© Hydra-Flex, Inc. 2018© Hydra-Flex, Inc. 2018
ZVC ASSURE PDS WITHAQUA-LAB™
TECHNOLOGYCHEMICAL DISPENSING SYSTEM
User ManualREV F
4000029 revF0118
© Hydra-Flex, Inc. 2018
Specifications 1
AssurePDSSystemDiagram 2
MotorStarter/PumpDiagram 3
LayoutDrawing 4
EstimatedInstallationTimeline 5
InstallationInstructions 6
WiringDiagram 8SinglePump 8Multi-Source/DualPump 10
StartUp 12
InitialInjectorSetup 13
TripleFoamSetup 13
OptimizingTheSystem 14
NozzleSetup 14
ChemicalUsageMeasurement 15
RecommendedMaintenance 16
AirOperatedValveReplacement 16
TroubleShooting 16PumpIssues 16InjectorIssues 17PressureRegulatorIssues 17Flow/Archissues 18ValveIssues 18
InjectorOptimizationTroubleshooting 18
InjectorVacuumCheck 19
Appendix 20Chem-FlexInjectorDilutionRatioChart 20RecommendedSetupStartingPoint 21Chem-FlexInjectorPartNumbers 21PressureLossInRunLength 22ReplacementPartsList 23Aqua-LabWarranty 24
TABLE OF CONTENTS
SPECIFICATIONSAIR-ACTUATED VALVES
24 VAC or 24 VDC or 120 VAC, 3.5 Watts Per Port
PUMPS
20 GPM
208-230V/3PH/8.9A or 460V/3PH/4.2A
POWER REQUIREMENTS
DIMENSIONS (W x H)
WATER SUPPLY
AIR SUPPLY
MOTOR CONTROL UNIT
Single / Dual
14” x 15”
PANELS
MD3 MD5
22” x 29” 22” x 29”
FULL STAND
Width 47.5” x Height 78” x Depth 28”
PUMP ASSEMBLIES
1-Pump 2-Pump 3-Pump
24”x 48” 24” x 48” 36” x 48”
Air Inlet Line 3/8” OD Polyflow Per MD Panel
Air Outlet Line 3/8” OD Polyflow Per Application
Air Inlet Pressure 20 CFM @ 80-120 PSI Dry Air
Water Inlet Lines20 GPM 40 GPM
1” ID 1 1⁄2” ID or 2x 1” ID
Solution Outlet LinesUp to 2.25 GPM 3.25 - 4.5 GPM 5.5 GPM
3/8” ID (1⁄2” OD Polyflow*) 1⁄2” ID* 5⁄8” ID*
Operating Water Pressure 200 PSI (Factory Set) Assuming 40 PSI City Feed
Maximum Water Source Temperature Recommended 110°F (43°C) - (max water temp) 137°F (58°C) with Booster Pump
Water Filtration (Suggested) 50 Micron
FOR ADDITIONAL SUPPORT CALL: 952-808-3640OR VISIT US ON THE WEB: www.hydraflexinc.com
Page | 1
*Assuming line length is 50’ (15 m) or less. Refer to user page 20 for recommended size chart for other lengths.
© Hydra-Flex, Inc. 2018 Page | 2
ASSURE PDS SYSTEM DIAGRAM
Mounting Slots (2 top, 2 Bottom)
Individual Air Regulators
Tri-Foam Manifold
Solution Ports (Front)Air Ports (Back)
Hydra-Cannon Manifold
M12 Junction Block
Solenoid Actuated Air Valves
Primary Air Regulator
16 3/8”
REFER TO PAGE 23 FOR PART NUMBERS & DIAGRAMS
Home RunCable (Goes to car wash controller for control voltage)
1
2
3
4
5A
5A
5B
5B
5C
5C
1
1 2 3 4 5A 5C
2 3 4 5
Grey M12 Cable (Goes To Motor Starter Box)
© Hydra-Flex, Inc. 2018 Page | 3
MOTOR STARTER/PUMP DIAGRAM(SINGLE SOURCE / SINGLE PUMP SHOWN)
REFER TO PAGE 24 FOR PART NUMBERS & DIAGRAMS
Wye-Strainer Pump Outlet Feed Line To MD Panels
Bypass Pressure Regulator
Timer Relay
Contactor
Thermal Overload
Temperature Shutdown Relay
Current Switch3 Phase Disconnect
Quick Connect Pump Plug Female
Back-up Pump
Temperature SwitchQuick Connect 9’ Cordset For Pump (Plugs Into Bottom Of Motor Starter)
Grey M12 Cables (Carry signal from yellow M12 distribution block to motor starter that turns on the pump)
EATON
© Hydra-Flex, Inc. 2018
LAYOUT DRAWING
Page | 4
21.9”
47.5”
15.75”
5 Port Assure PDS
(1x) Connection With Valve To Accommodate 1" Male Npt Hose MustTerminate Within 5 Feet Of Pump Inlet (Ø1.0" Recommended) Provided By Others
(2x) 20' Signal WireTo AQUA-LAB Included
(1x) 230V / 480V PumpPower Receptacle Included
(1x) 12ft 230V / 480VPump Power Cord Included With Each Pump
(1x) 6' X Ø1.0" MNPT Quick Change Pump Inlet Hose Included
(2x) 3/8" Poly Flow Air Inlet TubingProvided By Others (100 PSI Max)
(1x) 6' Quick Change Flexible Hose With Regulator & WyeStrainer To Assure PDS With 1/2" Quick Connect & Ball Valve Included With Each
13”
78”
30' SignalControl Cable
Included
© Hydra-Flex, Inc. 2018 Page | 5
5 EASY STEPS FOR INSTALLATIONCOMPLETE PRE-INSTALLATION CHECKLIST BEFORE THESE STEPS
1. Unpack
2. Setskidinplace
3. Makeconnections
4. Start-up
5. Optimizingtheequipment
5 EASY STEPS FOR INSTALLATION
WHO TASK EST. TIME
ZVC REP MONITOR & RECORD PERFORMANCE 2HR/WK
ZVC REP MAINTENANCEPERSCHEDULEORASNEEDED
POST INSTALLATION
TOTAL HOURS SPENT
INSTALLATION
TOTAL CUSTOMER .5 HR
TOTAL ZVC REP 13.75 HR
TOTAL ELECTRICIAN 4 HR
TOTAL PLUMBER 4 HR
PRE-INSTALLATION
ESTIMATED TIMELINE
WHO TASK EST. TIME
ZVCREP&CUSTOMER DETERMINELOCATIONTOINSTALLEQUIPMENT .25HR
PLUMBER/ZVCREP INSTALLWATERSUPPLYLINE 1 HR
ELECTRICIAN INSTALLELECTRICALSUPPLYLINE 2 HR
TECHNICIAN/ZVCREP LABELALLCONTROLLERRELAYSATCONTROLLER .5HR
TECHNICIAN/ZVCREP RUNSOLUTIONANDAIRLINES(IFNECESSARY) 5HR
TECHNICIAN/ZVCREP INSTALLAIRSUPPLYLINE 1 HR
TOTAL LABOR HOURS 9.75 HRS
WHO TASK EST. TIME
ZVCREP/TECHNICIAN SETSKIDINPLACEANDBOLTTOWALL .5HR
ZVCREP/TECHNICIAN CONNECTWATER,AIRANDSOLUTIONLINES 1 HR
TECHNICIAN CONNECTCONTROLLEADSTOMAINCONTROLLERORJUNCTIONBOX 2 HR
ZVCREP/TECHNICIAN STARTUP(INJECTOR,METERINGTIPANDNOZZLESELECTION) 2 HR
ZVCREP/TECHNICIAN DOCUMENTCONFIGURATION .5HR
TOTAL LABOR HOURS 6 HRS
InstallationtakesapproximatelyONEday.Anelectricianandaplumberareneededforhalfaday.
