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PEM SprayWand P-500, Manual

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PEM SprayWand P-500 Manual Download Page 8

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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

. 

 
 

Summary of Contents for SprayWand P-500

Page 1: ...PEM P 500 SprayWand Pretreatment Application System Installation Operation Maintenance Troubleshooting Revision 07 02 17 ...

Page 2: ......

Page 3: ...re 12 Guide to gas line pipe size 13 Venting the machine to the outside 14 Water supply 15 Float tank 15 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 chemi...

Page 4: ...V packings 32 Removing the pump manifold head 32 Replacing plungers 33 Replacing V packings 34 Reinstalling the manifold head 34 Pump parts list 5CP310 5CP3120G1 5CP3130G1 36 Intermittent ignition device 40 Wiring 40 Engineering data 41 Gas Valve 42 Adjusting the pilot light 43 Troubleshooting 44 Gas burner malfunction 45 Intermittent ignition device problems 46 Pump malfunction and pressure deliv...

Page 5: ... 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 500 General specifications Model P 500 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 1500 PSI Burner input 415 000 BTUH Gas ...

Page 6: ...3 Years Parts Pump drive assembly Frame Coil wrapper Heating coils Float tank 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 rep...

Page 7: ...fective 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 b...

Page 8: ...rself 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 pers...

Page 9: ...eave 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 m...

Page 10: ...otection 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 ...

Page 11: ...ch operations If leaking is evident do not use the hose Contact a qualified pressure washer service representative Never leave the discharge hose lying on the floor or ground to be driven over by vehicles or damaged by falling objects Always coil and hang the hose immediately after use Danger To prevent unexpected energizing startup or release of energy that could cause injury to people working on...

Page 12: ...formation from this plate in Table 1 Figure 1 Identification plate location on the back of the machine Model___________________________________ Output________ Gpm_________ Psi__________ Fuel_____________________________________ Elec _______Ph______ Volts_____ Amps_______ Serial Number_____________________________ Table 1 Machine identification from the plate Machine location The gas fired pressure...

Page 13: ...ine setup Exact machine setup may vary somewhat between machine models however the following information will be a general guideline Contact your dealer or authorized service representative for special installation or setup requirements Note In order to avoid unnecessary expense of complying with or correcting the violation of a regulation investigate all applicable state and local codes before at...

Page 14: ...by a licensed electrician and must conform to all federal state and local codes and ordnances regarding three phase electrical requirements Mechanical gas service Have a HVAC expert set up gas connections Burner fuel pressure Adjust the pressure to the type of burner fuel as follows Natural gas fired machines Operate on 3 of water column 2 oz pressure at the valve and must have from 7 to 9 water c...

Page 15: ...ll a gas shutoff valve in back of the machine on the gas line with a union between the valve and the gas regulator see Figure 4 Prior to operating the burner system purge the new lines If this is not done starting the burner can be difficult Figure 4 Gas Valve Guide to gas line pipe size See Table 2 for the minimum gas line iron pipe size required for gas supply per length of gas line from the val...

Page 16: ... is not in use Install UL listed weather cap on top of the building If the machine is used in an enclosed area and you are putting a chimney on it be sure a draft diverter available as an option see Figure 5 is installed and the chimney is as at least the same size as the stack on the machine 10 inches Poor draft will cause the unit to soot and not operate efficiently Position the machine to ensur...

Page 17: ...re occur install a pressure regulator in the supply line Use at least a inch ID supply hose Figure 6 Water connection in the back of the machine Caution To prevent machine damage use only perfectly clean water If the water supply exceeds 6 grains of hardness 100 ppm the coil conditioner will extend the coil life and maintain machine efficiency Float tank The float tank Figure 7 can be accessed by ...

Page 18: ... or kinked e g ran over by a forklift it may also cause the injector to malfunction Non standard piping or the addition of valves and elbows may also cause injection problems Black wand will be used for Rinse ONLY Do not use the black wands for chemical application Consult a PEM representative before purchasing additional or replacement wands as the color representation varies ...

Page 19: ...ndicator light turns on turn off the pump switch and let the machine cool down Turn the pump switch on again If the pump motor continues to shut down call PEM Flow indictor light This light will glow red during normal operation when the gun trigger is pulled indicating the circuit through the flow switch is good It will turn out when the gun trigger is released If the light remains out when the tr...

