ZVC Assure PDS User Manual - Hydra
Contents
1. 094 2 e 5 73 Lew REGERE HB po 6 P E NI 1 E C 1 HS Mp4 1 PO ie __ gt 0 0 Valve Signal 2 gt 4 Q 8 9 eno 9 3 5 1 a r m N 2 2 gt 4 Q 85 ame 98 4 E d i N Z 2 JSVHd 9 START UP 1 DISCONNECT amp FLUSH Close ball valve and remove the pump outlet line at the Hydra Cannon Manifold quick connect Image 1 Make sure water supply to pump is turned on 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 Then close the ball valve 2 CHECK ROTATION Open ASSURE PDS Motor Starter Box MSB and ensure 3 phase disconnect is on Note Door will not open with disconnect on Use a 1 4 wrench or crescent wrench to turn it back on after opening door MSB with blue and black Eaton disconnect can be opened without shutting off by depressing button under switch handle Press small button with screw driver to bypass disconnect Image 2 WARNING ELECTRIC SHOCK HAZARD HIGH VOLTAGE PRESENT INSIDE MOTOR STARTER BOX USE CAUTION Start the2. Port Assure PDS Power Receptacle Included 15 75 a Ii m p 9j 2x 20 Signal Wire To AQUA LAB Included 1x 6 Quick Change Flexible Hose With Regulator amp Wye Strainer To Assure PDS With 1 2 Quick Connect amp Ball Valve Included With Each 1x 6 X O1 0 MNPT Quick Change Pump Inlet Hose Included 1x 12ft 230V 480V Pump Power Cord Included With Each Pump Page 4 9 EASY STEPS FOR INSTALLATION 5 EASY STEPS FOR INSTALLATION COMPLETE PRE INSTALLATION CHECKLIST BEFORE THESE STEPS Unpack Set skid in place Make connections Start up qe Los OE ues Optimizing the equipment ESTIMATED TIMELINE PRE INSTALLATION WHO TASK EST TIME ZVC REP amp CUSTOMER DETERMINE LOCATION TO INSTALL EQUIPMENT 20 HR PLUMBER ZVC REP INSTALL WATER SUPPLY LINE TOTAL LABOR HOURS 9 75 HRS INSTALLATION WHO TASK EST TIME TOTAL LABOR HOURS 6 HRS POST INSTALLATION WHO TASK EST TIME ZVC REP MONITOR amp RECORD PERFORMANCE 2HR WK ze MAINTENANCE PER SCHEDULE OR AS NEEDED TOTAL HOURS SPENT TOTAL CUSTOMER SHR TOTALZVCEREP Installation takes approximately ONE day An electrician TOTAL ZVC REP 13 75 HR 13 75 HR and a plumber are needed for half a day TOTAL ELECTRICIAN 4HR TOTAL PLUMBER AHR Hydra Flex Inc 2015 Page 5 INSTALLATION INSTRUCTIONS General Skill Level e Mechanical Basic mounting equipment e Electrical Advanced
3. e ncreases or decreases the amount of water in the solution What do metering tips do e Increases or decreases the amount of chemical in the solution What do nozzles do e Determines the pattern and back pressure of the solution APPLICATION OPTIMIZATION REPEAT FOR EACH APPLICATION Application too wet e Increase foaming air pressure e Reduce injector size decreases water e Increase metering tip increases chemical Application too dry e Decrease foaming air pressure e Increase injector size increases water e Decrease metering tip decreases chemical e Nozzle sputters e Decrease foaming air pressure e Decrease number of nozzle s and or size used on arch e Increase injector size increases water Too much chemical used e Decrease metering tip e Decrease metering tip and injector size to maintain desired ratio Metering Tip 1 4 Poly Tube Chemical 200 PSI Water 66 PSI Max Solution e No chemical Check vacuum backpressure of injector for clogging see page 17 for Injector Vacuum Check Instructions or pages 15 for troubleshooting e Check foot valve Check metering tip e Nozzle fan pattern not filled e Reduce nozzle size e Increase injector size increases water Water not present at all nozzles on arch Verify check valves are functioning Verify nozzles are not plugged Reduce number of nozzles Reduce nozzle size Increase injector size inc