© Hydra-Flex, Inc. 2018 Page | 6
General Skill Level• Mechanical:Basic-mountingequipment
• Electrical:Advanced-threephasepowerandcontrolsknowledge(localcodesknowledgerequired)
• Plumbing:Moderate-principalsupplylinerequired
• Pneumatic:Basic-pneumaticutilityconnectionrequired
• ChemicalKnowledge:Moderate-chemicaltitrationsrequired
UNPACKINGTheAQUA-LABPDSisshippedonapallet.
1. Cutstrapsholdingskidtopallet
2. Un-bolttheskidfromthepallet.
3. Lifttheskidfromthepallet.Useassistanceifnecessary.
4. ***Be sure not to discard the manuals and accessories box.
LOCATION & MOUNTING**IflocationwasnotidentifiedduringthePre-InstallationProcess,makesuretoconsidertheproximitytofeedwater,powersupply,andthecontrolcabinetaswellasspacenearthesystemtostorechemicalcontainers.
***See drawing in reference for general layout1. Setskidinlocationidentified
2. Optional:Boltskidtowallusingwallanchorplates
INSTALLATION INSTRUCTIONS
• Utilityknife
• Wirestripper
• Adjustablewrench
• Screwdriverset
• Socketset
• Teflontape
Tools & Equipment Needed• DrillwithPhillipshead
• Concretedrillbit5/32”
Useful Tools:• AmpMeter
• VoltMeter
FEED WATER CONNECTION**PRIOR TO CONNECTION, ENSURE THAT THE FEED LINES ARE FREE OF DEBRIS BY FLUSHING OUT THE LINES FOR 15 MINUTES
• Connectpre-runmainwatersupplylinetopumpinletwithhosesupplied.
• Singleoperatingpump:1”MNPT
• Dualoperatingpump:1-1/2”MNPT
© Hydra-Flex, Inc. 2018 Page | 7
******************(HFI supplied motor starter)******************
1. ELECTRICAL CONNECTIONS (HFI MOTOR STARTER)a. Wire yellow homerun control cables to car wash control panel. (See diagram below for wiring schematic)
• Manifold position below designates which port is associated to what color wire.• Example: if you want Presoak 1 to be on manifold port 2, connect the green wire to your
controller relay for Presoak 1.
b. Remove the cap from port 6 then, connect the gray M12 cables hanging out of the motor starter box to the NEUTRAL/COMMON port 6 of the yellow M12 junction 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.
• Make sure to follow all applicable electrical codes.
1
12
3
4
5
3
12
3
4
5
5
12
3
4
5
2
12
3
4
5
4
12
3
4
5
6
12
3
4
5
Ground - Green/yellow
Do Not Use - Blue (Cap With Wire Nut)
Neutral / Common - Red
Hydra-Cannon Port 1 - White
Hydra-Cannon Port 2 - Green
To Motor Starter Box
Hydra-Cannon Port 3 - Yellow
Hydra-Cannon Port 4 - Grey
Hydra-Cannon Port 5 - Pink
Control Voltage Constant Hot / + Brown
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 on air valves refer to diagram on page 2)
PNEUMATIC CONNECTIONS• Connectpre-run3/8”ODpolyfeedlinetopushconnectfitting
onthesideoftheprimaryregulator.
• Connect3/8”ODpolylinesfromarchtoeachport thatwillbefoaming.
**If there are unused air ports, back out the individual line regulator until air no longer flows.
© Hydra-Flex, Inc. 2018 Page | 8
15
A1B1
1618 A2
TIMER
RELAY
3 PHASE
DISCONECT
1
6 3
4 5
2 1
63
45
2
RELAY 1
845113
14129
ACCURRENTSENSO
R
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
POW
ER IN FROM
BREAKER
CONTRO
L VOLTAGE
24/120VAC SINGLE SOURCE SINGLE PUM
P3 PHASE
24/120VAC SINGLE SOURCE SINGLE PUM
P
4000149_RevC0118
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RELAY 1
845113
14129
ACCURRENTSENSO
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9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
P1P1
RELAY 1
TS2TS1
112223
TS2TS1
© Hydra-Flex, Inc. 2018
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A1B1
1618 A2
TIMER
RELAY
3 PHASE
DISCONECT
1
6 3
4 5
2 1
63
45
2
RELAY 1
845113
14129
DCCURRENTSENSO
R
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
POW
ER IN FROM
BREAKER
CONTRO
L VOLTAGE
24VDC SINGLE SOURCE SINGLE PUM
P3 PHASE
24VDC SINGLE SOURCE SINGLE PUM
P
34
RELAY 1
34
15
A1B1
1618 A2
TIMER
RELAY
112223
3 PHASE
DISCONECT
1
6 3
4 5
2 1
63
45
2
RELAY 1
845113
14129
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
P1P1
RELAY 1
TS2TS1
112223
TS2TS1
DCCURRENTSENSO
R
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4000147_RevC0118
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© Hydra-Flex, Inc. 2018 Page | 10
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15
A1B1
1618 A2
TIMER
RELAY
15
A1B1
1618 A2
TIMER
RELAY
TS3TS4
112223
3A
TS2TS1
3 PHASE
DISCONECT
1
6 3
4 5
2 1
63
45
2
RELAY 1
845113
14129
RELAY 2
845113
14129
ACCURRENTSENSO
R
ACCURRENTSENSO
R
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
P1P1
P2
15
A1B1
1618 A2
TIMER
RELAY
15
A1B1
1618 A2
TIMER
RELAY
TS3TS4
112223
3A
TS2TS1
3 PHASE
DISCONECT
1
6 3
4 5
2 1
63
45
2
RELAY 1
845113
14129
RELAY 2
845113
14129
ACCURRENTSENSO
R
ACCURRENTSENSO
R
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
9596
N.C.97
98N.O
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THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
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1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
POW
ER IN FROM
BREAKER
RELAY 2
RELAY 2
RELAY 1
RELAY 1
CONTRO
L VOLTAGE
24/120VAC DUAL SOURCE DUAL PUM
P3 PHASE
24/120VAC DUAL SOURCE DUAL PUM
P
4000150_RevC0118
© Hydra-Flex, Inc. 2018
ACCURRENTSENSO
R
ACCURRENTSENSO
R
34
21
53
42
15
34
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A1B1
1618 A2
TIMER
RELAY
15
A1B1
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TS3TS4
112223
3A
TS2TS1
3 PHASE
DISCONECT
1
6 3
4 5
2 1
63
45
2
RELAY 1
845113
14129
RELAY 2
845113
14129
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
9596
N.C.97
98N.O
.
