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Safety - 4

Installation, Operations, and Maintenance Manual

The MART Corporation

Standard Turntable Power Washer v. 4.0

WARNING!   Be sure that people performing repairs are
qualified and trained for the task.

WARNING!   Disconnect/turn OFF power before opening the
control panel.  NEVER leave the control panel open when the
power is ON.

CAUTION!   You must turn the main power supply OFF before
performing many maintenance procedures.  BE SURE to turn
the main power supply back ON after you perform
maintenance.

CAUTION!   If the main power supply is OFF for a time period
that exceeds the power-outage carry-over specified in the
vendor-supplied 7-Day-Clock Manual, be sure to re-set the 7-
Day Clock (located inside the electrical control panel).

SAVE THE SAFETY INSTRUCTIONS AND WARNINGS IN THIS
SECTION!

Содержание Cyclone 30 Series

Страница 1: ...atents 4 741 351 4 143 669 4 213 475 5 529 080 5 524 653 5 427 128 5 540 246 This manual is an unpublished copyrighted work by The MART Corporation The information and drawings in this manual are the...

Страница 2: ...res Figures 1 Welcome and Introduction Welcome 1 Purpose of Manual Welcome 1 Audience Welcome 2 How the Manual Is Organized Welcome 2 How to Use This Manual Welcome 3 MART Technical Services Welcome 3...

Страница 3: ...m And Grit Blasting 1 7 3 1 2 Temperature 1 8 3 1 3 Chemical 1 8 Removal of Soils 1 9 Applications 1 9 Usage 1 10 3 1 4 Time 1 10 3 1 5 General Information and Conclusion 1 11 3 2 Operating Principles...

Страница 4: ...ce 2 15 Electric Heat Source 2 20 Steam Heat Source 2 20 5 2 2 Water Input 2 21 5 2 3 Compressed Air Input 2 22 5 2 4 Electricity Input 2 23 Earthgrounding to Prevent Corrosion 2 23 5 3 Connection Pro...

Страница 5: ...tting the Rinse Cycle optional 3 11 2 9 Starting the Washer 3 12 2 10 Verifying Proper Function 3 12 2 11 Opening the Door after a Cycle 3 13 2 12 Unloading Parts 3 13 3 Continuous Operation 3 14 4 Ad...

Страница 6: ...Washer Adjustments 5 4 2 1 Pumps and Power Blast Manifold PBM Assembly 5 4 2 1 1 Wash Pump Intake Filter Inspect Clean 5 4 2 1 2 PBM Swivel Joint Grease 5 5 2 1 3 PBM Nozzles Inspect Monitor 5 6 2 1...

Страница 7: ...e Clean Out and Heat Exchanger Suction Tube Clean 5 24 3 3 Heating Elements Clean electric only 5 24 4 Maintenance of Options 5 25 6 Troubleshooting 6 1 Purpose 6 1 Prerequisites 6 1 Safety Precaution...

Страница 8: ...s 7 13 2 3 1 Clean Machine Operation Frequency 7 14 2 3 2 Clean Machine Chemical Management 7 14 2 4 Maintenance 7 15 2 5 Troubleshooting 7 16 3 Center Manifold 7 18 3 1 Theory of Operation 7 18 3 2 I...

Страница 9: ...cy Drive 7 42 8 1 Theory of Operation 7 42 8 2 Installation 7 42 8 3 Operations 7 43 8 4 Maintenance 7 43 8 5 Troubleshooting 7 44 9 Hot Air Blow Off HABO 7 45 9 1 Theory of Operation 7 45 Steam Exhau...

Страница 10: ...68 14 3 Operations 7 68 14 4 Maintenance 7 68 14 5 Troubleshooting 7 69 15 Rack and Fixture Set or Small Parts Basket 7 70 15 1 Theory of Operation 7 70 15 2 Installation 7 70 15 3 Operations 7 72 15...

Страница 11: ...and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 19 Short High Manifold SHIM System 7 84 19 1 Theory of Operation 7 84 19 2 Operations 7 84 19 3 Maintenance 7 85 19 4...

Страница 12: ...ox Wiring 2 18 Fig 2 6 Steam Solenoid and Steam Trap Installation 2 20 Fig 2 7 Water Connection Location 2 21 Fig 2 8 Compressed Air Connection 2 22 Fig 2 9 General Layout of the Electrical Control Pa...