4. e Connect pre run 3 8 OD poly feed line to push connect fitting 2 on the side of the primary regulator FT PI Precision Dispensing S e Connect 3 8 OD poly lines from arch to each port that will be foaming If there are unused air ports back out the individual line regulator until air no longer flows 1 ELECTRICAL CONNECTIONS HFI MOTOR STARTER a Wire yellow homerun control cables to car wash control panel See diagram below for wiring schematic e Manifold position below designates which port is associated to what color wire e Example if you want Presoak 1 to be on manifold port 2 connect the green wire to your controller relay for Presoak 1 mop NS supplied motor starter vos mn P et NOR Make sure all BLUE wires are separately capped with wire nuts so that they do not touch any other electrical conductive objects One Wire Per Nut Left to right on water manifold top to bottom Ground Greenlydlew on air valves refer to diagram on page 2 Do Not Use Blue Cap With Wire Nut Control Voltage Constant Hot Brown Neutral Common Red Hydra Cannon Port 1 White Hydra Cannon Port 2 Green Hydra Cannon Port 3 Yellow Hydra Cannon Port 4 Grey Hydra Cannon Port 5 Pink b Remove the cap from port 6 then connect the grey M12 cables hanging out of the motor starter box to the NEUTRAL COMMON port 6 of the yellow M12 junctio
5. D 0 75 1 82 1 165 1 247 1 329 1 494 1 659 1 741 1 1071 1 1812 76 0 50 1 59 1 119 1 178 1 238 17357 1 475 1 535 152772 1 1307 0 25 1 34 1 68 1 102 1 136 1 204 12272 1 306 1 442 1 748 Remove all standard metering tips when using a Metering Plug in an application 3 8 Polyflow LLDPE tubing is required to ensure a seal between the tube wall and the flats on the OD of the Meter Plug Hydra Flex Inc 2015 Page 18 RECOMMENDED SETUP STARTING POINTS APPLICATOR Scent Dispenser INJECTORS PART NUMBER COLOR CTA Nozzles For Showerhead See Below Foam Stick Mitter Warp Nozzles 618083 2 0 GPM 618086 2 25 Undercarriage Rust Inhibitor V Jet Or Flat Fan Nozzle Arch K12 Nozzle Arch 618086 2 25 GPM K15 Nozzle Arch Hockey Puck 3 Rows Of Holes Showerhead 1 Row Of Holes 618086 2 25 Rain Quad Foam w 4X 618086 2 25 GPM Triple Foam w 3X 618086 2 25 GPM Foam Curtain Choose Foam Accessory Based On Of Inputs Foam Generators High Flow Foam Curtain Application 10 GPM High Flow Device w 618086 2 25 GPM Foaming Air Start at 25 PSI adjust based on unique application CHEM FLEX INJECTOR PART NUMBERS QUICK CONNECT INJECTORS PC2 X 3 8 NPT CONNECTIONS For exclusive use with Aqua Lab Chemical Dispensing Systems COLOR FLOW FLOW RATE SINGLE BARB DUAL BARB TRIPLE
6. amp SCHUH EATON 14 2 Timer Relay Current Switch Contactor 3 Phase Disconnect Thermal hi Overload Contactor Current Timer Relay Switch a 4 Thermal 2J Disconnect lt lt 7 MN Quick ES come 2 7 Connect ug Pump Plug Female Grey M12 Cables Carry signal from Grey M12 Cables Carry signal from yellow M12 distribution block to yellow M12 distribution block to motor starter that turns on the pump motor starter that turns on the pump Quick Connect 9 Cordset For Pump Plugs Into Bottom Of Motor Starter Thermal Relief Valve Back up Pump Bypass Pressure Regulator Pump Outlet Feed Line To MD Panels Wye Strainer REFER TO PAGE 22 FOR PART NUMBERS amp DIAGRAMS Hydra Flex Inc 2015 Page 3 LAYOUT DRAWING 2x 3 8 Poly Flow Air Inlet Tubing Provided By Others 100 PSI Max Control Cable Included 78 1x Connection With Valve To Accommodate 1 Male Npt Hose Must Terminate Within 5 Feet Of Pump Inlet 21 0 Recommended Provided By Others O Hydra Flex Inc 2015 LI D e 1 5 4 2 adi T F s ae ni A T r 5 7 1 s aem 5 2 i pem a sm wu LI hi EP tte f d h T gt 54 7 E a E 5 M ps Er 1x 230V 480V Pump
7. fd HYDRA FLEX FLU INNOVATION 680 East Travelers Trail Burnsville MN 55337 T 952 808 3640 e F 952 808 3650 www hydraflexinc com e info hydraflexinc com Hydra Flex Inc 2015 4000022 revC1015 Page 23
8. 32 X 1 4 Push To Connect Air Fitting For Air Valve 1 4 Push To Connect Tee 1 2 NPT Male Quick Connect Brass INOT SHOWN INOT SHOWN NOT SHOWN 1 4 Push To Connect To 1 8 NPT Elbow GOMA bible UD Hydra Flex Inc 2015 Page 21 REPLACEMENT PARTS LIST ASSURE PDS PUMP ASSURE PDS SINGLE SOURCE MOTOR STARTER J cccc PART NUMBER Bo Male Quick Comet Brass ___ 30005 PD Female Quick Comeet Brass 20 GPM Quick Connect Regulator Plumbing Assembly NOT SHOWN 1 2 Ball Valve Brass 3000565 NOT SHOWN Manifold Inlet Hose 1 2 ID Hose 1 2 NPT Ends 72 L 3000579 NOT SHOWN 20 GPM Quick Connect Regulator Pluming Assembly 1001775 PART NAME PART NUMBER Contactor Sprecher amp Schuh DC 3000866 Time Relay 3000664 Current Sensor Hydra Flex Inc 2015 Page 22 ASSURE PDS WARRANTY FACTORY LIMITED Hydra Flex Inc warrants its equipment to be free from defect in material or workmanship under proper normal use for a period of one 1 year beginning the date of purchase 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 no