THERMAL
OVERLO
AD
2 T16 T3
4 T2
CONTACTO
R
1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
P1P1
P2
15
A1B1
1618 A2
TIMER
RELAY
15
A1B1
1618 A2
TIMER
RELAY
TS3TS4
112223
3A
TS2TS1
3 PHASE
DISCONECT
1
6 3
4 5
2 1
63
45
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845113
14129
RELAY 2
845113
14129
9596
N.C.97
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OVERLO
AD
2 T16 T3
4 T2
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1 L13 L2
5 L313 NO
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2 T14 T2
6 T314 NO
A2
9596
N.C.97
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AD
2 T16 T3
4 T2
CONTACTO
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1 L13 L2
5 L313 NO
A1
2 T14 T2
6 T314 NO
A2
POW
ER IN FROM
BREAKER
CONTRO
L VOLTAGE
RELAY 2
34
RELAY 2
34
RELAY 1
RELAY 1
DCCURRENTSENSO
R
DCCURRENTSENSO
R
34
21
53
42
15
3 PHASE24VDC DUAL SO
URCE DUAL PUMP
24VDC DUAL SOURCE DUAL PUM
P4000148_RevC0118
Page | 11
© Hydra-Flex, Inc. 2018 Page | 12
START UPPUMP MUST BE PRIMED BEFORE OPERATION!WARNING!
1. FLUSHMakesurewatersupplytopumpisturnedon.Openballvalveanddirecttowardadrainorcontainertoremovethemajorityoftheairfromthepumpuntilasteadystreamofwaterisflowing(approx. 1 min).Thenclosetheballvalve.
2. CHECK ROTATIONOpenAqua-Lab™MotorControlUnit(MCU)andensure3phasedisconnectison.(Note: Door will not open with disconnect on. Use a 1/4” wrench or crescent wrench to turn it back on after opening door.) (MCU 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 1).
!WARNING! - ELECTRIC SHOCK HAZARD. HIGH VOLTAGE PRESENT INSIDE MOTOR CONTROL UNIT - USE CAUTION!Startthepumpmomentarilybydepressingthecenterofthecontractor(image 2).!WARNING! RUNNING THE PUMP BACKWARD WILL CAUSE CATASTROPHIC SYSTEM FAILURE! ENSURE THAT PUMP ROTATION IS CORRECT (image 3) asindicatedbythearrowonthecastingofthepumpandthat200psicanbereached.
• If pump cannot regulate to 200 psi, remove pump motor cover and look at shaft to confirm correct rotation.
• Verify pump inlet pressure remains positive when running.
3. CLOSE CABINET Turnon3phasedisconnect,ifhightempswitchispresent,pushtostart(Image 4).
4. PURGE BYPASSStartthepumpandslowlyopenballvalveuntilitiswideopen.Allowtorunfor60secondstoflushlinesandthenclosevalve.
5. CONNECT ConnectthepumpoutletlinetotheHydra-CannonManifoldandopenballvalve.
6. DOUBLE CHECKConfirmthatthepumpcanobtain200psiwhilefiringsolenoidsandthatthepumphousing(stainless steel tube)iscooltothetouchafteraminuteinoperation.
• If housing is hot or noisy, pump did not prime correctly.
• If pump does not prime, repeat steps 3-5.
• If not at 200 psi and the pump is correctly rotating you may need to adjust the bypass regulator to obtain 200 psi (Image 5).
Verifypumpprime24hoursafteroperationtoensureprimeheld.Paycloseattentiontothetemperatureofthepumpshaft,thewholestainlesssteelarea (Image 6)shouldbethesametemperature.Ifitstartsgettinghotterthanthesupplywaterorgreaterthan137°,thenitislikelythatthepumpdidnotprimecorrectlywhichWILL CAUSE DAMAGE TO PUMPS.Themotorhousing(paintedportion)willbehotduringoperation.
Image 1
Image 2
Image 5
Image 6Image 7
© Hydra-Flex, Inc. 2018 Page | 13
(Based on field experience this is HFI’s recommended starting point)1. Usingtherecommendedstartingpoint(Page21)orthetargetflowrateandthechemicaldilutions
chart(appendixPage20)installtheappropriateinjectorintoeachport.
2. Connectpre-runsolutionlinestoeachinjectorwiththesuppliedcouplerandpushconnectfitting.
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. Connect¼”polylinesfromeachchemicalcontainertothehosebarbontheappropriateinjector.
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. Meteringtipswillneedtobeinstalledtosetdilutionratio(seeappendixPage20forratiochartsto determinetip.)
INITIAL INJECTOR 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• Yourtriplefoamhasbeensetupfromthefactorytobeinport 3.
• Insertyourtriplefoammanifoldintoposition3withyourselectedinjectorsalreadyinserted.
• Onthesideofthepanelthe3rd(3A),4th(3B),and5th(3C)regulators(numberingstartsatthetop)willcontroltheairtoeachofyourtriplefoamcolors.
• Insertyourairlinestothearchintothebulkheadfittingsonthebottomofthepanel.The3rd(3A),4th(3B),and5th(3C)bulkhead(countingfromlefttoright)willbetheairlinesforeachcolor.
