HYDRO 0.3 Percent HAC SuperDos 30 Injector Instruction Manual

Quick Start-up

Operating Principle

Accurate and Reliable
Installed directly in the fluid supply line, the injector operates without electricity, using fluid (water) pressuras the power source. The fluid drives the injector, which pulls the required percentage of concentrate directly from the chemical solution container. Inside the Hydro patented mixing chamber, the concentrate is mixed with the fluid, and the fluid pressure forces the mixed solution downstream. The amount of concentrate will be directly proportional to the volume of fluid entering the injector, regardless of variations in flow or pressure.

Please read this manual carefully before putting the Hydro injector into operation.
This booklet has the information you will need for the use and care of your new Hydro injector. If you have any further questions about your injector, the warranty, routine maintenance or proper usage, please contact your nearest distributor or Hydro Systems customer service.
These models are designed to inject liquid concentrate or soluble powder that are recommended and approved for injection into fluid systems.
lt is the responsibility of the operator to determine the correct dosage settings of the unit using the chemical manufacturers’ recommendation for dispensing their product, and to assure that proper dosage is being maintained.
Maintenance and Warranty
Hydro offers a three year limited warranty from the original date of purchase for manufacturing or materials defects only. With proper use and care, your injector should provide you long-term performance.

For Your Records
The serial number of your Hydro injector is located on the injector body. Please record this number in the space below and reference it when calling your distributor or Hydro for information, parts and service.
Serial #……………………………………………………………………
Date Purchased ……………………………………………………….

This document does not form a contractual engagement on the part of Hydro Systems Company and is for information only. Hydro reserves the right to alter product specifications or appearance without prior notice.

Package Contents

The injector is packaged with the following items:

• Injector (not shown)
• Mounting Bracket
• Dosage Piston
• Mounting Nuts and Bolts
• O-ring
• Filter
• Manual (not shown)
• Suction Tube

Specifications

Model 0.3% 0.025% – 0.3% (1:4000 -1:333)
Model 2.5% 0.3% – 2.5% (1:333 -1:40)
Model 2.5% WSP 0.3% – 2.5% (1:300 -1:40)
*Model 5% 0.5% – 5% (1:200 -1:20)
Flow Rate:…………….. 0.15 – 30 gpm (34 – 6,800 lph)
Operating Pressure: ..5 – 100 psi (0.34 – 6.9 bar)
Pipe Coupling: ……….1″ NPT/BSP

• 5% model with remote injection kit has maximum operating pressure of 60 psi (4 bar) and maximum flow rate of 20 gpm.

Seal Material Available:*Contact your distributor for specific chemical information| Aflas – Alkaline concentrates Viton – Acids, oils & pesticides EPDM – Alkaline concentrates Kalrez

Safety Precautions/Warranty Compliance

Warning: Please read precautions thoroughly before operation. Must meet all applicable local codes and regulations.
Remove Red Caps Prior to Installation
Your injector is 100% factory tested before delivery and may contain a small amount of water. The three red plastic caps are fitted after testing to ensure cleanliness of the injector.
Before Applying Aggressive Chemicals
Please consult your distributor, chemical manufacturer or contact Hydro’s customer service to confirm compatibility with your injector. Always wear proper safety protection as recommended by chemical supplier.
Label all Fluid Lines, Valves and Connections
If the solution that is being injected is not suitable for drinking, all fluid lines should be labelled:
Warning – not for human consumption!
Monitor Outlet Flow
It is the user’s responsibility to monitor the output of chemical injected.
A Filter is Recommended and Required
Install a filter of 140 mesh (104 micron) or finer depending on your fluid quality to prolong the working life of the injector and for the warranty to be valid. A filter is imperative since most fluid contains impurities or particles, especially if the fluid source comes from a well, pond or lake.

Avoid a Potentially Hazardous Chemical Accident
Select a safe location. Chemical container should be kept away from children and/or high usage areas and the location must also not be susceptible to freezing temperatures.
Avoid Solution Contamination
Use only clean FILTERED fluid. Do not allow contaminants to enter the solution container. They can be pumped into the fluid line and may cause the spread of disease. Dirt, debris and other contaminants in the solution container may cause excessive wear to the unit.
Fluid Temperature
Min: 34°F (1°C), Max: 100°F (38°C)
Maximum Fluid Pressure
100 psi (6.9 bar). Operating pressure and flow are reduced while using remote injection kit. Install a pressure regulator and/or pressure relief valve to ensure operating pressure does not exceed the maximum specification.
Before Removing An Injector From The System
Release fluid pressure. While the system is in operation, turn off the incoming fluid valve. Leave the out going valve open. This will relieve the pressure at the injector and all parts of the system after the injector. Injector is now safe to remove.

General Tips

Please read this instruction manual thoroughly. Following the procedures, will increase the life of your injector.

