HydroMinder HP High Pressure Chemical Dispensing Unit User Manual

Minder HP High Pressure
Chemical Dispensing Unit
User Manual Hydro MinderTM HP

Overview

1.01 Safety Precautions

WARNING! Please read precautions thoroughly before operation. Must meet all applicable local codes and regulations.
THANK YOU FOR YOUR INTEREST IN OUR PRODUCTS
Please use this equipment carefully and observe all warnings and cautions.
WEAR protective clothing and eyewear when dispensing chemicals or other materials or when working in the vicinity of all chemicals, filling or emptying equipment, or changing metering tips.
protective foot ware, such as steel toed shoes, when installing the unit and its peripherals.
NOTE Disconnect all electrical power during installation, service, and/or any time electrical connections are exposed.
Installation of the system must be performed according to the instructions of this manual. It is the responsibility of the installer to ensure that the equipment or system into which the product is incorporated complies with all relevant  legislation and codes of practice which apply in the country of use.
Regularly inspect equipment and keep equipment clean and properly maintained.
Warranty is voided if the user modifies, adds, or suppresses any feature of the unit.
All components involved in maintenance tasks must be the ones registered in the spare parts list supplied by the manufacturer. Otherwise the Warranty is void.
1.02 Description of the System
The HydroMinder HP is a high pressure, venturi injector-based, multi-channel chemical dilution system for use in bay and tunnel car washes.
The panel works in conjunction with a pump to provide pressurized water and a VFD to regulate the pump’s output at a constant 200 psi.
HydroMinder HP is available in two sizes, 5 or 7 product configurations.
Product Features

• Valve Injector flow rates of 0.75 to 12 GPM per application.
• Individually controlled foaming pressure lines for each application.
• Triple foaming supported tied to three individually controlled foaming pressure lines.
• Quick disconnects and shutoffs for each valve for ease of installation and maintenance.
• Stainless steel componentry for superior longevity.

1.03 Panel Components
The diagram below list the componentry of a 7 valve system. The 5 valve system differs in number of valves and supporting componentry.

1.04 Panel Dimensions
Note: Dimensions are same for both 5 valves and 7 valves system.

Specification

HydroMinder HP Panel

Wall Mount
Provided Hardware| No. 8 Screw and Anchor kit
Air Supply
Min. Pressure Required
Tubing Size
Recommended Material
Connection Type| 80 psi Dry
3/8” OD – to be supplied on site
Polyethylene
Push-To-Connect
Control Signals
Signal Voltage
Cable length| Specified at purchase
30 meters
Chemical Supply
Tubing Size
Recommended Material
Connection Type| 1/4” ID – to be supplied on site
Vinyl
Barb
Solution Outlets
Tubing Size
Recommended Material
Connection Type| 1/2” OD – to be supplied on site
Polyethylene
Push-To-Connect
Foaming Outlets
Tubing Size
Recommended Material Connection Type| 3/8” OD – to be supplied on site Polyethylene/Polyurethane
Push-To-Connect
Injectors
Available Flow Rates|  0.75, 1, 1.5, 2, 2.25, 3.25, 4, 5.5,
7, 8, 9, 10, and 12 gpm
Weights and Dimensions
Weight
Height
Width
Depth| 75 lbs
31.07”
31.47”
6”
Pump

Floor Mount
Hardware| Anchors for 1/2” Bolt Holes – to be supplied onsite
Pump Inlet (From City)
Min. Pressure
Provided Hose Length
Provided Hose Size
Provided Connection Type| 40 psi
6 ft.
1” ID
1” Barb
Pump Outlet (To Panel)
Working Pressure
Provided Hose Length
Provided Hose Size
Provided Connection Type(Pump Outlet)
Provided Connection Type
(Panel Inlet)| 200 psi (Factory Set)
6 ft.
1” ID
1” NPT
Quick Connect
Electric
Input Voltage| Specified at purchase (Check VFD Name plate)
480 VAC 3-Phase
240 VAC 3-Phase
Weights and Dimensions Weight
Height
Width
Depth| 127 lbs
41”
10”
9”
Max. Pump Capacity| 20 gpm
VFD