5 Valve / 7 Regulator ASSURE PDS• Yourtriplefoamhasbeensetupfromthefactorytobeinport 5.
• Insertyourtriplefoammanifoldintoposition5withyourselectedinjectorsalreadyinserted.
• Onthesideofthepanelthe5th(5A),6th(5B),and7th(5C)regulators(numberingstartsatthetop)willcontroltheairtoeachofyourtriplefoamcolors.
• Insertyourairlinestothearchintothebulkheadfittingsonthebottomofthepanel.The5th(5A),6th(5B),and7th(5C)bulkheadfittings(countingfromlefttoright)willbetheairlinesforeachcolor.
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.
TRIPLE FOAM SETUP
© Hydra-Flex, Inc. 2018 Page | 14
What do metering tips do?• Increasesordecreasestheamountof
chemicalinthesolution.
What do nozzles do?• Determinesthepatternandbackpressure
ofthesolution.
APPLICATION OPTIMIZATION(REPEAT FOR EACH APPLICATION)• Application too wet
• Increase foaming air pressure• Reduce injector size (decreases water)• Increase metering tip (increases
chemical)
• Application too dry• Decrease foaming air pressure• Increase injector size (increases water)• Decrease metering tip (decreases
chemical)
• Nozzle sputters• Decrease foaming air pressure• Decrease number of nozzle(s) and/or
size used on arch• Increase injector size (increases water)
• Too much chemical used• Decrease metering tip• Decrease metering tip and injector
size (to maintain desired ratio)
OPTIMIZING THE SYSTEMCONSISTENTLY ACHIEVE THE DESIRED CLEANING AND PRESENTATION/PERFORMANCE USING THE LEAST AMOUNT OF CHEMICAL AND WATERINJECTORS VS. METERING TIPS VS. NOZZLESTHE KEY TO OPTIMIZING THE SYSTEM IS THROUGH TRIAL AND ERROR. DON’T BE AFRAID TO TRY THESE STEPS TO ACHIEVE YOUR IDEAL PERFORMANCEWhat do injectors do?
• Increasesordecreasestheamountofwaterinthesolution.
• No chemical • Check vacuum/backpressure of
injector for clogging (see page 19 for Injector Vacuum Check Instructions or pages 17 for troubleshooting)
• Check foot valve• Check metering tip
• Nozzle fan pattern not filled• Reduce nozzle size• 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 (increases water)
(Optional For Maximized Optimization)• Usingtherecommendedstartingpoint(appendix)installtherecommendednozzles.
• Thismayinvolveremovingandpluggingsomeports.• DuetothelowerwaterusagedeterminedbytheinjectoroftheASSUREPDSyouwillneedto
matchtheflowoftheapplicationdevicetotheinjector.• Setupthenozzlespraypatternsto“paint”thecar-slightlyoverlappingeachother.
NOZZLE SETUP
© Hydra-Flex, Inc. 2018 Page | 15
MINIMUM NUMBER OF NOZZLES NECESSARY WITH FOAMING AIR(Assuming <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
0.25 4 2 2 1 1 1 1 1 10.50 8 5 4 3 2 2 2 1 10.75 13 8 6 5 4 3 3 2 21.0 17 11 8 7 5 5 4 3 31.5 26 17 13 10 8 7 6 5 52.0 35 23 17 14 11 10 8 7 7
2.25 39 26 19 15 13 11 9 8 73.25 56 37 28 22 18 16 14 12 115.5 96 64 48 38 32 27 24 21 19IN
JECT
OR
FLO
W R
ATE
@ 2
00 P
SI (G
PM)
MINIMUM NUMBER OF NOZZLES NECESSARY WITHOUT FOAMING AIR(Assuming <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
0.25 1 1 1 1 1 1 1 1 10.50 2 1 1 1 1 1 1 1 10.75 3 2 1 1 1 1 1 1 11.0 5 3 2 2 1 1 1 1 11.5 7 5 3 3 2 2 1 1 12.0 10 6 5 4 3 2 2 2 2
2.25 11 7 5 4 3 3 2 2 23.25 16 10 8 6 5 4 4 3 35.5 27 18 13 11 9 7 6 6 5IN
JECT
OR
FLO
W R
ATE
@ 2
00 P
SI (G
PM)
Elbows/Pipe Fittings• Elbowsandotherpipefittingsaddbackpressurebycausingthefluidtochangedirectionand
thuschangingthefluid’smomentum.Trytofindsimplerwaystorouteyourfluidwithoutelbows.
Line Length• Longerlinesaddbackpressureduetotheinherentresistancecausedbyfriction.Seeifyoucan
reducethelinelengthorincreasetheinsidediameter.
CHEMICAL USAGE MEASURINGVERIFY TITRATION OF CHEMICALS BEFORE PROCEEDING1. Setuplabscalewithsmallbucketofchemicaltobemeasured.
2. Putthesuctionlineintothebucket.
3. Runtheapplicationbeingtestedto“prime”theline.(Allairbubblesmustberemovedforaccuracy.)
4. RecordtheInitial Weight fromthescale.(Tarringthescalewithweightonthescalecanaffectaccuracy.)5. Runtheapplicationfor1vehicle(ormanuallyforthesameamountoftimeitwouldbeonfor1
vehicle).
6. RecordtheFinal Weightfromthescale.7. SubtracttheInitialWeightfromtheFinalWeighttodeterminetheweightofusedproduct.
8. DividethePer Car Weightingramsbythespecificgravityofthechemicaltodeterminethemillilitersofchemicalusedpervehicle.
9. Repeatforeachchemicalapplication.
0
8
16
24
© Hydra-Flex, Inc. 2018 Page | 16
RECOMMENDED MAINTENANCETHE RECOMMENDED SERVICE AND MAINTENANCE ON THE ASSURE PDS SYSTEM ARE AS FOLLOWS. Monthly
• Check/drainprimaryairregulator/filterseparator.• Checkwaterfilterandreplaceasneeded(ifinstalled).• Checkandcleanwyestrainer.
Semi-Annually• Checkandreplaceinjectormeteringtips.• Inspectandreplacechemicallinesasneeded.• Ensurelinesaretightlysecuredtoinjectorhosebarbs,clip1”offoldhoseasneededthatwas
stretchedbyhosebarb.
Annually• Cleanwaterregulator.• Inspectmotorstarterforcorrosion,ifidentifiedorderreplacement/spareparts.
1-3 Years• Inspectandreplaceinjectors.• Replacewatervalves.• Replacemainpressureregulator.