Страница 13: ...4 21 Fig 5 1 Service Schedule 5 3 Fig 5 2 Cleaning the Pump Intake Filter Box 5 5 Fig 5 3 Lubrication Chart 5 6 Fig 5 4 Cleaning and Replacing the PBM Nozzles 5 7 Fig 5 5 Swivel Jam Nut Non adjustable...

Страница 14: ...Troubleshooting Oil Skimmer Tank Overflows into Cyclone Separator Tank 7 17 Fig 7 7 Troubleshooting Skimmer Wheel Drain Trough Backs Up 7 17 Fig 7 8 Center Manifold Mechanism and Superstructure 7 20...

Страница 15: ...ting Skimmer Wheel Does Not Skim 7 62 Fig 7 33 Troubleshooting Power Assist Does Not Activate 7 65 Fig 7 34 Troubleshooting Pump Pressure Gauge Does Not Work 7 67 Fig 7 35 Troubleshooting Pump Pressur...

Страница 16: ...ions and Warnings contains general warnings and cautions that are meant to be observed at all times when you work with the washer Personnel training is required to work with the power washer Be sure a...

Страница 17: ...mes when you work with the washer Be sure all operators read and heed the instructions in that section Chapter 1 Overview presents an overview of the MART Standard Turntable Power Washer including a t...

Страница 18: ...y use the Table of Contents List of Figures and Index to refer to information as you need it MART Technical Services MART s technical services department is available to provide you with the extra sup...

Страница 19: ...cuments for additional details on installation operations and maintenance Startup A MART factory trained technician is optionally available to perform startup and customer training Call MART technical...

Страница 20: ...ake Ovens EPA OSHA and Hazardous Waste Disposal How MART Power Washers Work Printed Material Hazardous waste lab reports Procedure for sludge disposal Message to financial management Ins outs of leasi...

Страница 21: ...AND WARNINGS IN THIS SECTION GENERAL SAFETY INSTRUCTIONS FOR OPERATING THIS PRODUCT 1 Read all safety and operating instructions procedures before installing operating maintaining repairing or troubl...

Страница 22: ...result causing loss of life personal injury or damage to property WARNING VENTING OF EXHAUST GASES Do NOT vent exhaust gases into a wall a ceiling or a concealed space of a building Refer to the instr...

Страница 23: ...d for the task WARNING Set up your power washer installation to conform to all local code requirements WARNING The standard power washer is designed to be installed inside a building not outside WARNI...

Страница 24: ...l panel open when the power is ON CAUTION You must turn the main power supply OFF before performing many maintenance procedures BE SURE to turn the main power supply back ON after you perform maintena...

Страница 25: ...your power washer before you attempt to install operate or maintain the washer Prerequisites You will find it helpful to have read the introductory material especially Welcome so that you understand...

Страница 26: ...nd manufacturing information This section also shows you a diagram of the washer with principal parts labeled 1 1 Getting Acquainted MART Power Washers are non solvent based cleaning systems They are...

Страница 27: ...ew 1 3 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 1 1 Standard Turntable Power Washer View 1 Power Blast Manifold Door Mounted Turntable Water and Compressed Air Electrical Control...

Страница 28: ...aintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 1 2 Standard Turntable Power Washer View 2 Skimmer Box Ttbl Drive Sprocket Enclosed Turntable Drive Gearmotor Lifting E...

Страница 29: ...d valves outside the electrical control panel and all electrical devices for example timers relays motor starters inside the electrical control panel are clearly labeled Separate temperature compensat...

Страница 30: ...on of the factors must be determined for your application based on the types of soils to be removed the degree of cleanliness required the cycle time required the types of parts to be cleaned and so o...

Страница 31: ...that most directly affects how quickly and effectively the soils are removed The impact per square inch of a given nozzle depends on the following Flow and pressure produced by the pump Type of nozzl...

Страница 32: ...does not rely primarily on chemical concentration This is because your MART sales technician worked with you to determine your cleaning needs such as Required degree of cleanliness Nature of the soil...

Страница 33: ...emoved as sludge A key feature of this type of cleaner is that you only have to dispose of the contaminants as waste the washer can recycle the liquid until the saturation point As the wash solution i...

Страница 34: ...fresh water to flash dry parts without rusting 4 If you need to dry the parts quickly MART can provide an air or heated drying phase 5 All parts and materials washed in a MART Power Washer are clean...

Страница 35: ...as to overpower the soils Cleanliness is proportional to the combination of the following factors Power Temperature Chemical Time The exact combination of these factors is variable and depends on you...