For A Long Service Life
Start with clean fluid by using an inline filter to reduce impurities. Keep the solution container covered and clean. Keep the suction tube filter 2″ (5 cm) from the bottom of the container. Perform maintenance procedures as recommended (see Maintenance ).
Soluble Powder Use
Ensure the chemical is completely dissolved before starting the injector. If necessary, dissolve the chemical in hot water and allow to cool before using. Failure to thoroughly dissolve the chemical will cause premature wear to the dosage piston and the inner cylinder.

Keep From Extreme Temperature
Protect the injector from freezing temperatures or excessive heat.
Rinse Injector After Each Use
Additive allowed to remain in injector can dry out, foul or damage the lower end at the next start-up (see Maintenance).
Injector Not in Use for an Extended Period
If the injector has not been stored properly deposits may have dried onto the motor (see Maintenance ).
Before operation, soak entire unit into room temperature water approx. 72°F (22°C) for an eight hour period.

Operations

Clicking Sound is Normal
Fluid flowing through the injector will automatically cause the injector to “click” and inject a set amount of solution into the fluid line. The higher the flow rate the more frequent the “clicking”. The injector is designed to inject solution proportionally (at the same set ratio) regardless of fluid flow.
Service Fluid Flow
Fluid flow and pressure must be within the established specifications (see Specification on page 6) for your model.
Change Feed (Injection) Rate
The feed rate on the injector is adjustable EVEN WHILE OPERATING AND UNDER PRESSURE. To change feed rate see (Fig. 1 and Fig. 2).

• Do not remove #79 when injector is under pressure.

  1. Remove Upper Interlock Pin (#65) (Fig. 1).
     

  2. Rotate Ratio Adjuster Sleeve (#61) up or down to the desired setting (Fig. 2).
     
     Use the top of the Ratio Adjuster Sleeve to line up with the desired feed rate on the setting (Fig. 2a).
     

  3. Re-insert Upper Interlock Pin (#65). Clip must be parallel with settings to be able to re-insert.

NOTE: Do not screw Ratio Adjuster Sleeve below lowest setting line. Measure outlet fluid to assure desired feed rate is being delivered.

Bypass Operation
Injecting solution into the fluid line can be TEMPORARILY stopped with the On/Off feature (Fig. 3).

Moving the On/Off Lever to the OFF position allows service fluid to pass through the injector without injecting chemical. No “clicking” will be heard.
With the On/Off lever set to the ON position the injector will operate as normal and “clicking” will be heard when fluid is flowing. It is recommended to use the three-valve bypass (see Fig. 5), for continued bypassing or servicing of the injector.

Installation & Startup (Refer to Fig. 4 and Fig. 5)

Fluid Filter (Required)
Install a filter of 140 mesh (104 micron) or finer depending on your fluid quality to prolong the working life of the injector and for the warranty to be valid. Hydro recommends a Twist II Clean® filter that can be ordered with your injector.
Mounting Injector
Securely fasten your injector to a solid object such as a wall or in a cold fluid line. Note arrow on injector indicates fluid flow.
Backflow Preventer (Recommended)
Install one that meets local code requirements.
Pressure Safety Release Device (Recommended)
Prevents pressure from exceeding specifications of the unit.
Bypass Valve Set-up (Recommended)
Allows the injector to be taken off-line for maintenance or storage when not in use.
Fluid-Hammer Arrester (Recommended)
Prevents fluid-hammer damage to the injector when operating quick closing solenoid, pneumatic or hand-operated ball valves on the fluid system.
Anti-Siphon Valve (Optional)
To prevent solution from being siphoned out (from the solution container) into the feed lines when the upstream valve is shut off.
The anti-siphon valve must be installed on the downstream outlet.

Additional Siphoning Prevention
Place solution container on a level below the injector suction tube fitting. Using the inlet side as a shut-off valve could cause full strength solution to siphon into the feed line.
Solution Container
Use any size container. A lid or cover is recommended. To connect your solution container, gently push the end of the suction tube onto the bottom of the suction tube fitting assembly.
Place the filter into the solution container at least 2″ (5 cm) from the bottom and fill with at least 2″ (5 cm) of chemical solution.
Never Use Petroleum Based Lubricants
The injector is shipped with a thin coat of silicone around the seals for ease-of-assembly. Petroleum based lubricants such as Vaseline©, baby oil, WD40©, or motor oil on the O-rings or any part of the injector should never be used as this can cause particles to adhere and clog or damage the injector.
Check System for Leaks and Start-Up Procedures
Open the bypass valve (A), close inlet valve (B) and outlet valve (C) to prevent fluid flow into the injector. SLOWLY turn on the main fluid line. Run fluid flows between 5 – 12 gpm (11-45 l/m) through the plumbing system. Turn on all of the valves located downstream from your injector to release trapped air. SLOWLY turn on the inlet valve (B). Open the outlet valve (C) and close valve (A). As fluid travels through the injector, you will hear a “clicking” sound. Check for leaks and correct if necessary.