AIR OPERATED VALVE REPLACEMENT1. ShutofftheballvalvetoASSUREPDSorHydra-Cannonmanifold.2. Disconnectairlinefromfrontofvalve.3. Unscrewquickconnectfittingbyhand(DO NOT LOSE BLACK WASHER).4. UnscrewvalveassemblyfromtheHydra-Cannonmanifold.5. Screwnewvalveintomanifolduntilhandtightandthreadedpilotportisfacing
forward.6. Removethecapfrompilotportandthreadinquick
connectfittingtofrontofvalve–HAND TIGHT ONLY.7. Pushairlinebackintofitting.8. OpentheballvalvetotheHydra-Cannonmanifold.
Unscrew from manifold using this portion of valve
PUMP ISSUES
TROUBLESHOOTING
PROBLEM POTENTIAL CAUSES SOLUTIONS
Pump Operates, But Only Delivering 100-150 Psi Incorrectmotorrotation Reverserotationbyinterchangingtwoleads.
Pump Operates, But Delivers Little Or No Water
Pumpnotprimed Seepriminginstructions.
Missing1of3phases Wireaccordingtodiagram/checkbreaker(turnoffonback).
InadequatewatersupplyCheckpressureoninletsideofpumptobesurepositivepressureismaintained.
Undersizedpiping Replacewithlargerpiping.
Leakontheinletside Makesureconnectionsaretight.
Wornordefectivepumpparts Replacewornpartsorentirepump,cleanpartsifrequired.
© Hydra-Flex, Inc. 2018 Page | 17
Excessive Noise From Pump
Pumpnotsecuredfirmly Secureproperly.
Restrictedinlet Cleanorcorrectrestriction.
Waterregulatorfluttering/chattering
Trytoadjustregulatordownandthenbackuporreplaceregulator/removecheckvalves/pressureregulatorsfromH20feedtopump.
Cavitation(soundslikemarblesinpump) Increaseinletsize/inletpressure.
Wornmechanicalseal Replacepump.
Notprimed Re-primepump.
Pump LeaksLoosefittings,andornotenoughthreadtape
Tightenfittings,andortakepartoffandputnewthreadtapeon.
Failedseals Replacepump.
INJECTOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONSInjector Is Not Drawing Chemical - Passes Vacuum Pressure Check Cloggedchemicalfeed
Checkchemicalhose,footvalve,meteringtip,andhosebarbfordebrisorclogs.
No Flow From InjectorValvemalfunction,valvenotopening
Ensureminimum60psionprimaryairregulator,ensurevalvereceivingsignal.
Cloggedinjector Removeinjectorandblowoutdebriswithcompressedair.
Nowatersupply Checkthatthesystemhasasupplyofwater.
PROBLEM POTENTIAL CAUSES SOLUTIONS
Pump Will Not Start Or Run AtFull Speed
ConstanthotnotconnectedMakesureconstantcontrolvoltageissuppliedincarwashcontroller.
Blownfuseorcircuitbreaker
Couldbeduetoblownpumpmotor.Trytoturnbreakerbackonorreplacefuse.Ifbreakertripsaftertryingtofiremotoritismostlikelyburnedout.Replacewithnewmotorandpump.
Defectivemotorstartercontactor Replacemotorstartercontactor.
Thermaloverloadsettoolow/tripped Adjustsettingonthermaloverloadtomatchvoltage.
IncorrectmotorvoltageVoltagemustbewithin10%ofmotorratedvoltage.(Checkthatpumpiswiredforcorrectvoltage.)
Defectivemotor Replacemotor.
3phasedisconnectturnedoff Turndisconnecton.
Pumpcomponentsdamaged Replacewornpartorentirepump.
CurrentSensornotseeinganycurrent
Turnononevalveandverifyredlightblinksfast,verifyatleast10wrapsofwirearoundcurrentsensor.
Injector Is Not Drawing Chemical - Fails Vacuum Pressure Check
ToomuchbackpressureoninjectorCleanorreplacedownstreamcheckvalves,increasenozzlesizeorquantity,uselargertubing,orusesmallerflowinjectors.
CloggedinjectorcheckvalveBlowcompressedairthroughthechemicalhosebarbontheinjectortoremovedebris.
Cloggedinjectornozzle Removeinjectorandblowoutanydebriswithcompressedair.
Defectiveinjector Replaceinjector.
Productspecific-Sonny’sRainBar Removeelbowatinlettofoamgeneratorandremovenozzle.
Manifoldinletclogged(rare)Removeendfittingsandretentionrod.Cleanoutinletholestoallowfullflow.
Injector stainless steel disintegrating StrongHydro-FluoricAcid CallHydra-Flexandordercompositeversionofinjectors.
PRESSURE REGULATOR ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS
System Won’t Regulate Up To 200 Psi
Pumpnotprimed Followpriminginstructions.
Debrisinregulator Removeregulatorandcleanoutdebris.
Motorrotationincorrect Verifyrotation/switch2leads.
OpeningtoomanyvalvesatonceSystemislimitedbysizeofpumpandsizeofinjectors,increaseflowbyaddingsecondarypumpsorreducesize/numberofinjectorsopen.
Defectivecheckvalve(ifapplicable) Replacecheckvalve.
DefectiveRegulator Replaceregulator.
DefectivePump ReplacePump.
© Hydra-Flex, Inc. 2018 Page | 18
FLOW / ARCH ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS
Flow At Arch Is Too Low
Incorrectinjectorflowrateselection
Replacewithlargerinjector
Systempressuretoolow Ensuresystempressureissetat200psi
Foamgeneratorplugged Ensurecleanedandclear
DownstreamplumbingrestrictiveIncreasesizeofplumbing/tubing,ensurecheckvalvesarecleanedornew,reduceelbowsinlineorotherturnsthatwouldrestrict
VALVE ISSUESPROBLEM POTENTIAL CAUSES SOLUTIONS
Valve Will Not Open
AirpressuretoolowEnsureprimaryairregulatorreadingatleast60psi,turnupto80-90psiifpossibleandcheckagain.
Internalvalveo-ringjammed/twisted
Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallallenwrenchfromoppositeendandchecko-ringcondition.Replaceandlubricateifneeded.
Valve Leaks Air Or Water Out Top
Internalo-ringsealdamaged/worn
Removevalvefrommanifold,Carefullyremovetopofvalve (caution – under high spring pressure)pushwhitepistonupwithsmallscrewdriverfromoppositeendandchecko-ringcondition.Replacewith018&008VitonO-ringandlubricatewithDow111valvelube.
Valve Remains Open After Signal Is Off
Manifoldpressureisabove230psi Reducepressuretomanifoldto200psioperatingpressure.
Airexhaustmufflerisclogged Replaceexhaustmuffler.