9. BARB ORIFICE 200 PSI WHITE 0 029 25 GPM sm 618029 YELLOW 0 040 5 GPM 618040 wb 629040 TAN 0 051 75 GPM 618051 Sie 629051 i 639051 RED 0 057 1 0 GPM 618057 629057 539057 ORANGE 0 070 1 5 GPM 618070 xh 629070 5539070 GRAY 0 083 2 0 GPM 618083 629083 639083 BLUE 0 086 2 25 GPM 618096 629086 539086 LIGHT GREEN 0 098 3 25 GPM 618098 629098 539098 DARK GREEN 0 125 5 5 GPM 618125 629125 39125 SPECIFICATIONS Pressure Range Up to 500 PSI Max 34 bar Inlet 333 PSI 23 bar Max Outlet Temperature Range Maximum Wrench Torque 30 ft lbs 41 N m Hydra Flex Inc 2015 Page 19 PRESSURE LOSS IN RUN LENGTH GREEN GOOD YELLOW USE CAUTION All solution line tubing should be selected for 10 PSI or less of pressure loss 20 PSI pressure loss may be acceptable depending upon nozzle sizing foamers check valves and other line restrictions present in application All numbers represent pressure loss in PSI for selected solution line tubing 5 8 ID BRAIDED Flow Rate GPM at 200 PSI 9 Injector Color gt Nozzle Size 125 2 100 75 50 25 1 2 ID BRAIDED 0 25 0 50 0 75 White Yellow Tan 0 029 0 040 0 051 0 057 0 7 mm 1 0 mm 1 4 mm Flow Rate GPM at 200 PSI 9 Injector Col
10. Check valves have too high of cracking pressure Replace check valve with lower pressure check valve 8 Clean foot valve BACK PRESSURE TOO LOW LOWER RED SECTION Back Pressure May Be Affected By One Or Several Of These Things FOR TROUBLESHOOTING INJECTORS 1 1 2 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 Image A 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 2 20 in Hg If vacuum reads 20 in Hg image B remove solution metering tip image C and retest a If retest vacuum reads gt 20 in Hg image D The Injector flow too low Increase injector size Nozzle size too large Reduce nozzle size INJECTOR VACUUM CHECK solution metering tip is clogged Replace the metering tip b If Retest vacuum reads 20 in Hg continue to STEP 5 Remove a nozzle on the arch or the chemical feed line from the foam generator and retest vacuum a If retest vacuum reads gt 20 in Hg back pressure is being created Continue to STEP 6 b If back pressure is not still not being created try these steps and retest after each 1 Clean nozzle tips 2 Loosely replace media in foam generator Do not over pack 3 Decrease air pressure for foaming 4 Try smaller inject
11. three phase power and controls knowledge local codes knowledge required Plumbing Moderate principal supply line required e Pneumatic Basic pneumatic utility connection required e Chemical Knowledge Moderate chemical titrations required Tools amp Equipment Needed Useful Tools e Drill with Phillips head Utility knife Adjustable wrench Socketset Amp Meter e Concrete drill bit 5 32 e Wire stripper Screw driver set Teflontape Volt Meter UNPACKING The AQUA LAB PDS is shipped on a pallet 1 Cutstraps holding skid to pallet 2 Un bolt the skid from the pallet 3 Liftthe skid from the pallet Use assistance if necessary 4 Be sure not to discard the manuals and accessories box LOCATION amp MOUNTING If location was not identified during the Pre Installation Process make sure to consider the proximity to feed water power supply and the control cabinet as well as space near the system to store chemical containers See drawing in reference for general layout 1 Setskid in location identified 2 Optional Bolt skid to wall using wall anchor plates FEED WATER CONNECTION PRIOR TO CONNECTION ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES e Connect pre run main water supply line to pump inlet with hose supplied e Single operating pump 1 MNPT e Dual operating pump 1 1 2 MNPT Hydra Flex Inc 2015 Page 6 PNEUMATIC CONNECTIONS
