PEM SprayWand P-300 Betriebsanleitung

PEM P-300

SprayWand™ Pretreatment Application System

Installation • Operation • Maintenance • Troubleshooting

Revision 11.16.15

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Table of Contents

Introduction ..................................................................................................3

General specifications........................................................................................3

Limited warranty................................................................................................4

Safety .................................................................................................................6

Safety Rules....................................................................................................6

Installation ..................................................................................................10

Machine delivery and inspection.....................................................................10

Machine identification.....................................................................................10

Machine location .............................................................................................10

Machine setup .................................................................................................11

Electrical service ..........................................................................................11

Mechanical (gas) service..............................................................................12

Burner fuel pressure ................................................................................12

Guide to gas line pipe size .......................................................................13

Venting the machine to the outside........................................................14

Water supply................................................................................................15

Coil conditioner............................................................................................15

Neutralizer ...................................................................................................16

Wand and Hose............................................................................................16

Initial start-up..............................................................................................17

Control panel ...................................................................................................17

Switches.......................................................................................................17

Pump switch.............................................................................................17

Burner switch...........................................................................................17

Indicator lights.............................................................................................17

Pump motor overload indicator light ......................................................17

Flow indictor light ....................................................................................17

Temp indicator light.................................................................................17

Fuel indicator light ...................................................................................17

Temperature control ...................................................................................18

Initial startup procedure..............................................................................19

Adjusting chemical concentration...............................................................20

Daily Operation............................................................................................22

Starting the machine........................................................................................22

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Shutting down the machine.............................................................................22

Winterizing the machine..................................................................................23

Predictive maintenance................................................................................24

Pressure hose...................................................................................................24

Water inlet tank filter screen...........................................................................25

Pump................................................................................................................25

Pump lubrication..........................................................................................25

Pump belt.....................................................................................................26

High-pressure filter ..........................................................................................27

Heating coil descaling ......................................................................................28

Machine exterior..............................................................................................30

Repair..........................................................................................................31

Pump................................................................................................................31

Servicing the pumping section.....................................................................31

Servicing the ceramic plungers and V-packings...........................................32

Removing the pump manifold head ........................................................32

Replacing plungers...................................................................................33

Replacing V-packings ...............................................................................34

Reinstalling the manifold head ................................................................34

Intermittent ignition device.............................................................................38

Wiring...........................................................................................................38

Engineering data..........................................................................................39

Gas Valve..........................................................................................................40

Adjusting the pilot light ...............................................................................41

Troubleshooting ..........................................................................................42

Gas burner malfunction...................................................................................43

Intermittent ignition device problems.............................................................44

Pump malfunction and pressure delivery problems........................................44

General malfunctions.......................................................................................46

Chemical system malfunction..........................................................................46

Electrical malfunction ......................................................................................47

Service record..............................................................................................49

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Introduction

The PEM P-300 Spraywand™ Pretreatment Application System is designed to

meet the demands of high production environments. The heavy-duty system

and precision fixed-ration chemical injectors ensure consistent outputs and

results.

The PEM system features an optional air-activated gel pump. This allows the

operator to apply gel products to metal surfaces that standard cleaners cannot

handle.

Another option delivers sealer right from the drum through a low-volume, low-

pressure pump.

Warning: To prevent injury and equipment damage, thoroughly read

and understand the contents of this manual before operating the P-300.

General specifications

Model: P300

HP: 7.5

Electrical: 230 V, 3 phase –20 A

460 V, 3 phase –10 A

Connection: 4 wire through junction box

GPM: 5

Pressure

- Phosphatize: 1500 PSI

- Optional seal rinse: 800 PSI

Burner output: 550,000 B.T.U.

Gas connection: ¾ NPT

Fuel requirements:

- Natural gas: 5”-9” W.C.

- L.P.: 11” WC

Stack size: 12”

Water connection: Standard garden hose, female swivel

Dimensions (L,W,H): 56” x 28” x 64”

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Weight:

- Dry: 900 lbs.

- Shipping: 1100 lbs.

Nozzles: 1-15085 x ¼ NPT

Note: The manufacturer reserves the right to make improvements in design

and/or changes in specifications at any time without incurring any obligation to

install them on units previously sold. Some photos and/or illustrations may not

be exact representations of your particular machine; however, the technical

information will apply.

Limited warranty

PEM Corporation warrants each machine sold by us to be free from

manufacturing defects in normal service for 90 days commencing with the

delivery of the machine to the original owner.

If the machine is used with approved products, the warranty is extended to two

full years or 2000 hours, whichever occurs first.

Three (3) Years Parts

• Belt guards

• Frame

• Float tank

• Pump drive assembly

• Float tank

• Coil wrapper

•Heating coils (Self-contained

and stationary models)

Two (2) Years Parts

Plumbing

One (1) Year Parts

• Control switches

•Electric motors

•Float valves

•Safety switches

•Pulleys

•Thermostat

• Ground fault circuit

interrupter

Ninety (90) Days Parts

• Lights

• Trigger gun

• Unloaders

• Wand

• Ignition module

• Coil wrapper

Our obligation under this warranty is expressly limited at our option to the

replacement or repair by our company approval, or a service facility designated

by us¸ of such part or parts as inspection shall disclose have been defective. This

warranty does not apply to defects caused by damage or unreasonable use

(including failure to provide reasonable and necessary maintenance) while in

the possession of the consumer.

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This warranty does not apply to nozzles, V-belts, hoses, pump wear parts, filters

or 0-rings or damage to the wand or gun due to mishandling.

PEM Corporation shall not be liable for consequential damage of anything,

including but not limited to the consequential labor costs or transportation

charges in connection with the replacement or repair of the defective parts.