Wall Mount
Provided Hardware| No. 8 Screw and Anchor kit
Electric
Input/ Output Voltage
Max Rated Power
Max Frequency| Specified at purchase (Check VFD
Name plate)
480 VAC 3-Phase
240 VAC 3-Phase
6.4 Amps at 480 VAC
12.9 Amps at 240 VAC
60 Hz
Pressure Transducer
Cable
Provided cable Length| 6 ft.
Weights and Dimensions
Height
Width
Depth| 11”
7.5”
8”

Panel Installation

3.01 Site Survey
When determining where to install the panel, consider the distance to the pump stand, air supply, car wash control panel, and chemical containers. Incoming/outgoing connections will need to accommodate the distance. Also consider  how the solution, chemical, and air lines will be routed, and what hardware will be required to accomplish that scheme. Refer the below diagram to locate the panel and peripheral components.

3.02 Required Skills and Tools

Skills

Mechanical| Mounting the panel and assembling injectors
Electrical| Knowledge of 3 phase systems and local electrical code for VFD/Pump Familiar with car wash controller trigger signals
Plumbing| Assembling pump flanges, threaded connections, and hose connections Connecting solution lines
Air| Connecting air lines
Chemical| Connecting chemical pick up lines
Process| Knowledge of car wash applications
Tools

Mechanical| Hammer Drill
Masonry Bits
Impact Driver
Bubble Level
Tape Measure
Pencil/Marker
Wrench Set
Screwdriver Set
Electrical| Cable – length determined by pump/VFD location
Cable Stripper
Wire Stripper
Multimeter
Flexible Watertight Conduit
Ring Terminals and Crimper
Plumbing| Pipe Wrench
Teflon tape/Pipe dope
Tube Cutters
1” Hose Clamps

3.03 Mounting the Panel
Warning! – Wear protective PPE, such as steel toed shoes and safety glasses, when installing the unit and its peripherals.
Note: Two people will be required to mount the panel.

1. Determine where the panel will be mounted. The surface must be vertical and able to withstand the weight of the panel. Refer to the site survey diagram for location.

2. A paper template with bolt hole locations is included for ease of installation. Tape the template to the mounting surface.
   The template must be tight for accurate placement of the bolts.

3. Drill pilot holes and insert the anchors into the holes. Drive the bolts approximately 1/4 in. from the wall to allow the panel to drop in the key slot.

4. Align the panel over the bolts and drop it into place. After dropping the panel into position, drive the bolts hand tight.

5. Install the angled seat valves to the quick connect fittings on the ball valves. Insert each corresponding air tube to the seat valve.

3.04 Signal Wiring
Warning! – Ensure the voltage from the car wash trigger signals matches the voltage stated on the air solenoids.
Run the signal box cable to the car wash control panel and connect the trigger wires to the appropriate terminals.
Refer the below table and the car wash control panel schematics to identify the appropriate wiring locations.

Signal Box Wiring

Connections| Wire Color
Supply VAC| Brown (Not Used)
Neutral| Blue
Valve 1| White
Valve 2| Green
Valve 3| Yellow
Valve 4| Grey
Valve 5| Pink
Valve 6| Red
Valve 7| Black
Valve 8| Violet (Not Used)
Ground| Green/Yellow

3.05 Air Supply
Run tubing from the compressed air supply to the main air regulator on the panel. Adjust the panel’s regulator to 80-120 psi.
3.06 Foaming Outlets
Run tubing from the foaming applications to the panel’s foaming outlets. The order of the valves corresponds to the order of the foaming outlets. If an application doesn’t require a foaming connection, leave the outlet empty.
Triple Foaming Application
The first three foaming outputs are for triple foaming applications on solution valve 1. If a single foaming application is used on valve 1, only one foaming output needs connected