12. 42 1 68 1 93 1 98 1 143 1 224 E LIGHT BLUE 1 11 1 17 1 24 1221 1 47 1 64 1 66 1 98 1 166 f BROWN 8 1 10 1 15 1 22 1 28 1 43 1 58 1 59 1 88 1 150 2 RED amp 1 12 1 17 1 23 1 34 1 45 1 46 1 69 1 116 WHITE 1 12 1 16 1 22 1 31 1 42 1 43 1 64 1 108 GREEN 2 1 11 1 14 1 20 1 28 1 37 1 38 1 59 1 94 BLUE 1 10 1 12 1 17 1 23 1 30 1 31 1 46 1 77 YELLOW 159 1 12 1 16 1 20 1 22 1 31 1 52 BLACK amp 1 10 1 13 1 16 1 17 1 24 1 40 PURPLE 1 6 6 1 8 3 1 9 1 10 1 13 1 21 GRAY 1 6 7 1 6 9 1 7 6 1 10 1 16 1 4 9 1 5 3 155 2 1 6 0 1 61 1 10 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 SPIRAL METERING PLUGS Flow Rate GPM 200 PSI Injector Color Nozzle 0 029 0 040 0 051 0 057 0 070 0 083 0 086 0 098 0 125 Size 0 7 mm 1 0 mm 1 3 mm 1 4 mm 1 8 mm 2 1 mm 2 2 mm 2 5 mm 3 2 mm 3 00 1 251 1 503 1 754 1 1006 1 1509 1 2012 1 2263 1 3269 1 5532 E 2 00 1 181 1 363 1 544 1 726 1 1089 1 1451 1 1633 1 2359 152201 5 1 00 1 104 1 208 1 311 1415 1 623 1 831 1 934 1 1350 1 2284
13. 8 Single Dua 24 x 48 24 x 48 36 x 48 22 29 22 29 14 15 WATER SUPPLY 20 GPM 40 GPM Water Inlet Lines 1 ID 1 12 ID or 2x 1 ID Up to 3 GPM 255 GPM 6 8 GPM Solution Outlet Lines 1 2 OD Polyflow 1 2 ID Min 8 ID Min Operating Water Pressure 200 PSI Factory Set Assuming 40 PSI City Feed Maximum Water Source Temperature 140 F Water Filtration Suggested AIR SUPPLY Air Inlet Line 3 8 OD Polyflow Per MD Panel Air Outlet Line 3 8 OD Polyflow Per Application Air Inlet Pressure 60 120 PSI Dry Air FOR ADDITIONAL SUPPORT CALL 952 808 3640 OR VISIT US ON THE WEB www hydraflexinc com Hydra Flex Inc 2015 Page 1 ASSURE PDS SYSTEM DIAGRAM Mounting Slots 2 top 2 Bottom Precision Dispensing System i SS HYDRAFLEX Primary Air Regulator Solenoid Actuated Air Valves Individual Air Regulators M12 Junction Block 4 4 4 A M 9 Home Run Cable Goes to car wash controller for control e voltage E Grey M12 i Cable 73 Goes To Motor 4 F5BN 5C 907 Starter Box Hydra Cannon my OPPO TAN Manifold Manifold Air Ports Back Solution Ports Front REFER TO PAGE 21 FOR PART NUMBERS amp DIAGRAMS Hydra Flex Inc 2015 Page 2 MOTOR STARTER PUMP DIAGRAM SINGLE SOURCE SINGLE PUMP SHOWN SPRECHER
14. S The motor housing painted portion will be hot during operation Hydra Flex Inc 2015 Page 10 INITIAL INJECTOR SETUP Based on field experience this is HFl s recommended starting point 1 Using the recommended starting point Page 19 or the target flow rate and the chemical dilutions chart appendix Page 18 install the appropriate injector into each port 2 Connect pre run solution lines to each injector with the supplied coupler and push connect fitting a Be sure to use Teflon tape when connecting the injector to the coupler and push connect fitting to ensure there are no leaks b Do not over tighten poly fittings or they may crack 3 Connect 4 poly lines from each chemical container to the hose barb on the appropriate injector a Ensure a foot valve or similar check valve filter is installed on each line i These must be present or metering tips may clog 4 Metering tips will need to be installed to set dilution ratio see appendix Page 18 for ratio charts to determine tip TRIPLE FOAM SETUP For ASSURE PDS if ordered with extra regulators If your MD5 panel was ordered with 3 air valves and 5 air regulators or with 5 air valves and 7 air regulators the below instructions will show you how to setup your triple foam 3 Valve 5 Regulator ASSURE PDS e Yourtriple foam has been setup from the factory to be in port 3 e your triple foam manifold into position 3 with your selected injec
15. ZVC ASSURE PDS WITH AQUA LAB TECHNOLOGY CHEMICAL DISPENSING SYSTEM User Manual REV 4000029 revC1015 Hydra Flex Inc 2015 HYDRA FLEX FLUID INNOVATION Es TABLE OF CONTENTS Recommended Maintenance Specifications 14 Assure PDS System Diagram 2 Air Operated Valve Replacement 14 Motor Starter Pump Diagram 3 Trouble Shooting 14 Pump Issues 14 Injector Issues 15 Estimated Installation Timeline p Pressure Regulator Issues 15 Installation Instructions 6 Flow Arch issues 10 Valve Issues 16 Wiring Di 8 EISE F rst 9 Injector Optimization Troubleshooting X 16 Multi Source Dual Pump Injector Vacuum Check 17 Start Up 10 Appendix 18 Chem Flex Injector Dilution Ratio Chart 18 Initial Injector Setup OA 11 Recommended Setup Starting Point 19 Triple Foam Setup 11 Chem Flex Injector Part Numbers 19 The system 12 Pressure Loss In Run Length 20 Replacement Parts List 21 Nozzle Setup 12 Aqua Lab Warranty 23 Chemical Usage Measurement 13 SPECIFICATIONS POWER REQUIREMENTS PUMPS AIR ACTUATED VALVES 20 GPM 24 VAC or 24 VDC or 120 VAC 3 5 Watts Per Port 208 230V 3PH 8 9A or 460V 3PH 4 2A DIMENSIONS W x H FULL STAND PUMP ASSEMBLIES PANELS MOTOR CONTROL UNIT Width 47 5 x Height 7