Страница 36: ...the pump inlet Finally the solution leaves the pump under pressure and travels through piping to the power blast manifold PBM The pump is capable of handling hot alkaline cleaners and can pass solids...

Страница 37: ...means cleaner parts Nozzles Nozzle placement evenly distributes blasted solution throughout the wash cabinet From the bottom up across the cabinet and from the top downward This ensures that each por...

Страница 38: ...om the power washer cabinet during the wash cycle and the optional automatic rinse cycle ARC and for a timed period after the rinse cycle The ASE serves two purposes 1 It reduces the amount of steam t...

Страница 39: ...osion resistant materials Rinse time is controlled by two factors The amount of water that can be made up due to water loss through steam exhaust evaporation or drag out or The rinse timer inside the...

Страница 40: ...am First let s look at general operating principles that apply to all the systems Following that we ll take a closer look at principles specific to each system Note The discussions of heating system o...

Страница 41: ...LOW neither the heating system nor the wash pumps will function The water fill valve will be open to provide water fill LOW This is the minimum safe operating condition The heat exchanger should be fu...

Страница 42: ...up Overnight This allows longer rinses than would be possible with a simple single set point water fill and rinse system With the single set point system only water evaporated or discharged from the...

Страница 43: ...he electrical control panel to the left side of the door Major system controls are housed inside the electrical panel A number of system features are logically interdependent in order to help ensure s...

Страница 44: ...art Run Light Press the START button all the way to begin the wash cycle The green run light illuminates indicating cycle running Note The start circuit is interlocked with the door closed limit switc...

Страница 45: ...controls include Timers and relays that control the cycle logic 7 day clock A programmable device that allows the operator to preset the days of the week and time of day for the washer to heat up The...

Страница 46: ...begins the wash cycle When the 0 30 minute wash cycle timer times out the wash pump starter and power blast manifold PBM stop operating This ends the wash cycle Rinse System optional The rinse solenoi...

Страница 47: ...pump comes on How this works depends on whether you have a single pump or a duplex pump system Single Pump System All 20 30 and 40 horse power systems have an APE Automatic Pressure Equalization unit...

Страница 48: ...lation Here are some tips Inspect For Entire cabinet including the top dents or scrapes Electrical wire conduits breakage Cabinet door dents or scrapes Misalignment Water hoses and pipes breaks or cra...

Страница 49: ...ern To ensure that you have a valid warranty Prerequisites Before you begin to install the power washer be sure you have followed the recommendations in this section q Information Read the entire manu...

Страница 50: ...om the cabinet doorframe m Operations Access Leave adequate room to work with the washer during normal operations Allow sufficient room for loading and unloading the washer with the door in a half ope...

Страница 51: ...en exhaust and makeup air in the plant Refer to the latest issue of the National Fuel Gas Code American National Standard ANSI Z223 1 for details In general it specifies that a permanent opening or op...

Страница 52: ...ding provides a path of least resistance for electric current thus reducing the risk of electric shock during maintenance troubleshooting or repair CAUTION GROUNDING INSTRUCTIONS The washer must be co...

Страница 53: ...ING Do NOT add water chemical or turn on the power during installation These steps are part of the startup procedure Wait until Startup Procedure at the end of this chapter to add water chemical or tu...

Страница 54: ...e lifting eyes located on the top left and top right sides of the cabinet as shown in FIG 2 1 WARNING Use lifting equipment rated for the weight of your power washer To find out the weight refer to th...

Страница 55: ...on 2 7 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 2 1 Raising the Power Washer by the Lifting Eyes Lifting Eyes Steam Vent Pipe Attachment Flange Flue Pipe Attachment For Gas Heate...

Страница 56: ...installation location place it according to your plan Watch the overhead and side areas around the washer as you place it Walk around the washer and verify clearances Refer to section Prerequisites Pl...

Страница 57: ...r slowly and carefully Note Some items secured to turntable may have shifted during shipment 3 Remove the cartons strapped to the turntable 4 Check all standard items accessories and documentation aga...

Страница 58: ...sure correct installation as you follow the steps in the next several sections Use the Field Startup Procedure FSP form in this way 1 As you install the washer fill in the Field Startup Procedure FSP...

Страница 59: ...Concrete pad Steel structure 4 1 Leveling Follow this procedure 1 Find the leveling and anchoring feet at each corner of the washer at floor level 2 Find the leveling bolt nut and the anchor hole on e...