3.07 Solution Lines

1. Choose the injector size for each application. Refer to each application’s flow recommendation for a starting size. The injector flow rates are specified by the color and have the flow rate stamped on the body.
2. Insert the injector into the angled seat valve’s quick connect.
3. Run solution lines to the Push-In connections

3.08 Chemical Supply Lines

1. The chart below should be used as a guideline for selecting the metering tip but is based on water-thin products. Performing a titration will guarantee desired dilutions are achieved.
   *Inlcuded in Lean Tip Kit HYD90031210
2. Insert the metering tip into the hose barb.
3. Slide the chemical pick-up tubing completely over the barb.
4. Install a foot valve/check valve and/or filter (not provided) on the other end of supply tube and place in the chemical container.

Pump Installation

4.01 Pump Overview
Warning! Do not run the without water. The pump needs primed before operation.
Note: Only qualified personnel should perform the installation.
Pump Installation Consideration

1. Use pipe dope or Teflon tape for threaded connections.
2. Consider the proximity of the panel and VFD when choosing the pump location. A 6 ft. hose is provided that connects from the pump outlet to the panel. A 6 ft transducer cable will need to connect from the VFD to pressure inducer at the pump outlet.
3. Consider the pump inlet and outlet locations. The orientation will determine the distance it can be installed from the wall. The water hammer arrestor extends approximately 9 in. and the pressure transducer extends approximately 6 in.
4. Ensure the correct orientation of tee connector, cross connector and water arrestor while installing the hardware.
5. A water filter is provided that can either be installed on the pump’s inlet plumbing or at the source of the water supply. If installed on the pump’s inlet plumbing, it will require installing before the pump is mounted as it will require tilting the pump up to prevent interference when screwing the filter on

4.02 Floor Mount

1. The pump should be installed on cement base, or other similar base. The pump should be located in a well ventilated but frost-free area. Refer to Section Site Survey diagram for location.
2. Align the pump into position and create pilot holes using the stand’s bolt holes as guides. Drive the four anchors to secure the pump base to the floor.

Pump Connection

4.03 Gaskets Installation
Sealing gaskets and the following hardware needs to be installed on both the inlet and outlet of the pump.

1. Remove the cover sticker. Rotate the flange to protrude slightly.
2. Place and hold the gasket on the black flange.
3. Align the flange on the gasket with shortest face towards the gasket.
4. Secure the flange with bolts, washers and nuts. Tighten with star method. Install the 1” Female reducer bushing.
5. Install the straight connector.

4.04 Pump Inlet
Note: Follow step 2a if the filter will not be installed on the pump inlet plumbing. Follow step 2b if the filter will be installed on the pump inlet plumbing.

1. Install the Tee Connector. The branch of the tee must face towards the water hammer arrestor.

2. Install the Metal Barb fitting at the center branch and the plastic barb fitting in the remaining open branch.
   Install the filter before the pump plumbing. Arrows on the filter indicate the flow of water

3. Add a straight connector and plastic barb fitting to the filter. Arrows on the filter indicate the flow of water. The filter will interfere with the ground when installing so the pump will need tilted up.

4.05 Pump Outlet

1. Install the cross fitting into the straight connector. The cross’s branches should be approximately horizontal to the floor.
2. Install the water hammer arrestor and ensure the arrestor’s opening is facing towards the pump inlet.
3. Install the barb fitting on the arrestor and reducer bushing on the cross fitting.
4. Thread the pressure transducer inside the Bushing.

4.06 Hoses

1. Install the incoming water supply and recirculation hose on the barb fittings using hose clamps.
2. Connect outlet hose to the pump inlet and attach the opposite end to the quick connect on the panel. Turn the ball valve on the hose to ON position.