16. awing chemical the best and easiest way to diagnose the problem is to check the back pressure See instructions below STEPS 1 Plugthe optimization tool into the outlet line of injector and connect solution output line Part Number 1002018 m Hydra Cannon Valve Injector 2 Turn on function from car wash controller to actuate Hydra Cannon valve such that fluid is flowing through both the injector and injector optimization tool and out to the applicator Injector Optimization Tool 27 Chemical Draw Line 3 Read injector optimization tool If the gauge is in the RED ZONE the back pressure of the L outlet line is either too low or too F high See steps below to correct T Solution Output Line Chemical Bucket Hydra Flex Inc 2015 Page 16 BACK PRESSURE TOO HIGH UPPER RED SECTION Back Pressure May Be Affected By One Or Several Of These Things 1 Foam generators are clogged degraded Clean or replace media in generator 2 Injector flow size is too large Go down an injector size less GPM 3 Nozzle size on the arch is too small Go up in nozzle size 4 Check valves are dirty and or failing Clean or replace check valves 5 There is a kink in the line or excess fittings elbows and reducers increase the back pressure Check line and replace any kinked sections Try to reduce fittings 6 ID of tubing going out to the tunnel is too small Go up a size in inside diameter 7
17. heck breaker turn off on back ee ue RE Check pressure on inlet side of pump to be sure Pug Operates But Delivers 5 EE positive pressure is maintained Little Or No Water 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 Hydra Flex Inc 2015 Page 14 PROBLEM POTENTIAL CAUSES SOLUTIONS Make sure constant control voltage is supplied in car Constant hot not connected g Pp wash controller Could be due to blown pump motor Try to turn breaker back on or replace fuse If breaker trips after trying to fire motor it is most likely burned out Replace with new motor and pump Defective motor starter contactor Replace motor starter contactor Pump Will Not Start Or Run At Thermal overload set too low tripped Adjust setting on thermal overload to match voltage Full T spese Voltage must be within 10 of motor rated voltage Incorrect motor voltage e Check that pump is wired for correct voltage Defective motor Replace motor 3 phase disconnect ued of Pump components damaged Replace worn part or entire pump Current Sensor not seeing any Turn on one valve and verify red light blinks fast verify current at least 10 wraps of wire around current sensor Pump not secured firmly Secure properly Restricted inlet Clean or correct restriction Try to adjust regulator down and then back up
18. ipe Fittings e Elbows and other pipe fittings add back pressure by causing the fluid to change direction and 2 3 thus changing the fluid s momentum Try to find simpler ways to route your fluid without elbows Line Length e Longer lines add back pressure due to the inherent resistance caused by friction See if you can reduce the line length or increase the inside diameter CHEMICAL USAGE MEASURING VERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING Set up lab scale with small bucket of chemical to be measured Put the suction line into the bucket Run the application being tested to prime the line All air bubbles must be removed for accuracy A 5 SN 5 p lt e Record the Initial Weight from the scale Tarring the scale with weight on the scale can affect accuracy Run the application for 1 vehicle or manually for the same amount of time it would be on for 1 vehicle Record the Final Weight from the scale Subtract the Initial Weight from the Final Weight to determine the weight of used product Divide the Per Car Weight in grams by the specific gravity of the chemical to determine the milliliters of chemical used per vehicle Repeat for each chemical application Hydra Flex Inc 2015 Page 13 RECOMMENDED MAINTENANCE THE RECOMMENDED SERVICE AND MAINTENANCE ON THE ASSURE PDS SYSTEM ARE AS FOLLOWS Monthly e Check drain