Suggested Installation Diagram

Remote Injecting

Fig. 6 Remote Injector Kit shown on a single injector.

Fig. 7 Remote Injector Kit shown in a series.

Kit Part Numbers
012705

Remote Injector Kit (not included)
Is recommended for the following:
Single Injector:
To prevent mineral buildup within the body of the unit. Use when injecting chemicals that cause minerals to precipitate from fluid (see Fig. 6)
Injectors In a Series:
When injecting multiple chemical injections, using two or more injectors. Each injector adds chemical to the fluid(water) system, while bypassing the next injector and eliminating the potential damage to that injector (see Fig. 7).
NOTE: when mixing more than one chemical, always refer to your chemical manufacturer information guide for proper application. Contact your local distributor or Hydro customer service for information or to order.

Maintenance

Rinse Injector After Each Use
Additive allowed to remain in injector can dry, foul or damage the lower end at the next start-up. Place suction tube into a 1 qt. (0.95 liters) or more container of fresh filtered water. Flow fresh water through the injector by operating until container is empty. This procedure is not needed for continuous operation.
Clean Solution Container
Keep covered to prevent dirt, flies and flying debris from entering the container. Rinse container thoroughly and often.
Do not mix chemicals together that might react and cause a precipitate. Use FILTERED fluid when filling container.
Clean Suction Tube Filter Screen
Inspect each time new solution is added. Clean filter screen (#27) and suction tube (#25) as necessary by rinsing in fresh water. Replace if necessary. Keep filter screen off bottom of solution container to prevent dirt and precipitate from clogging filter.
Clean Inlet Filter
Clean or replace inlet filter as required to increase the life of the unit as well as reduce pressure loss.
Bypass Injector
When not in use place the injector in bypass mode by using the three valve bypass (preferred) or turn the on/off lever on the top of the injector to the off position.
Storage
For extended storage, rinse injector (see “Rinse Injector After Each Use”) and place underwater in a container.
Apply monthly, <0.1 oz. (29 ml) of chlorine bleach to avoid algae growth. KEEP FROM FREEZING.

Perform these maintenance procedures to extend the life of your unit.

Refer to SuperDos 30 (0.3%) Models

Every 3 – 6 Months| Every 6 – 12 months| Replace as necessary
---|---|---

1. Clean seal areas (# 17 & 13).
2. Check #17 O-ring,#68 Cylinder, clean and/or replaces necessary.

|

1. Replace #17 O-ring and #51 Lower Shaft Assy.
2. Clean and/or replace #13 Check Poppet,#11 Suction Tube Fitting.

|

1. 68 Cylinder

2. 51 Lower Shaft Assembly

Refer to SuperDos 30 (2.5%), (5%) Models

Every 3 – 6 Months| Every 6 – 12 months| Replace as necessary
---|---|---

1. Clean seal areas (# 13 & 14, #44 – WSP)
2. Check #17 O-ring,#7 Cylinder, clean and/or replace as necessary.

|

1. Replace #17 O-ring and#44 Dosage piston/gasket (WSP model). Clean and/ or replace

2. 13 Check Poppet, #11 Suction Tube Fitting.

|

1. 7 Cylinder

2. 14 (#44 – WSP)O-ring

Routine Maintenance Instructions

Step 1. Unscrew LOWER END CYLINDER ASSEMBLY from body. Remove LOWER END CYLINDER ASSEMBLY.

Step 2. Rotate #51 SHAFT 90º and pull from body.

Step 3. Pry the #15 SEAL
RETAINER from the injector.
Pry #17 O-ring from the unit.
NOTE: O-ring may still be seated at the base of the unit.

Step 4. For 2.5% & 5% Replace #44 DOSAGE PISTON flared-end up and #14 O-ring.

Step 4a. For 2.5% WSP Pinch and pull #44 DOSAGE GASKET over the retainer lip. Slide off the #51 shaft assembly.

Step 4b. For 0.03%. Replace LOWER SHAFT assembly into upper shaft.

Step 5. Reinsert #15 SEAL RETAINER and #17 O-ring onto # 51 SHAFT ASSEMBLY.

Step 6. Reinsert #51 SHAFT ASSEMBLY into body and rotate 90º to lock. Confirm the shaft is locked in by gently tugging on the shaft. Shaft should remain inserted.

Step 7. Screw LOWER END CYLINDER ASSEMBLY onto body. Ensure #16 gasket is seated on the top of cylinder assembly.