4.07 Prime Pump

1. Ensure the pump’s water supply is on and the pump’s outlet hose is connected to the panel with the ball valve in the ON position

2. Slowly open the vent plug on the pump to bleed air in the system. Once water starts spraying out the valve, ensure that all air pockets have escaped by leaving the valve open until no air is observed for at least one minute. Close the  vent plug.
   Note: Water will spray out of the vent plug when performing this step.

3. Ensure minimum 40 psi pressure is maintained on the panel water pressure gauge.

VFD Installation

5.01 VFD overview
WARNING!: The Pump must be primed before installing the VFD to prevent dry running.
WARNING!: Please follow safe electrical precautions.
Follow the directions below for installing the VFD. Only qualified personnel should perform the installation.

VFD Installation Considerations

1. Determine how to connect the electrical cables from power source to the VFD and from VFD to the pump.
2. The VFD mounting height needs to be considered for ease of access to operate the unit. Refer to section Site survey.
3. The VFD is preset so that once power is received, it will drive the pump to 200 psi. The pump must be primed before this step and connected to the panel so that pressure can be checked on the panel’s gauge.

Types of VFD

5.02 Mounting the VFD

1. Refer to section Site Survey diagram for mounting VFD.
   Note: Mount the VFD away from areas subjected to steam or chemicals.

2. Place the VFD on the wall and mark the screw locations.

3. Drill 1/4” pilot holes and insert anchors. Drive the bolts approximately 1/8” from the wall.

4. Place the VFD key holes on the bolts and push down to lock into position. Tighten the bolts on the VFD frame.

5.03 Wiring the VFD

1. Remove the two bolts on the VFD cover for terminal locations. Also remove the pump cover
2. Wire the following:
   a. Three phase cable from the power source to the VFD
   b. Three Phase Power cable from VFD to the pump
   c. Pressure Transducer cable from VFD to the pressure transducer
   Note: Do not turn ON power to VFD until the next step.

5.04 VFD and Pump Operation Check
On the pump motor, rotating direction is critical. Rotation will need to be checked in tandem when the power is released to the VFD. The rotating direction is indicated on the fan cover.

1. Before releasing power to the VFD, Confirm the following:
   a. The pump is primed.
   b. The water supply is on.
   c. The pump’s outlet hose is connected to the panel with the ball valve open and pressure atleast 40 psi.
   d. The pressure transducer is plugged in.
   e. You are prepared to quickly turn power off if the motor rotation is wrong. Two people may be required; one to control the power and one to watch the motor rotation.

2. Turn the VFD’s power source on while checking the motor rotation in tandem. Immediately stop power to the VFD if the rotation is wrong. Interchanging any two leads with power off can reverse the pump rotation.

3. Verify the pressure gage reads approximately 200 psi.

5.05 Operating the VFD
Automatic ON/OFF operation
If desired, the installer can preserve pump life by automating the VFD so that is only on during the car wash’s operating hours.
T1 is tied to the VFD’s internal (isolated) 24V supply. T2 has the function of ‘Run Enable’, meaning the VFD will operate only when it receives the 24V signal from T1. When these connections are bridged, run is always enabled. To enable run only during operating hours, remove the bridge and wire T1 and T2 to a relay or contactor that is only energized during operating hours.
Manual ON/OFF Operation
To preserve pump life, the VFD will need to be turned off during non operating hours.
5.06 System Start UP
After installing the panel, pump and VFD the operating variables will needs to be optimized. Perform the following steps

1. Ensure incoming air pressure is at 80 psi and water pressure at 200 psi.
2. Prime the chemical lines by manually engaging each air solenoid button.
3. Set the foaming pressure for each application.
4. Verify Injector Flow rates and chemical dilutions to the car wash application. Injectors and metering tips initially chosen may needs to be exchanged to achieve desired results. Performing a titration will guarantee desired dilutions are achieved. A chemical scale may be used to verify amount of chemical used per car.