19. n boxes i If you have more panels than gray wires from the motor starter box connect the lose gray wires sent in the shipment into the same jumpers as the pre wired gray cables This step must be completed for unit to function c Connect Powerfast Cordset on motor s to motor starter box d Connect male plug to outlet previously installed by electrician e sure to follow all applicable electrical codes Hydra Flex Inc 2015 Page 7 WIRING DIAGRAM SINGLE PUMP Thermal Overload Current Switch Disconect Qu 9 3Phase OO 000000 0 D From Grey M12 Cables From Breaker Port 6 on M12 Block 2T1 4T2 ro s gt Control Voltage Qu 3 Phase NIlZlizi2 2 Xli x 5 6 a a Jumper Jumper To Pump Through Power Fast Quick Connect Hydra Flex Inc 2015 Page 8 MULTI SOURCE DUAL PUMP Jexeeug WO4 j euoosiq O ETE 1 euuo AAND 1524 Jamog u amp nouu dung OL g o Q HB 09 5 ZLIN M Hydra Flex Inc 2015 Oe O 7 9 O cen O cen 3 O en 9 3 er 9 eeu 3 O 9 Q O 09 2 0 E LLL 577 e 2 MEME ___ gt rez oe 66 2
20. or Nozzle Size Run Length 0 25 0 50 0 75 White Yellow Tan 0 029 0 040 0 051 1 0 mm 0 057 1 4 mm 3 8 ID 1 2 OD POLY TUBE Flow Rate GPM at 200 PSI 9 Injector Color gt 1 00 Nozzle Size 125 o 100 5 75 E 50 25 Hydra Flex Inc 2015 0 25 0 50 0 75 White Yellow Tan 0 029 0 040 0 051 0 7 mm 1 0 mm 0 057 1 4 mm 0 070 0 070 1 8 mm 1 50 0 070 18 PSI 14 PSI 12 PSI 0 083 0 083 2 1 mm 2 00 0 083 0 086 0 086 2 2 mm 11 PSI 2 25 0 086 18 PSI 12 PSI 15 INJECTOR 1 00 1 50 2 00 2 25 3 25 5 50 0 098 0 125 3 2 mm 18 PSI 16 PSI INJECTOR 1 00 1 50 2 00 2 25 3 25 5 50 0 098 2 5 mm 0 125 3 2 mm 18 PSI 14 PSI 11 PSI 18 PSI 3 25 5 50 0 098 0 125 13 PSE Page 20 REPLACEMENT PARTS LIST ASSURE PDS 2 A23 Dispensing System d YDRA FLEX PART NUMBER Solenoid Actuated Air Valve Replacement Foaming M12 X Din Air Regulator With LED Primary Air Regulator Replacement Bowl 1 4 Poly Tubing Small Regulator amp 0 60 PSI Gauge 10
21. or replace regulator remove check valves pressure regulators from H20 feed to pump Cavitation sounds like marbles in pump Increase inlet size inlet pressure Worn mechanical seal Replace pump Not primed Re prime pump Loose fittings and or not enough Tighten fittings and or take part off and put new Pump Leaks thread tape thread tape on INJECTOR ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Injector Is Not Drawing Chemical Check chemical hose foot valve metering tip and Passes Vacuum Pressure Check 99 hose barb for debris or clogs 8 Ensure minimum 60 psi on primary air regulator ensure valve receiving signal Fow Frominjector Clogged injector Remove injector and blow out debris with compressed air No water supply Check that the system has a supply of water Clean or replace downstream check valves increase Too much back pressure on injector nozzle size or quantity use larger tubing or use smaller flow injectors Clogged injector check valve Blow compressed air through the chemical hose barb Injector Is Not Drawing Chemical on the injector to remove debris Fails Vacuum Pressure Check Clogged injector nozzle Remove injector and blow out any debris with compressed air Defective injector Replace injector Product specific Sonny s Rain Remove elbow at inlet to foam generator and remove nozzle Remove end fittings and retention rod Clean o
22. or this will produce less flow and thus less back pressure c If retest vacuum reads 20 in Hg replace injector and retest If vacuum continues to read 20 Hg call your service provider Repeat steps 2 5 for each chemical lane that a vacuum reading is needed for Once testing is complete turn off the ASSURE PDS pump from the main car wash control cabinet Hydra Flex Inc 2015 Page 17 APPENDIX CHEM FLEX INJECTORS CHEMICAL DILUTION RATIOS Assumes feed pressure of 200 PSI 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 8 32 METERING TIPS Flow Rate GPM at 200 PSI Injector Color gt Nozzle Size COPPER amp 1 57 1 104 1 155 1 195 1 281 1 406 1 468 1 629 1 1074 PUMPKIN 1 43 1 82 1 119 1 126 1 238 1 348 1 398 1 554 1 946 BURGUNDY amp 1 34 1 67 1 97 1 111 1 207 1 304 1 347 1 495 1 845 LIME 1 28 1 57 1 81 1 100 1 183 1 270 1 307 1 447 1 764 TAN amp 1 28 1 57 1 81 1 100 1 183 1 270 1 307 1 447 1 764 ORANGE amp 1 23 1 44 1 64 1 78 1 137 1 196 1 215 1 314 1 536 TURQUOISE amp 1 17 1 31 1 45 1 55 1 91 1 126 1 134 1 197 1 336 PINK amp 1 14 1 24 1 35 1