BACKGROUND:ThistoolisforinitialsetupandtroubleshootingofChem-Flex™InjectorsandanASSUREPDSChemicalDispensingSystem.Inorderfortheinjectortoworkproperlyanddrawchemicalthisgaugemustbeinthe“GREEN”sectionwheninstalledimmediatelyafteraninjectorthatisrunning.Ifthegaugeisintheredyouwilleithersee:intermittentchemical,nochemicaldraw,orchemicalbeingappliedataverylowpressure.
Backpressurereferstothepressureinthesolutionoutputline.Excessivebackpressureisthemainreasonthatinjectorswillnotdraw.Ifthereiseveranyconcerntowhyaninjectorisnotdrawingchemical,thebestandeasiestwaytodiagnosetheproblemistocheckthebackpressure.Seeinstructionsbelow:
INJECTOR OPTIMIZATION TOOL
STEPS:1. Plugtheoptimizationtoolintothe
outletlineofinjectorandconnectsolutionoutputline.
2. TurnonfunctionfromcarwashcontrollertoactuateHydra-Cannonvalvesuchthatfluidisflowingthroughboththeinjectorandinjectoroptimizationtoolandouttotheapplicator.
3. Readinjectoroptimizationtool.
4. Ifthegaugeisinthe“RED ZONE”thebackpressureoftheoutletlineiseithertoolowortoohigh.Seestepsbelowtocorrect. Solution
Output Line
Hydra-Cannon Valve
Injector Optimization Tool
Injector
Chemical Draw Line
Chemical Bucket
© Hydra-Flex, Inc. 2018
BACK PRESSURE TOO HIGH (UPPER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)
1. Foamgeneratorsareclogged/degraded.Cleanorreplacemediaingenerator.2. Injectorflowsizeistoolarge.Godownaninjectorsize(lessGPM).3. Nozzlesizeonthearchistoosmall.Goupinnozzlesize.4. Checkvalvesaredirtyandorfailing.Cleanorreplacecheckvalves.5. Thereisakinkinthelineorexcessfittings(elbowsandreducersincreasethebackpressure).
Checklineandreplaceanykinkedsections.Trytoreducefittings.6. IDoftubinggoingouttothetunnelistoosmall.Goupasizeininsidediameter.7. Checkvalveshavetoohighofcrackingpressure.Replacecheckvalvewithlowerpressurecheckvalve.8. Cleanfootvalve.
BACK PRESSURE TOO LOW (LOWER RED SECTION):(Back Pressure May Be Affected By One Or Several Of These Things)
1. Injectorflowtoolow.Increaseinjectorsize.2. Nozzlesizetoolarge.Reducenozzlesize.
INJECTOR VACUUM CHECK
C
B
(FOR TROUBLESHOOTING INJECTORS) 1. AttheChem-Flexinjector,removethechemicalfeedlinefrom
theinjectorhosebarb.
2. AttachthetubingofthevacuumgaugetotheChem-Flexhosebarb(ImageA).
3. Withthepump(s)on,manuallyactivatethechemicalthatistobetestedatthemaincarwashcontrolcabinet.Aninjectorthatisworkingproperlywillhaveareadinggreaterthanorequalto(≥) 20inHg.
4. Ifvacuumreads<20in/Hg(imageB),removesolutionmetering tip(imageC)andretest. a. If retest vacuum reads >20 in/Hg (image D), The solution metering tip is clogged. Replace the metering tip. b. If Retest vacuum reads <20 in/Hg, continue to STEP 5
5. Removeanozzleonthearchorthechemicalfeedlinefromthefoamgeneratorandretestvacuum. a. If retest vacuum reads >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 injector (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 in/ Hg, call your service provider.
6. Repeatsteps2-5foreachchemicallanethatavacuumreadingisneededfor.
7. Oncetestingiscomplete,turnofftheASSUREPDSpumpfromthemaincarwashcontrolcabinet.
A
D
Page | 19
© Hydra-Flex, Inc. 2018 Page | 20
APPENDIXCHEM-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.
***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.
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.
#8-32 METERING TIPS
Flow Rate(GPM) at 200 PSI
0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray Blue Light Green Purple Dark
Green
Nozzle Size
0.029” (0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.098”(2.5 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
COPPER 1: 57 1: 104 1: 155 1: 195 1: 281 1: 406 1: 468 1: 629 1: 881 1: 1074
PUMPKIN 1: 43 1: 82 1: 119 1: 126 1: 238 1: 348 1: 398 1: 554 1: 774 1: 946
BURGUNDY 1: 34 1: 67 1: 97 1: 111 1: 207 1: 304 1: 347 1: 495 1: 690 1: 845
LIME 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 447 1: 622 1: 764
TAN 1: 28 1: 57 1: 81 1: 100 1: 183 1: 270 1: 307 1: 447 1: 622 1: 764
ORANGE 1: 23 1: 44 1: 64 1: 78 1: 137 1: 196 1: 215 1: 314 1: 437 1: 536
TURQUOISE 1: 17 1: 31 1: 45 1: 55 1: 91 1: 126 1: 134 1: 197 1: 274 1: 336
PINK 1: 14 1: 24 1: 35 1: 42 1: 68 1: 93 1: 98 1: 143 1: 188 1: 224
LIGHT BLUE 1: 11 1: 17 1: 24 1: 31 1: 47 1: 64 1: 66 1: 98 1: 136 1: 166
BROWN 1: 10 1: 15 1: 22 1: 28 1: 43 1: 58 1: 59 1: 88 1: 122 1: 150
RED 1: 12 1: 17 1: 23 1: 34 1: 45 1: 46 1: 69 1: 95 1: 116
WHITE 1: 12 1: 16 1: 22 1: 31 1: 42 1: 43 1: 64 1: 88 1: 108
GREEN 1: 11 1: 14 1: 20 1: 28 1: 37 1: 38 1: 55 1: 76 1: 94
BLUE 1: 10 1: 12 1: 17 1: 23 1: 30 1: 31 1: 46 1: 63 1: 77
YELLOW 1: 9 1: 12 1: 16 1: 20 1: 22 1: 31 1: 42 1: 52
