from the injector hose barb Attach the tubing of the vacuum gauge to the Chem Flex hose barb 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 gt 20 in Hg 4 lf injector is not functioning a Check metering tip for clogs can be tested with no metering tip to ensure injector is performing b Try smaller injector this will produce less flow and thus less backpressure c Remove a nozzle s at the arch allowing water to free flow this will reduce backpressure 5 Repeat steps 2 4 for each chemical lane that a vacuum reading is needed for 6 Once testing is complete turn off the AQUA LAB pump from the main car wash control cabinet GE There is a variation of performance in the injectors that comes from sligh
12. t variations in the dimensions of the parts and in assembly that are unavoidable It is common to see the resultant vacuum range from 20 in Hg all the way up to 28 There is also variation in the through hole size on the meter tips from Dema within their manufacturing 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 Injector Issues Injector is not Clogged chemical feed Check chemical hose foot valve metering tip and drawing chemical hose barb for debris or clogs PASSES vacuum pressure check Too much back pressure on injector Clean or replace downstream check valves increase nozzle size or quantity use larger tubing or use smaller flow injectors Injector is not barb on the injector to remove debris FAILS vacuum compressed air pressure check Defective Injector Replace injector remove nozzle inlet holes to allow full flow No Elow from ensure valve receiving signal injector compressed air No water supply Check that the system has a supply of water Injector Stainless Strong Acid Call Hydra Flex and order composite version of Steel disintegrating injectors Hydra Flex Inc 2014 Page 9 Air Operated Valve Replacement Shut off the ball valve to Hydra Cannon manifold Disconnect air line from front of valve Unscrew quick connect fitting by hand DON T LOSE BLAC
13. ty increases As the velocity increases the pressure decreases creating a vacuum which allows the precise amount of chemical to be pulled into the chamber where it mixes with water This precise chemical mixing along with the proper nozzle creates an optimal display in the wash bay Optional components that are included with the Istobal EVO system include an inlet water selection valve a foaming air wing a system protection pressure switch and the tri foam manifold The inlet water selection value is operated using an air solenoid valve This valve allows the option of using two different water sources The foaming air wing is used as a blow out frost protection When the temperature drops below a certain pre set point air is forced through the lines clearing them of water or solution that could potentially freeze and cause damage The pressure switch is supplied to ensure that if the pump is not getting pressure a signal will be sent to the controller to shut the system down The tri foam manifold is a three position quick connect manifold that fits into a single port to support triple foam or equivalent operations O Hydra Flex Inc 2014 Page 4 Startup Pump Priming Instructions 1 Pull the pump outlet line at the manifold quick connect Open ball valve and direct toward a drain or container to remove the majority of the air from the pump until a steady stream of water is flowing approx 1 min Start the pump using a
14. zzle fan pattern not filled o Reduce nozzle size o Increase injector size increases water e Water not present at all nozzles on arch o Verify check valves are functioning Verify nozzles are not plugged Reduce number of nozzles Reduce nozzle size Increase injector size increases water O O O O Chemical Usage Measuring Verify titration of chemicals before proceeding 1 Setup lab scale with small bucket of chemical to be measured 2 Putthe suction line into the bucket 3 Run the application being tested to prime the line All air bubbles must be removed for accuracy 4 Record the Initial Weight from the scale Tarring the scale with weight on the scale can affect accuracy 5 Run the application for 6 vehicles or manually for the same it would be on for 6 vehicles 6 Record the Final Weight from the scale 7 Subtract the Initial Weight from the Final Weight to determine the weight of used product 8 Divide this Used Weight by 6 to get a per car weight 9 Divide the Per Car Weight in grams by the specific gravity of the chemical to determine the milliliters of chemical used per vehicle 10 Repeat for each chemical application Hydra Flex Inc 2014 Recommended Maintenance The recommended service and maintenance on the AQUA LAB System are as follows Monthly e Check air regulator e Check water filter and replace as needed if installed Semi Annually e Check and replace injector mete
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