23. primary air regulator filter separator e Check water filter and replace as needed if installed e Check and clean wye strainer Semi Annually e Check and replace injector metering tips 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 AIR OPERATED VALVE REPLACEMENT Shut off the ball valve to ASSURE PDS or Hydra Cannon manifold Disconnect air line from front of valve Unscrew quick connect fitting by hand DO NOT LOSE BLACK WASHER Unscrew valve assembly from the Hydra Cannon manifold Screw new valve into manifold until hand tight and threaded pilot port is facing forward 6 Remove the cap from pilot port and thread in quick connect fitting to front of valve HAND TIGHT ONLY OF 22 a Unscrew from manifold using this 7 Push air line back into fitting portion of valve 8 Open the ball valve to the Hydra Cannon manifold TROUBLESHOOTING PUMP ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Pump Operates But Only Delivering 100 150 Psi Incorrect motor rotation Reverse rotation by interchanging two leads Missing 1 of 3 phases Wire according to diagram c
24. pump momentarily by depressing the center of the contractor image 3 WARNING RUNNING THE PUMP BACKWARD WILL CAUSE CATASTROPHIC SYSTEM FAILURE ENSURE THAT PUMP ROTATION IS CORRECT image 4 as indicated by the arrow on the casting of the pump and that 200 psi can be reached e f pump cannot regulate to 200 psi remove pump motor cover and look at shaft to confirm correct rotation e Verify pump inlet pressure remains positive when running 3 PURGE BYPASS 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 4 RECONNECT Reconnect the pump outlet line to the Hydra Cannon Manifold and open ball valve 5 DOUBLE CHECK 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 e fhousing is hot or noisy pump did not prime correctly e f pump does not prime repeat steps 3 5 e f notat 200 psi and the pump is correctly rotating you may need to adjust the bypass regulator to obtain 200 psi Image 5 Verify pump prime 24 hours after operation to ensure prime held Pay close attention to the temperature of the pump shaft the whole stainless steel area Image 6 should be the same temperature If 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 PUMP
25. r 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 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
26. reases water NOZZLE SETUP Optional For Maximized Optimization e Using the recommended starting point appendix install the recommended nozzles e his may involve removing and plugging some ports e Due to the lower water usage determined by the injector of the ASSURE PDS you will need to match the flow of the application device to the injector e Setup the nozzle spray patterns to paint the car slightly overlapping each other Hydra Flex Inc 2015 Page 12 INJECTOR FLOW RATE 200 PSI GPM INJECTOR FLOW RATE 200 PSI GPM MINIMUM NUMBER OF NOZZLES NECESSARY WITHOUT FOAMING AIR Assuming lt 10 PSI line loss and 40 PSI at the nozzle SPRAY NOZZLE SIZE 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 5 3 2 2 1 1 1 1 1 7 5 3 3 2 2 1 1 1 10 6 5 4 9 2 2 2 2 11 7 5 4 3 3 2 2 2 16 10 8 6 5 4 4 3 3 27 18 13 11 9 7 6 6 5 MINIMUM NUMBER OF NOZZLES NECESSARY WITH FOAMING AIR Assuming lt 10 PSI line loss and 40 PSI at the nozzle SPRAY NOZZLE SIZE 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 0 10 0 4 1 1 1 1 1 1 8 3 2 2 2 1 1 13 8 5 4 3 3 2 2 17 11 7 5 5 4 3 3 26 17 13 10 8 7 6 5 5 35 23 17 14 11 10 8 7 7 39 26 19 15 13 11 9 8 7 56 37 28 22 18 16 14 12 11 96 64 48 38 32 27 24 21 19 Elbows P