Maintenance and Troubleshooting

6.01 Maintenance

| 3 month| I 6 month| I Annually
---|---|---|---
Panel
Check Foot Valves Strainers| x| |
Check and Replace Metering Tips| x| |
Check and Drain Supply Air Regulator| x| |
Check the chemical pick-up tubing, air tubing, and solution tubing for brittleness. Exchange if necessary| | x|
Check all tubing connections| | x|
Pump
Check pump filter| x| |
Inspect piping and joints for leaks| x| |
Check the power cable ensuring screw terminals are correctly torqued with no signs of heat damage| | | x
VFD
Check all electrical connections, ensuring screw terminals are correctly torqued; and that power cables have no signs of heat damage| | | x
Check the enclosure is free from dust and condensation| | | x

6.02 Troubleshooting

Problem

| Cause| Solution
---|---|---

Panel

No Concentrate Draw| • Clogged foot valve| • Clean or replace
• Metering Tip/Check Valve/Injector has scale build up| • Clean or replace
• Concentrate Container is empty| • Replace with full container
• Air leak in chemical pick-up tube| • Check connections or replace tube if brittle
• Clogged application nozzle| • Clean or replace
Excess concentrate draw| • Metering tip missing or not in place| • Press correct tip firmly into barb
• Chemical above injector| • Place concentrate below the injector
No Solution discharge| • No water| • Open water supply
• Injector Clogged| • Clean or replace
•Water Supply ball valve in OFF position| • Move ball valve to ON position
•Injector ball valve in OFF position| • Move ball valve to ON position
•Inadequate water pressure| • Check if VFD is ON
• Inadequate supply air pressure| • Check incoming air pressure — 80 psi required
• Faulty air solenoid| • Replace
• Signal not received| • Verify air solenoid indicator light is on when triggered
• Injector valve fails to open| • Replace

Panel

4. Nonstop solution discharge| •  Injector valve fails to close| •  Replace valve
•  Air Solenoid fails to close| •  Replace valve
•  Trigger signal fails to stop| •  Check source of trigger signal
5. No Foaming Pressure| •  Inadequate supply air pressure| •  Check incoming air pressure – 80 psi required
•  Inadequate foaming air pressure| •  Check applications pressure
•  Air tubing disconnected| •  Check tubing connections
6. The Standard HYD690014 and Lean HYD90031210 tip kits are combined and the two reds are not discernable| •  Red and New Red tip colors look very similar| •  Hold Red and New Red and look through the orifice of both, you will see a distinct difference in the aperture. The opening of Red is much larger than New Red
PumpNFD
1. Pump can’t maintain 200 psi| •  Total injector flow rates more than 20 gpm| •  Lower total flow rate for max. 20 gpm
•  Undersized supply piping| •  Replace with larger piping
•  Inadequate water supply| •  Check source supply pressure – 40 psi required
•  Leak in pump plumbing| •  Check and fix leaks
2. Pump doesn’t turn ON| •  No Electric Supply| •  Check power going to VFD
•  Lose wiring in VFD or pump motor| •  Check wiring at VFD and pump motor
•  T2 Not Receiving Voltage from T1| •  Check wiring
•  Overheating relay tripped| •  Check system
•  Motor is defective| •  Repair
3. Pump trips immediately when power turned on| •  Fuses are blown| • Replace fuses
•  Cable connection is loose or faulty| •  Check wiring at VFD, pump motor, and pressure transducer