Страница 60: ...his will interfere with the leveling bolts Shim under the frame of the washer only 5 When the washer is level and the shims are in place back off the tension of the screws on the leveling bolts so tha...

Страница 61: ...cause corrosion When placing grout follow the manufacturer s detailed instructions to the letter This will help prevent voids and other grout repair problems later In general use only non shrink grout...

Страница 62: ...Placement Planning at the beginning of this chapter Your plan and the SBO tell you which of the following utility connections and options installations you must make Use this manual to locate the con...

Страница 63: ...ctions in this manual for information on making the necessary connections 5 2 1 Heat Source Depending on the washer s configuration and options it will use one of the following heat sources Gas natura...

Страница 64: ...ious figure 1 Attach Heat exchanger flange A Burner gasket B Burner locking collar C to the heat exchanger opening located on the right side of the washer Use the mounting bolts provided 2 Insert the...

Страница 65: ...pe gasket supplied with the burner Wind it in a spiral on the face of the burner flange inside the bolthole circle in a single layer Cut off the excess rope NOTE The rope may be held in place by maski...

Страница 66: ...the green ground screw in burner junction box For Gordon Piatt burners the orange wire connects to 1 the white wire connects to 2 and the green wire connects to the green ground screw in the junction...

Страница 67: ...ngs and joints including all connections on the burner and all piping installed to the burner To do this smear a solution of soap and water around all fittings and look for bubbles If you see bubbles...

Страница 68: ...and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 3 Make connections to your in plant steam power system according to plant and other local codes Fig 2 6 Steam Solenoid...

Страница 69: ...eater than 125 PSI 862 kilopascals The regulator should regulate water pressure to 100 125 PSI 690 862 kilopascals NOTE The water regulator is not provided by MART 2 Connect a 1 2 inch diameter 13 mm...

Страница 70: ...IZED fitting If you do NOT have a galvanized fitting you may not need a compressed air line Follow this procedure 1 Install a 1 2 inch diameter 13 mm compressed air line to the washer The incoming pre...

Страница 71: ...system OR an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the washer Earthgrounding to Prevent Corrosion The washe...

Страница 72: ...er supply to the washer following NEC methods Use proper size wires in the conduit and make watertight connections to the electrical control panel 5 Attach the feeder wires to the power distribution b...

Страница 73: ...erequisites PVC Kit at the beginning of this chapter MART washers are set up for using PVC pipe for the steam exhaust Your washer and ASE auto steam exhaust blower unit arrive equipped for using PVC f...

Страница 74: ...st pipe connection must be independent of any other pipe connection It can not share a steam vent pipe with any other equipment Steam Exhaust Pipe Refer to the following figure for the location of the...

Страница 75: ...blower Note Install venturi such that fan motor shaft is horizontal Use a twist transition supplied from MART if required Fig 2 11 Auto Steam Exhaust ASE Piping and Blower Installation Configurations...

Страница 76: ...calculating pipe length each 90 angle bend equals 10 feet 3 m of straight pipe CAUTION You must mount the ASE assembly in line with the steam exhaust pipe and as far away from the washer as possible a...

Страница 77: ...Installation 2 29 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 2 13 Auto Steam Exhaust ASE Piping and Blower Assembly...

Страница 78: ...efer to your machine s panel layout drawing on the inside of the enclosure door for the exact location Splice the other end of the red wire to one of the black wires on the ASE motor 3 Attach one end...

Страница 79: ...lation Your MART Power Washer is capable of producing exhaust gas temperatures up to 1000 degrees F The gas burner flue installation must comply with all applicable local and or national gas codes for...

Страница 80: ...a minimum of 1 4 inch 6 mm per pipe foot per 30 5 cm of pipe 3 Be sure the exhaust vent ends in a vertical position The vent termination point must be above the roof peak by the required height as st...

Страница 81: ...rntable Power Washer v 4 0 The MART Corporation 5 4 Installation of Options If you have purchased any options with your washer such as a Clean Machine refer to chapter Options later in this manual for...

Страница 82: ...nsure that all connections have been properly made During this inspection you will inspect the following items and document your inspection results on the FSP Visual inspection Leveling Anchoring Phys...

Страница 83: ...Power up Procedure Preliminary checks Supply Voltage Water Fill Water Level Control Control Voltage Heat Gas Electric Steam Oil Pump s Rotation Direction Temperature Control Voltage Readings Amp Readi...