27. t Open mE Remove valve from manifold Carefully remove top of Internal valve o ring jammed valve caution under high spring pressure push white twisted piston up with small allen wrench from opposite end and check o ring condition Replace and lubricate if needed Remove valve from manifold Carefully remove top of valve caution under high spring pressure push white piston up with small screwdriver from opposite end and check o ring condition Replace with 018 amp 008 Viton O ring and lubricate with Dow 111 valve lube Valve Remains Open After Signal Manifold pressure is above 230 psi Reduce pressure to manifold to 200 psi operating pressure Is Off Air exhaust muffler is clogged Replace exhaust muffler INJECTOR OPTIMIZATION TOOL BACKGROUND This tool is for initial setup and troubleshooting of Chem Flex Injectors and an ASSURE PDS Chemical Dispensing System In order for the injector to work properly and draw chemical this gauge must be in the GREEN section when installed immediately after an injector that is running If the gauge is in the red you will either see intermittent chemical no chemical draw or chemical being applied at a very low pressure Valve Leaks Air Or Water Out Internal o ring seal damaged Top worn Back pressure refers to the pressure in the solution output line Excessive back pressure is the main reason that injectors will not draw If there is ever any concern to why an injector is not dr
28. tors already inserted e Onthe side of the panel the 3rd 4th and 5th regulators numbering starts at the top will control the air to each of your triple foam colors e Insert your air lines to the arch into the bulkhead fittings on the bottom of the panel The 3rd 4th and 5th bulkhead counting from left to right will be the airlines for each color 5 Valve 7 Regulator ASSURE PDS e Your triple foam has been setup from the factory to be in port 5 e Insert your triple foam manifold into position 5 with your selected injectors already inserted e On the side of the panel the 5th 6th and 7th regulators numbering starts at the top will control the air to each of your triple foam colors e Insert your air lines to the arch into the bulkhead fittings the bottom of the panel The 5th 6th and 7th bulkhead fittings counting from left to right will be the airlines for each color Note Occasionally if all three regulators are pre set too high you may need to lower all three regulators to their lowest setting and then turn them up to the desired pressure Hydra Flex Inc 2015 Page 11 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 15 THROUGH TRIAL AND ERROR DON T BE AFRAID TO TRY THESE STEPS TO ACHIEVE YOUR IDEAL PERFORMANCE What do injectors do
29. ut inlet Manifold inlet clogged rare Call Hydra Flex and order composite version of injectors PRESSURE REGULATOR ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Pump not primed Follow priming instructions Debris in regulator Remove regulator and clean out debris Motor rotation incorrect Verify rotation switch 2 leads System is limited by size of pump and size of injectors Opening too many valves at once increase flow by adding secondary pumps or reduce size number of injectors open Detective check valve if applicable Replace check valve Defective Regulator Replace regulator Defective Pump Replace Pump Blown fuse or circuit breaker Water regulator fluttering Excessive Noise From Pump chattering System Won t Regulate Up To 200 Psi Hydra Flex Inc 2015 Page 15 FLOW ARCH ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS Incorrect injector flow rate Replace with larger injector selection System pressure too low Ensure system pressure is set at 200psi Flow At Arch Is Too Low Foam generator plugged Ensure cleaned and clear Increase size of plumbing tubing ensure check Downstream plumbing restrictive valves are cleaned or new reduce elbows in line or other turns that would restrict VALVE ISSUES PROBLEM POTENTIAL CAUSES SOLUTIONS th er ne ene mE Ensure primary air regulator reading at least 60 psi turn p up to 80 90psi if possible and check again Valve Will No
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