Troubleshooting

New Install – Always Pressure Up Slowly (Follow start up )

openings removed?Is the unit installed backward? The arrow on the unit must point in the direction of the fluid flow.If still not clicking, do not open the upper body. Call Hydro Customer Service.
**** Fluid flowing through unit| Fluid rate is below or exceeds rated service flow of injector. (see Specifications page 6).Has the new injector been stored for an extended period? If so, submerge the injector in room temperature fluid for 24 hours so that the working parts can reabsorb fluid and swell back to the proper size.Operating pressure exceeds maximum limit. Install a pressure reducer valve. (see Specifications page 6).On/Off Lever in off position. Place the On/Off lever switch to the ON position. By- pass valve (A) not closed. Check and set valve to the CLOSED position.

Injector in Operation or After Scheduled Maintenance

Main Piston Assembly. Clean fluid filter.
Cover #1 or main body #40 worn or scored| Install or clean fluid filter.
On/Off Lever in off position| Place the On/Off lever switch to the ON position.
By-pass valve (A) open| Set Valve (A) to the closed position.
Dirty or plugged inlet filter| Ensure mesh size is correct for proper filtration. Clean filter.

17 Worn or not seated properly| Re-seat #17 or replace.

**Clicking Sound No Suction Of Solution| Cylinders #7 or #68 worn| Replace.
Dosage piston/gasket (WSP model) #44 (0.3% model #51) worn or installed incorrectly| Replace. Ensure during maintenance replacement that #44 dosage piston was installed correctly flared-end up.
O-ring retainer #15 installed incorrectly| Install correctly.
O-ring seat #14 or dosage piston/ gasket (WSP model) #44 (0.3% model#51) damaged| ** Replace.

17 O-ring worn and/or loose| Replace.

Suction tube #25 or suction tube fitting #11 cracked, leaking oror clogged suction tube filter| Replace and/or clean as necessary.
Check valve #13 leaking| Clean & replace as necessary.
**Clicking Sound. Under Injecting**| #44 (0.3% model

51) Dosage Piston/ Gasket (WSP model) worn| Replace.

7 (#68 – 0.3%) Inner Cylinder worn| Replace.

Unit operates at high-flow and not at low flow| Replace #17 O-ring.
Main Piston Assembly #9 worn| Replace # 9 Main Piston Assembly. Clean fluid filter.
Cover #1 or main body #40 worn or scored| Install or clean fluid filter.
Fluid Re-filling Solution Tank| Check valve #13 leaking| Check seat area on suction tube fitting #11. Check valve and seal must fit loose in the suction tube fitting. Clean seal and inside fitting for debris.
Washer seal on #13 is swollen or chemical attack| Replace with new check valve assembly.

Kits & Spare Parts List

Injector Repair Parts

0.3% HAC

Lower End Assembly

Accessories

Available In:
3/4″ – 25 gpm (95 l/mn) 100 psi (7 bar)
1″ – 39 gpm (114 l/mn) 100 psi (7 bar)
1.5” – 78 gpm (295 l/mn) 100 psi (7 bar)
2″ – 150 gpm (568 l/mn) 100 psi (7 bar)

• Various mesh sizes available.

Warranty

Limited Warranty
Seller warrants solely to Buyer the products will be free from defects in material and workmanship under normal use and service for a period of one year from the date of completion of manufacture. This limited warranty does not apply to (a) hoses; (b) products that have a normal life shorter than one year; or (c) failure in performance or damage caused by chemicals, abrasive materials, corrosion, lightning, improper voltage supply, physical abuse, mishandling or misapplication.
In the event the products are altered or repaired by Buyer without Seller’s prior written approval, all warranties will be void.
No other warranty, oral, expressed or implied, including any warranty of merchantability or fitness for any particular purpose, is made for these products, and all other warranties are hereby expressly excluded.
Seller’s sole obligation under this warranty will be, at Seller’s option, to repair or replace F.O.B. Seller’s facility in Cincinnati, Ohio any Products found to be other than as warranted.
Limitation of Liability
Seller’s warranty obligations and Buyer’s remedies are solely and exclusively as stated herein. Seller shall have no other liability, direct or indirect, of any kind, including liability for special, incidental, or consequential damages or for any other claims for damage or loss resulting from any cause whatsoever, whether based on negligence, strict liability, breach of contract or breach of warranty.

Fluid Flow Range:

0.15 gpm to 30 gpm
34 lph to 6,800 lph
Injection Range
Dosage:
0.025% to 5%
1:4000 to 1:20
Operating Pressure:
5 to 100 psi
0.34 to 6.9 bar
*Specifications vary by model.

Hydro Systems Company 3798 Round Bottom Road Cincinnati, OH 45244 U.S.A.

Phone : 513-271-8800
Toll Free : 800.543.7184
Fax : 513-271-0160
Web : hydrosystemsco.com
HYD013826 Rev J 12/23

References

• Chemical Dilution, Dosing and Injection Equipment | Hydro Systems

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>