Page 20: ...r temperature Caution Left loose the gun or wand assembly could damage and cause injury to personal or property damage Do not start the machine without having the trigger gun or wand completely under your control Caution Never run the cleaning unit dry Costly damage to the pump will result Always be sure the water supply is completely turned on before operating the machine Figure 8 Control panel ...

Page 21: ... the burner switch off and back on Continue to do this until the temp light illuminates This indicates the pilot valve solenoid is open and the igniter switch activated the pilot light The Temp light will come on The system is ready to fire Note The system has series of safety checks that must be satisfied before the Temp light comes on If the Temp light is not on the burner will not fire If the T...

Page 22: ...d using the color coded metering orifices that can be threaded into the chemical pick up An assortment of various sized metering orifices is included with the machine in the instruction packet See Table 3 The injector will draw approximately 2 5 chemical with no metering tips The metering tips can be used to reduce this percentage in 0 2 increments down to approximately 0 8 percent These metering ...

Page 23: ...ns If chemical does not come up check the chemical filter on the end of the chemical hose Caution Chemicals not compatible with the system materials will cause damage to the components down the line from the chemical injector Ensure the chemicals will not damage stainless steel Buna N and Viton Warning High pressure spray detergents fluid injector or debris dislodged by the high pressure spray can...

Page 24: ...which is located next to the pump and is used to bypass the coil when the wand is not in use Adjusting the unloader valve will not increase performance of the unit and will void the manufacturer s warranty Caution Do not drag the hose over an abrasive surface such as cement This will cause excessive wear and shorter hose life Lift the hose up instead of dragging it Caution To prevent injury when r...

Page 25: ...he float tank and refill it with the antifreeze solution 4 Hold open the trigger gun while keeping the float tank full of the antifreeze solution 5 Turn the Pump switch on When antifreeze solution appears at the end of the gun release the trigger once or twice and then turn the Pump switch off 6 When preparing to operate the machine the next time have an antifreeze container handy Reconnect the wa...

Page 26: ...o prevent accidental startup Pressure hose Inspect the hose for wear or damage see Figure 9 If there is damage replace the hose Do NOT repair it Wrap up the hose as soon as you turn off the machine and store it on the hose hooks or other safe location Caution Avoid extending the hose across high traffic areas which can damage the hose Never leave the hose where it can be run over by any type of ve...

Page 27: ... place after cleaning it Pump Pump lubrication The pump see Figure 10 is pre lubed at the factory However check the pump oil level frequently as follows 1 Locate the oil site glass on the back side of the CAT pump The site glass is a clear circle with a red dot in the middle see Figure 11 Ensure the oil level is at the red dot If the oil is low remove the fill plug and add oil 2 Fill the crankcase...

Page 28: ...l as follows 1 Drain the oil by 1 removing the plug located at the rear of the pump crankcase or 2 removing the fill plug Figure 12 and suctioning the oil out with a suction gun that has a flexible tub 2 Fill the crankcase to the red dot on the site glass with SAE 30 weight oil preferably with no detergent Do not overfill 3 Replace the check fill plug Figure 12 Pump oil check fill plug ...

Page 29: ...ne half to one turn Turn the tension bolt nut clockwise to tighten the belt or counterclockwise to loosen it 4 Tighten the mount bolt nuts 5 Using a straight edge verify the pump drive pulley alignment If it is off adjust the position of the pump by loosening the pump mounting nuts adjusting the pump position and re tightening the nuts Figure 13 Measuring pump belt deflection Inspect the belt for ...

Page 30: ...r scale in that breaks loose from the I D of the coil If this debris is not filtered it could plug the orifices in the chemical injector Service this filter weekly as follows 1 Remove the hose from the top of the filter 2 Remove the end cap and filter element screen 3 Examine the filter element for damage Do not reinstall a filter element showing any sign of damage 4 If the filter element is intac...

Page 31: ...areas with hard water plugging can occur in less than a month unless the coil conditioning system is used Descale the coil as follows 1 Disconnect the hose leading from the unloader valve to the bottom of the coil at the unloader Connect the discharge hose from the descaler to the hose leading to the coil 2 Disconnect the hose leading from the high pressure coil to the thermostat Connect the free ...