Spare Parts

7.01 Panel Spare Parts – 1 of 2

5 Valve Manifold Cover
4| HYD10100126| Manifold Plug, 1” NPT
5| HYD10100349| Ball Valve, 3/8” NPT
6| HYD10100349| Quick Connect Plug, 3/8” MPT, Brass
7| HYD10100123
HYD10100380| 7 Valve Support Bar
5 Valve Support Bar
8| HYD10100382
HYD10100347| Pneumatic Solenoid manifold
7 valve Solenoid manifold
5 valve Solenoid manifold
9| HYD10100383| Blanking Plate, 3 Way, 100 Series
10| HYD10100335
HYD10100336
HYD10100337| Pneumatic Solenoid Valve 24 VDC Assembly
Pneumatic Solenoid Valve 120 VAC Assembly
Pneumatic Solenoid Valve 24 VAC Assembly
11| HYD10100342| Main Air Regulator and Input Connector
12| HYD10100350| Pressure Gauge 1/4 NPT Male Bottom
Connection, 2-1/2” Dial
13| HYD10100127
HYD10100477| 1” Quick Connect Socket
1” Quick Disconnect O-ring Kit
14| HYD10100352| Ball Valve, 1” NPT
15| HYD10100121
HYD10100343| Ball Valve, 1” NPT
16| HYD10100386| Male Connector, 3/8 in Tube Size, 1/4” Pipe Size
17| HYD10100385| Elbow, 1/4 Tube x 1/8 MNPT
18| HYD10100389| Foaming Air Outlet Connector, 3/8” X 1/4” Tube
19| HYD10100341| Foaming Air Regulator and 2 elbows
20| HYD10100351| Bushing Adapter with Hex Body, 1 NPT Male, 1/4
NPT Female
21| HYD10100362| Tee Connector
22| HYD10100128| Quick Connect Plug
Not Shown:
| HYD10100338| Solenoid Valve Gasket
| HYD10100387| Air Union Tee, 1/4” (behind panel)
| HYD10100388| Air Check Valve, 1/4” (behind panel)
| HYD10100122| Water Manifold Spacer (behind manifold)

7.02 Panel Spare Parts – 2 of 2

23a
b| HYD10100346
HYD10100479| Quick Connect Socket, 3/8“ MPT SS, with Viton O-ring
3/8” Stainless Steel Quick Disconnect O-ring Kit
24| HYD10100385| Elbow, 1/4 Tube x 1/8 MNPT
25| HYD10100344| Angled Seat Valve Assy with Quick Connects/ Elbow
26| HYD10100379| Injector John Guest Fitting
27| HYD10100348| Injector Check Valve
28| HYD10100331| KYNAR/AFLAS HAAS Valve
29a
b| HYD10100345
HYD10100478| Quick Connect Socket, 3/8” MPT Brass
3/8” Brass Quick Disconnect O-ring Kit
30| HYD10100119| Triple Foam Manifold with Quick Connects
Part Number| Size of Injector
---|---
HYD-HP1-EP75| 0.75 GPM Injector Kit
HYD-HP1-E1P0| 1.00 GPM Injector Kit
HYD-HP1-E1P5| 1.50 GPM Injector Kit
HYD-HP1-E2P0| 2.00 GPM Injector Kit
HYD-HP1-E2P25| 2.25 GPM Injector Kit
HYD-HP1-E3P25| 3.25 GPM Injector Kit
HYD-HP1-E4P0| 4.00 GPM Injector Kit
HYD-HP1-E5P50| 5.50 GPM Injector Kit
HYD-HP1-E7P0| 7.00 GPM Injector Kit
HYD-HP1-E8P0| 8.00 GPM Injector Kit
HYD-HP1-E9P0| 9.00 GPM Injector Kit
HYD-HP1-E10P0| 10.00 GPM Injector Kit
HYD-HP1-E12P0| 12.00 GPM Injector Kit

Note: Injector kit includes Injector, HAAS valve,
Check valve, John Guest Fitting and Dilution Tips.

7.03 Pump Spare Parts

Not Shown:
| HYD10100357| Flange Gasket

Warranty

8.01 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.
8.02 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.

Hydro Systems
3798 Round Bottom Road
Cincinnati, OH 45244
Phone 513.271.88OO
Toll Free 8OO.543.7184
Fax 513.271.O16O
Web hydrosystemsco.com
HYD10100374 Rev B 1/24

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  >>