PEM Corporation makes no warranty with the respect to trade accessories. They

are subject to the warranties of their manufacturers.

Any implied or statutory warranties, including any warranty of merchantability

or fitness for a particular purpose are expressly limited to the duration of this

written warranty. We make no other express warranty, nor is anyone

authorized to make any on our behalf of PEM Corporation.

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Safety

This safety alert symbol indicts important messages in this manual. When you

see this symbol, carefully read the message that follows, and be alert to the

possibility of personal injury or death if you do not adhere to the requirements

of the safety message. Also be review and follow the safety decals on the

machine.

Note: PEM Corporation encourages the use of environmentally friendly

chemicals and waste storage and disposal practices. Always store and/or

dispose of chemicals in a manner that complies with local, state and federal

regulations. Furthermore, always read and follow the directions printed on

product labels when using chemicals.

Safety Rules

PEM Corporation cannot anticipate every possible circumstance that might

involve a potential hazard. The warnings and cautions in this manual are

therefore not all inclusive. If you use an operating procedure, installation or

work method not specifically recommended, you must satisfy yourself that it is

safe for you and for other persons. You must also ensure that the product will

not be damaged or made unsafe by the procedure that you use.

Warning: Fluids under pressure spray can be nearly invisible and can

penetrate the skin and cause extremely serious injury. Avoid contact with high

pressure spray. Specifically:

•Never point the spray gun at any part of your body or at any other

persons.

•Never put your hands or fingers over the spray tip while the machine is

in operation.

•Never use your hands to stop or detect leaks.

•Always shut of the machine and trigger the pressure gun to relieve

system pressure before removing the spray tip or servicing the machine.

•Always wear full eye protection (preferably a face shield), protective

clothing and rubber boots when operating the machine to protect you

from burns caused by hot spray, fluid injection or debris dislodged by

high-pressure spray.

•If any fluid appears to have penetrated the skin, get emergency medical

care at once. Do not treat as a simple cut. Tell the doctor exactly what

was injected. For treatment instructions, have your doctor call the

National Poison Control Network at 412-681-6669.

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Warning: Operate and maintain the machine in a manner that prevents

injury to you and others and damage to equipment. Specifically:

•Never alter or modify the equipment.

•Never exceed the factory pressure or temperature rating of the system.

Be sure all accessory equipment and system components used will

withstand the pressure developed.

•Never let the pump or burner run without water supply flowing through

the unit.

•Never attempt to run or relight the burner if ignition does not take place

the first time. Unburned gas, which may cause a fire or explosion, may

have accumulated.

•Never allow children or any unauthorized or untrained persons to

operate, adjust or repair this machine.

•Always keep other persons at a safe distance when using this machine.

•Never attempt to clean or wash down the machine using its own spray

gun. Cleaning the machine in this manner will increase the hazard of

electrical shock and/or damage to the machine. The machine is water

resistant but not water proof.

•Never leave an operating machine unattended. Always shut off the

machine and relieve pressure before leaving the machine.

•Never spray inflammable or toxic liquids or chemicals such as

insecticides or weed killer.

•Never operate the machine when combustible fumes or dust may be

present.

•Never use detergents that are not compatible with the discharge hose.

Read and follow instructions provided by the detergent manufacturer.

Also follow directions on the container regarding contact with the eyes,

nose or skin.

•Always provide approved vent stacks if the machine is to be used in an

enclosed area. Exhaust fumes contain odorless, invisible gasses that can

kill without warning. Comply with all federal, state and local codes for

locating, venting and using the machine in an enclosed area.

•Always connect the machine to the correct electrical supply outlet.

Comply with all federal, state and local codes and ordinances regarding

electrical requirements.

•Never allow electrical extension cord connections to fall or lay in water.

Use only extension cords rated for use with this machine.

•Always respect and be alert for the potential hazards of electrical

equipment, hot burners, moving parts, high-pressure spray and steam.

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•Always be certain that the machine safety decals are kept clean and

legible. Replace any decals that become damaged, lost or painted over.

•Always disconnect the electrical plug before performing any repairs or

service on machine.

•Never attempt repairs or modifications that you do not understand.

Contact your service dealer or contractor.

•Always keep protective guards covers and shields in place. Replace any

that were removed for service or that were damaged before operating

the machine.

•Always use a gas regulator of the specified type on LP tanks for butane

or propane-fired machines.

•Never exceed the 210° F temperature setting for hot water, high-

pressure cleaning. Be sure the correct nozzle is used.

Danger: Chemicals used for cleaning are dangerous. Keep all chemicals

out of reach of children and untrained adults. Take proper safety precautions

before handing any chemicals. Read and follow all directions and instructions on

the product label as well as the safety data sheets before using the chemical.

Wear eye protection and rubber gloves when handling or using chemicals.

Always have a clean supply of water available to wash off any contact with the

skin or eyes. Should any chemical contact the eyes, immediately flood the eyes

with clean water and seek medical attention at once. If skin contact occurs,

flood the affected area with plenty of water for 15 minutes. If irritation persists,

seek medical attention. If chemicals are swallowed, follow the product label

directions and get immediate medical attention.

Warning: Do not start the machine unless you have the trigger gun or

wand assembly completely under your control. Left loose, the gun or wand

could recoil and damage property or cause injury.

Warning: The discharge hose supplied with the machine is designed for

use on steam and high-pressure cleaners. Special care, handling, and

maintenance are required to provide proper and safe operation. Follow the

guidelines to ensure safe operation and maximum hose service life:

•Never exceed rated machine pressure or temperature.

•Do not route the hose in a manner that will cause sharp bending,

kinking, cutting, abrasion or exterior damage.

•Do not pull on the hose to move the machine, untangle knots or pull

excessively or cause stress on the hose.

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