BLACK 1: 10 1: 13 1: 16 1: 17 1: 24 1: 33 1: 40
PURPLE 1: 6.6 1: 8.3 1: 9 1: 10 1: 13 1: 17 1: 21
GRAY 1: 5.3 1: 6.7 1: 6.9 1: 7.6 1: 10 1: 13 1: 16
OPEN 1: 4.9 1: 5.3 1: 5.2 1: 6.0 1: 6.1 1: 8.3 1: 10
Met
erin
g Ti
p
SPIRAL METERING PLUGS
Flow Rate(GPM) at 200 PSI
0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray Blue LightGreen Purple Dark
Green
Nozzle Size 0.029” (0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.098”(2.5 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
3.00” 1: 251 1: 503 1: 754 1: 1006 1: 1509 1: 2012 1: 2263 1: 3269 1: 4526 1: 5532
2.00” 1: 181 1: 363 1: 544 1: 726 1: 1089 1: 1451 1: 1633 1: 2359 1: 3266 1: 3991
1.00“ 1: 104 1: 208 1: 311 1: 415 1: 623 1: 831 1: 934 1: 1350 1: 1869 1: 2284
0.75” 1: 82 1: 165 1: 247 1: 329 1: 494 1: 659 1: 741 1: 1071 1: 1483 1: 1812
0.50” 1: 59 1: 119 1: 178 1: 238 1: 357 1: 475 1: 535 1: 772 1: 1069 1: 1307
0.25” 1: 34 1: 68 1: 102 1: 136 1: 204 1: 272 1: 306 1: 442 1: 612 1: 748
Spira
l Plu
g Le
ngth
© Hydra-Flex, Inc. 2018 Page | 21
RECOMMENDED SETUP STARTING POINTSAPPLICATOR INJECTORS PART NUMBER/COLORScentDispenser 618057 (1 GPM)
CTANozzles(ForShowerhead,SeeBelow) 618057 (1 GPM)
FoamStick 618070 (1.5 GPM)
Mitter/WarpNozzles 618070 (1.5 GPM)
Undercarriage/RustInhibitor 618083 (2.0 GPM)
VJetOrFlatFanNozzleArch 618086 (2.25 GPM)
K12NozzleArch 618086 (2.25 GPM)
K15NozzleArch 618098 (3.25 GPM)
HockeyPuck 1 Row Of Holes618051 (.75 GPM)
2 Rows Of Holes618057 (1 GPM)
3 Rows Of Holes618070 (1.5 GPM)
Showerhead 1 Row Of Holes618057 (1 GPM)
2 Rows Of Holes618070 (1.5 GPM)
3 Rows Of Holes618083 (2.0 GPM)
RainBar 1 Row Of Holes618086 (2.25 GPM)
2 Rows Of Holes618098 (3.25 GPM)
3 Rows Of Holes618125 (5.5 GPM)
FoamCurtain-ChooseFoamAccessoryBasedOn#OfInputs/FoamGenerators**
Duo-Foam w/(2X) 618098 (3.25 GPM)
Triple-Foam w/(3X) 618086 (2.25 GPM)
Quad-Foam w/(4X) 618086 (2.25 GPM)
HighFlowFoamCurtainApplication(10+GPM) High Flow Device w/ 618086 (2.25 GPM)
FoamingAir:Startat25PSI(adjustbasedonuniqueapplication)
CHEM-FLEX INJECTOR PART NUMBERS
Pressure Range: Up to 500 PSI Max. (34 bar) Inlet, 333 PSI (23 bar) Max. Outlet
Temperature Range: 33°F - 175°F ( .5°C - 79°C)
Maximum Wrench Torque: 30 ft-lbs (41 N-m)
SPECIFICATIONS
QUICK CONNECT INJECTORS - PC2 X 3/8” NPT CONNECTIONS(For exclusive use with Aqua-Lab™ Chemical Dispensing Systems)
COLOR FLOWORIFICE
FLOW RATE @ 200 PSI
SINGLE BARB DUAL BARB
WHITE 0.029 0.25 GPM 618029 -
YELLOW 0.040 0.5 GPM 618040 629040
TAN 0.051 0.75 GPM 618051 629051
RED 0.057 1.0 GPM 618057 629057
ORANGE 0.070 1.5 GPM 618070 629070
GRAY 0.083 2.0 GPM 618083 629083
BLUE 0.086 2.25 GPM 618086 629086
LIGHT GREEN 0.098 3.25 GPM 618098 629098
PURPLE 0.117 4.5 GPM 618117 629117
DARK GREEN 0.125 5.5 GPM 618125 629125
© Hydra-Flex, Inc. 2018 Page | 22
PRESSURE LOSS IN RUN LENGTH
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.
GREEN = GOOD YELLOW= USE CAUTION RED = NOT RECOMMENDED
INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray Blue Light Green Purple Dark Green
Nozzle Size 0.029”(0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.098”(2.5 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 7 PSI 13 PSI* 18 PSI*125’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 6 PSI 11 PSI* 16 PSI*100’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 3 PSI 5 PSI 9 PSI 13 PSI*75’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI 7 PSI 9 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 4 PSI
Run
Leng
th
5/8” ID BRAIDED
INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray Blue Light Green Purple Dark Green
Nozzle Size 0.029”(0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.098”(2.5 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 9 PSI 11 PSI* 21 PSI 36 PSI 56 PSI125’ 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 8 PSI 9 PSI 18 PSI* 30 PSI 47 PSI100’ 1 PSI 1 PSI 2 PSI 2 PSI 4 PSI 7 PSI 8 PSI 14 PSI* 24 PSI 36 PSI75’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 5 PSI 6 PSI 11 PSI* 18 PSI* 26 PSI50’ 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 4 PSI 4 PSI 8 PSI 12 PSI* 18 PSI*25’ 1 PSI 1 PSI 1 PSI 1 PSI 1 PSI 2 PSI 2 PSI 4 PSI 6 PSI 9 PSI
Run
Leng
th
1/2” ID BRAIDED
INJECTORFlow Rate (GPM) at 200 PSI 0.25 0.50 0.75 1.00 1.50 2.00 2.25 3.25 4.50 5.50
Injector Color White Yellow Tan Red Orange Gray Blue Light Green Purple Dark Green
Nozzle Size 0.029”(0.7 mm)
0.040”(1.0 mm)
0.051”(1.3 mm)
0.057”(1.4 mm)
0.070”(1.8 mm)
0.083”(2.1 mm)
0.086”(2.2 mm)
0.098”(2.5 mm)
0.117”(2.9 mm)
0.125”(3.2 mm)