Page 32: ...caler 8 Carefully lift the discharge hose out of the decaling drum and place it in fresh water Restart the descaler and run for 5 minutes During this time the water will become very dirty Change the water in the container and run the descaler another 6 7 minutes If the second water becomes very dirty change the water again 9 Remove the descaler from the machine Reattach the hose leading from the u...

Page 33: ...air all the valves in the pump The kit includes new O rings and a valve assemblies valve seat poppet spring and retainer all preassembled Service the valves using the kit as follows 1 Remove each valve plug using a 24 mm socket see Figure 16 Figure 16 Removing valve plugs 2 Examine the O ring gaskets and replace if needed see Figure 17 Figure 17 Examining the O ring gaskets 3 Using a needle nose p...

Page 34: ...place the valve cap and torque it to 70 75 foot pounds Servicing the ceramic plungers and V packings Removing the pump manifold head 1 Using a 6 mm hex key wrench remove the eight cap bolts from the manifold head see Figure 19 Figure 19 Removing the cap bolts 2 Separate the head form the crankcase It may be necessary to tap the head with a rawhide mallet in order to loosen it see Figure 20 ...

Page 35: ... they are damaged as follows Replacing plungers 1 Using a 10 mm socket remove the ceramic plunger and plunger retainer from the piston rod see Figure 21 Figure 21 Removing plunger 2 If the barrier slinger or keyhole washer comes off with the plunger replace them before installing a new plunger 3 Separate the plunger retainer from the plunger 4 Install a new seal washer on the plunger retainer Use ...

Page 36: ... of grease and insert it in the cavity Repeat with the second V packing Lubricate the seal case O ring 7 Firmly press the seal cases into the V packing 8 Press the low pressure seal into the seal case with the garter spring down 9 Replace the seal retainer with tabs facing down and holes away from the crankcase 10 Coat each plunger with a thin film of grease Reinstalling the manifold head 1 Carefu...

Page 37: ...35 P a g e Figure 23 Pump exploded view ...

Page 38: ... NBR Seal Oil Crankshaft 2 15 14480 STL Bearing Ball 2 20 48658 HS Rod Connecting Assembly 2 00 3 25 46928 FCM Crankshaft Duel End 3120 5120 6120 6120G1 1 48233 FCM Crankshaft Single End 31201G1 1 48368 FCM Crankshaft Single End 31201G1 5150G1 1 30 48224 AL Cover Bearing Blind 1 32 46798 Cap Oil Filler Domed 1 33 14179 NBR O Ring Bubble 2 Gasket 80 D 1 37 92241 Gauge Oil Bubble w Gasket 80 D 1 38 ...

Page 39: ... 46746 CM Pin Crosshead 3 65 48458 BBNP Rod Plunger 3 70 46838 NBR Seal Oil Crankcase 70D 3 75 43900 S Slinger Barrier 3 88 45697 S Washer Keyhole M18 3 90 46884 CC Plunger M16x50 3 98 46730 NBR Washer Seal 3 48394 FPM Washer Seal 3 99 48201 SS Retainer Plunger w Stud M6 3 100 46749 PVDF Retainer Seal 3 106 43316 NBR Seal LPS w S Spg 3 106660 FPM Seal LPS w S Spg 3 120 46888 BB Case Seal Press in ...

Page 40: ...8 NY Adapter Male 3 139 22179 BBCP Plug Inlet 1 2 NPT 1 162 Back up Ring Seat 6 163 17457 NBR O Ring Seat 6 11685 FPM O Ring Seat 6 164 46658 S Seat 6 166 46429 S Valve 6 167 43750 S Spring 6 168 44565 PVDF Retainer Spring 6 172 17549 NBR O Ring Valve Plug 6 26996 FPM O Ring Valve Plug 6 173 48365 D Baku up Ring Valve Plug 6 174 45900 BB Plug Valve 6 185 46886 FBB Manifold Head 1 ...

Page 41: ...39 P a g e 188 87872 STZP Screw HSH M8x70 8 196 22187 BBCP Plug Discharge 3 8 NPT 1 250 118672 STCP Protector Shaft 1 ...