Страница 84: ...l panel to be sure they are seated in their sockets Close the electrical control panel door 6 2 Lubrication Procedure Your power washer was pre lubricated at the factory If you install the washer with...

Страница 85: ...wer supply to the Power Washer 3 Turn electrical disconnect located on the MART Washer Control Enclosure door to the OFF position 4 Open electrical enclosure door 3 Measure and record incoming voltage...

Страница 86: ...inutes 7 After about two hours check the washer reservoir to verify or adjust the set point water level While the reservoir fills you can continue with the power up procedure Water Level Control The w...

Страница 87: ...lower the water level When the washer has completed filling to the set point water level the cam and float limit switches should appear as shown in the following figure Fig 2 17 Float Cam at SET POINT...

Страница 88: ...rect skip to step 6 4 Mark the current location of the cam on the float rod with a marker or a piece of tape before making any adjustments If the water level measurement you made is higher than the in...

Страница 89: ...correct set point water level after operations have started you must allow the washer to fill to the set point You can check this by observing the position of the float cam relative to the limit switc...

Страница 90: ...rned ON 2 Verify that the incoming pressure is within the range specified in the table below Lower gas pressures can reduce the burner firing rate and increase the time it takes for the machine to hea...

Страница 91: ...ue to various installation variables it may be necessary to adjust operating parameters to obtain consistent burner performance Maximum Actual Operating Temperature Altitude in Feet Temperature F 0 20...

Страница 92: ...efficiency 70 or more Stack temperature 350 F to 1000 F 177 C to 371 C Carbon monoxide 200 PPM or less 8 Record the water temperature and time of day for reference Refer to the following figure for g...

Страница 93: ...rol unit to 220 degrees F 2 Allow the burner to operate until the water temperature reaches 200 degrees F 3 Measure and record the exhaust stack temperature 4 Adjust the Hi Limit controller 100 degree...

Страница 94: ...s Be sure the people performing this task are qualified and trained for the task 4 Turn the electrical disconnect on the control enclosure door OFF Open electrical enclosure door With door open turn t...

Страница 95: ...air entering a hot enclosure When the pump system comes on this cool air is rapidly heated by the hot water solution which results in a rapid expansion in excess of the normal exhaust system capacity...

Страница 96: ...hemical Charging Procedure If you have successfully completed the startup procedure to this point you are ready to charge the washer with chemical When you charge the washer with chemical always follo...

Страница 97: ...e main power supply OFF 2 Pump out the amount of water that is to be replaced by liquid chemical 3 Pump the liquid chemical SLOWLY from drums onto the false floor or over the doorframe CAUTION Use ext...

Страница 98: ...ave to do is open a chemical barrel place the strainer tube in the bottom of the barrel and prime the injector pump To prime the injector pump follow these guidelines 1 Shut off the incoming water sup...

Страница 99: ...anel 10 To set the rinse timer and injector pump speed control refer to chapter Advanced Operations Process Control 6 7 Startup Problems If you have any problems during the startup procedure do the fo...

Страница 100: ...owing thoroughly Important Safety Instructions and Warnings in the front material Chapter 1 Overview This chapter Basic Operations assumes that appropriate operating parameters have been established f...

Страница 101: ...due remain on part surfaces and in recesses Before you remove a part from the washer cabinet be sure to drain back into the washer any solution that remains on a part surface or in recesses What You W...

Страница 102: ...the turntable for easier loading unloading Start Run Light Press the START button all the way to begin the wash cycle The green run light illuminates indicating cycle running Note The start circuit is...

Страница 103: ...orporation Standard Turntable Power Washer v 4 0 FIG 3 1 Standard Turntable Power Washer Control Panel HOUR METER SKIMMER ON OFF AUTO OPTIONAL CLOCK OVERRIDE TURNTABLE JOG START CYCLE LIGHT WASH STOP...

Страница 104: ...gure for the gauge s location WARNING Do NOT operate the washer unless it has reached minimum operating temperature Scheduled Shift During a scheduled shift check the temperature gauge about every 15...

Страница 105: ...internal temperature control unit is to be considered normal operation of the system To increase the average wash temperature increase the set point temperature on the control unit inside of the elect...

Страница 106: ...oration 2 3 Opening the Door Door Latch Pull the latch handle away from the washer cabinet to release the latch Refer to the following figure Swing the latch hook away from the door handle Pull the do...