150’ 1 PSI 5 PSI 7 PSI 11 PSI* 22 PSI 36 PSI 44 PSI 88 PSI 154 PSI 239 PSI125’ 1 PSI 4 PSI 6 PSI 9 PSI 18 PSI* 30 PSI 37 PSI 73 PSI 129 PSI 200 PSI100’ 1 PSI 3 PSI 5 PSI 7 PSI 14 PSI* 23 PSI 28 PSI 54 PSI 103 PSI 142 PSI75’ 1 PSI 2 PSI 4 PSI 6 PSI 12 PSI* 18 PSI* 22 PSI 42 PSI 77 PSI 106 PSI50’ 1 PSI 1 PSI 3 PSI 4 PSI 8 PSI 12 PSI* 15 PSI* 28 PSI 52 PSI 73 PSI25’ 1 PSI 1 PSI 1 PSI 2 PSI 3 PSI 6 PSI 7 PSI 13 PSI* 26 PSI 34 PSI
Run
Leng
th
3/8” ID, 1/2” OD POLY TUBE
© Hydra-Flex, Inc. 2018
REPLACEMENT PARTS LIST - ASSURE PDS
A
B
Q
D
E
F
G N I
J
K
L
H
M
O
P
C
PART NAME PART NUMBERA MDPrimaryAirRegulator 1001184
BSolenoidActuatedAirValveReplacement-Foaming
24 VAC - 1001428
24 VDC - 1001429
120VAC-1001430
C M12XDinIAirRegulator-WithLED120VAC-3000948
24VDCor24VAC-3000958
D PrimaryAirRegulatorReplacementBowlAluminum-3000952
Plastic-3000870
E M12JunctionBlock-6Port,With30’HomerunCable 3001301
F OutletPressureGauge0-400PSIBottomMount 3000491
G AirActuatedHydra-CannonValveReplacementKit StainlessSteel-3000925
H 1/4”PolyTubing 3000812
IDuo-FoamManifoldKit(NOTSHOWN) 1001289
Tri-FoamManifoldKit 1001288
J SmallRegulator&0-60PSIGauge 3000808
K 10-32”X1/4”Push-To-ConnectAirFittingForAirValve 3000987
L 1/4”PushToConnectTee 3000815
M 1/2”NPTMaleQuickConnect-Brass 3000500
N SingleBlackHydra-CannonReplacementAssembly 1001384
O Hydra-CannonEndFittingAssembly 1001556
P Hydra-CannonInterfaceFittingAssembly 1002034
Q 3/8”PolyTubing 3000520
(NOTSHOWN) SolenoidO-RingReplacementKit 1001155
(NOTSHOWN) 1/4”HoseBarbFoamingAirCheckValve 3000819
(NOTSHOWN) 1/4”PushToConnectTo1/8”NPTElbow 3000803
(NOTSHOWN) Anti-SiphonKit(Contains5) 1001436
Page | 23
© Hydra-Flex, Inc. 2018
ASSURE PDS SINGLE SOURCE MOTOR STARTER
ASSURE PDS PUMP
J
I
H
KA
D
F E
BC G
PART NAME PART NUMBERA Replacement/Backup20GPMPump 1001362
B 1”MaleQuickConnect-Brass 3000205
C 1”WyeStrainer,20Mesh 3000490
D 1”FemaleQuickConnect-Brass 3000206
E TemperatureSwitch 3000507
F QuickConnect9’CordsetForPump 3000782
G 40GPMBypassPressureRegulator-StainlessSteel 3000464
(NOTSHOWN) 1”NPTT16WyeStrainerScreen&GasketKit 1001938
(NOTSHOWN) 1”NPTT15WyeStrainerScreen&GasketKit 1001939
(NOTSHOWN) 20GPMQuickConnectRegulatorPlumbingAssembly 1001775
(NOTSHOWN) 1/2”FemaleQuickConnect-Brass 3000502
(NOTSHOWN) 1/2”BallValve-Brass 3000565
(NOTSHOWN) ManifoldInletHose1/2”IDHose-1/2”NPTEnds-72”L 3000579
(NOTSHOWN) 20GPMQuickConnectRegulatorPlumingAssembly 1001775
PART NAME PART NUMBERH ThermalOverload-Sprecher&Schuh 3000862
I
Contactor-Sprecher&Schuh
24VAC-3000863
24VDC-3000864
120VAC-3000865
Contactor-Eaton
24VAC-3001336
24VDC-3001337
120VAC-3001338
J CurrentSensorAC-3000666
DC-3000866
K TimeRelay 3000664
REPLACEMENT PARTS LIST
Page | 24
© Hydra-Flex, Inc. 2018 Page | 25
FACTORY LIMITEDHydra-Flex,Incwarrantsitsequipmenttobefreefromdefectinmaterialorworkmanshipunderproper
normaluseforaperiodofone(1)yearbeginningthedateofpurchase.
Hydra-Flex,Inc’sliabilityshallbelimitedtorepairorreplacementofpartsfoundtobedefectivewithinthe
warrantyperiodandfollowingHydra-Flex,Inc’sinspection.Hydra-Flex,Incshallhavetheoptionrequiring
thereturnofdefectivematerialtoestablishthepurchaser’sclaim.Intheeventofrepairorreplacement
thislimitedwarrantyisnon-cumulative.Neitherlabornortransportationchargesareincludedinthis
warranty.
Thiswarrantyisbaseduponthepropercareandmaintenanceofthewarrantedequipment.Warranty
doesnotapplyifthemerchandiseisalteredormodifiedinanyway.Warrantydoesnotapplytoany
equipmentwhichhasbeensubjecttomisuse,inappropriateuseoftools,includingexposuretoharsh
chemicals,neglect,lackofmaintenance,freezing,fluidhammer,accident,thirdpartydamage,fluid
impuritiessuchassandorminerals,actsofGodoractsofwar.Nordoesitapplytoanyequipmentwhich
hasbeenrepairedoralteredbyanyonenotsoauthorizedbyHydra-Flex,Inc.Allequipmentmustbe
properlyinstalledinaccordancewithspecifiedplumbing,electrical,andmechanicalrequirements.The
warrantydoesnotapplytonormalwearandtearorroutinemaintenancecomponentsasdescribedinthe
equipmentmanual.
Exceptasexpresslystatedherein,Hydra-Flex,Incshallnotbeliablefordamagesofanykindin
connectionwiththepurchase,maintenance,oruseofthisequipmentincludinglossofprofitsandall
claimsforconsequentialdamages.Thislimitedwarrantyisinlieuofallotherwarrantiesexpressedor
implied.Hydra-Flex,Incneitherassumesnorauthorizesanypersontoassumeforitanyotherobligation
orliabilityinconnectionherewith.Thiswarrantyisneitherassignablenortransferable.
Transportationdamageclaimsaretobesubmittedtothecarrierofthedamagedmaterial.
ASSURE PDS WARRANTY
T:952-808-3640•F:952-808-3650•www.hydraflexinc.com•[email protected]
4000022 revF0118