Page 42: ...ions to the control module Refer to Figure 24 for proper hookup See the front of the device Figure 25 for a key to the fail codes which are indicated by a green LED located next to the cable connector Refer to the troubleshooting section for Troubleshooting procedures Warning To prevent shock and damage to equipment do not apply power to the control module until wiring is completed and the igniter...

Page 43: ...d Continuous pilot burner Flame failure response time Main gas shut off 2 0 seconds max Pilot gas Continuous Flame failure re ignition time 0 8 seconds max Voltage 24 Vac 60 Hz Note Total current drain for control will include gas valve loads in addition to control module current drain Operating temperature range 0 to 175 F Spark voltage 25kV Peak open circuit Spark gap 0 125 max Spark type Synchr...

Page 44: ...a qualified serviceperson Shut off the gas supply before starting installation or service Do not connect the appliance before pressure testing To prevent damage to the thermostat do not short the gas valve terminals Do not grip control the body with a wrench or vise Use the inlet boss only Leak test after installation or service With gas flowing through the control main burner on coat possible lea...

Page 45: ... the pilot light 1 Remove the adjusting cap using a fine screwdriver 2 The pilot flame should be about 2 inches high Turn the pilot adjustment cap screw clockwise to make the pilot lower Turn the pilot adjustment cap counterclockwise to make the pilot higher ...

Page 46: ...vice of the machine It does not give all the possible methods to correct the problems listed but is meant to stimulate a train of thought and indicate a work procedures directed toward finding the source of the problem Most problems are simple and easily corrected To save time and trouble always check the easiest and obvious thing first Study the problem thoroughly and ask yourself these questions...

Page 47: ...djustment 1 Install a draft diverter see the Installation section or relocate the machine to a less drafty area or provide shields or walls to isolate the burner 2 Replace electrode 3 Install a larger gas supply hose 4 Adjust the flame to reasonable size 5 Fix intermittent ignition as follows a Repair b Replace c Adjust Burner will not light 1 No fuel 2 Pilot out 3 Thermostat set too low 4 Faulty ...

Page 48: ...ction and pressure delivery problems Problem Probable cause Solution Low pressure 1 Worn or oversize spray nozzle 2 Clogged water inlet strainer 3 Out of detergent pump sucking air through detergent line 4 Air leak in inlet plumbing 5 Belt slipping 6 Dirt or foreign particles in the valve assembly 7 Worn or damaged inlet or discharge valve 8 Inline filter plugged 9 Coil scale 10 Faulty unloader 1 ...

Page 49: ... adequate tap water supply 2 Check key and tighten set screw 3 Replace bearing s 4 Replace pump Oil leaks Worn crank seals crankcase cover and seal or drain plug Replace seals Excessive pump shaft play Worn and loose bearings Replace bearings Check bearing seals spacers and retainers replacing any worn parts Irregular spray pattern Worn or partly clogged spray nozzle Clean or replace nozzle ...

Page 50: ...n valve in the pump Remove and replace pump valve see the Repair section Chemical system malfunction Problem Probable cause Solution Injector s won t draw 1 Plugged wand nozzle 2 Damaged wand nozzle 3 Chemical pick up filter clogged 4 Injector clogged 5 Hose damaged 6 Not adequate flow pressure 7 Temperature too high 1 Clean or replace nozzle 2 Replace nozzle 3 Check clean or replace 4 Remove and ...

Page 51: ...to an adequate voltage supply Thermal overload protector in main pump motor trips often 1 Partially or totally clogged spray nozzle overburdens the motor 2 Undersized spray nozzle in use 3 Restriction in plumbing of the machine 4 High ambient temperature 5 Supply voltage is low 1 Remove and clean out the nozzle Make sure the strainers on the inlet and chemical suction tube are present ad in good c...

Page 52: ...50 P a g e Figure 27 Electrical diagram ...

Page 53: ...______________________________ _________ _________________________________________ _________ _________________________________________ _________ _________________________________________ _________ _________________________________________ _________ _________________________________________ _________ _________________________________________ _________ _________________________________________ _____...

Page 54: ...PEM 320 Mallard Lane Mankato MN 56001 USA T 507 345 1512 F 507 345 5828 www spraywand com Parts and Service T 888 969 1601 Email sales spraywand com ...

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