Страница 107: ...door back slowly 3 Release the position lock 4 Continue pushing the door until it locks in place The position lock handle is located at the bottom of the door The two position locks hold the door open...

Страница 108: ...loaded exactly at the center of the turntable Guideline Assume that every nozzle hits every part with 15 lbs 6 8 kg of force Recommendations Wrap securing devices tightly around all fixtures and part...

Страница 109: ...tom of the door Refer to Fig 3 4 Door Latch Swing the latch hook toward the door handle Push the latch handle toward the washer cabinet to close and lock the latch Refer to Fig 3 3 2 6 Verifying Wash...

Страница 110: ...NOTE In general most cleaning cycles can be completed in less than 15 minutes 2 8 Setting the Rinse Cycle optional If you have the optional Automatic Rinse Cycle ARC setting the rinse off auto switch...

Страница 111: ...en to the pump does it sound normal Is the turntable drive motor jackshaft rotating Cycle Completion At the end of the cleaning cycle the following things should happen START button light turns off Tu...

Страница 112: ...Fig 3 4 Securing the Door Always be sure that the open door is locked in position Visually check the position lock Or Try to pull or push the door 2 12 Unloading Parts Press the TURNTABLE JOG button t...

Страница 113: ...about the following to help get the best cleaning results and optimize energy usage while minimizing chemical usage and problems Managing chemical concentration Setting rinse cycle time optional ARC...

Страница 114: ...tion instructions WARNING Never get inside the washer cabinet when the main power supply is ON This could result in severe injury or death What You Will Learn In This Chapter In this chapter you will...

Страница 115: ...t as necessary this is important not only for cleaning results but it will also reduce cleaning time and other chemical related problems such as foaming You must also use some chemical during the clea...

Страница 116: ...potassium hydroxide will blacken the surface of the parts being cleaned and if exposed for five minutes or more can etch the surface Type of Soils A wide of range of compounds is available to remove s...

Страница 117: ...cal to add Divided by 128 fluid ozs Gal You must test and adjust the variables in your application to determine an effective chemical type and concentration Chemical concentration depends on Your clea...

Страница 118: ...all the variables in your application in order to give you the best cleaning results while using the least amount of chemical possible For help in developing a chemical concentration monitoring sched...

Страница 119: ...y a light chemical charge you may need to add a booster charge of de foamer if foaming is a problem Consider adding a defoaming agent rather than more chemical given the following conditions Your clea...

Страница 120: ...condition is called supersaturation of solution To correct this problem you must remove greases and oils from the solution Allow solution to cool and oils to rise to surface then Manually skim greases...

Страница 121: ...s a Power Kleen product specifically designed for your particular cleaning applications In all cases Power Kleen products provide the highest degree of efficient effective cleaning Power Kleen product...

Страница 122: ...insability factor with no conductive residue Power Kleen IV Aerospace Specially formulated Power Washer detergent for removing carbon grease and dirt from Aerospace Metals Aircraft Parts and chemicall...

Страница 123: ...ting Temperature Altitude in Feet Temperature F 0 2000 190 F 88 C 2000 4000 185 F 85 C 4000 5000 180 F 82 C 5000 and above call MART WARNING Do NOT exceed recommended settings or serious damage can oc...

Страница 124: ...temperature increases greases and oil become more fluid Since grease is the primary binder that holds and contains the soils on the parts heat melts the binder generally producing better cleaning resu...

Страница 125: ...up water needed due to water loss through evaporation or drag out Automatic rinse system ARC timer In controlling rinse cycle time water loss takes priority The amount of makeup water required determi...

Страница 126: ...emical supplier for the appropriate inhibitor chemical and for instructions on using it NOTE Monitor inhibitor chemical usage visually Replace drums as needed to ensure that inhibitor chemical is appl...

Страница 127: ...rations find the correct rinse regulator pressure line on the graph NOTE There are five rinse regulator pressures represented on each graph Refer to the key code box under the graph to select the corr...

Страница 128: ...0 10 20 30 40 50 60 70 80 90 100 Injector Pump Output Setting 0 00 0 50 1 00 1 50 2 00 Mix Ratio OZ GAL 10 PSI 20 PSI 30 PSI 40PSI 50 PSI Chemical Injection Mix Ratio 3 Nozzle Rinse System Rinse Regu...

Страница 129: ...T Corporation Fig 4 6 Injector Pump Output Setting 5 Nozzle Rinse System 0 10 20 30 40 50 60 70 80 90 100 Injector Pump Output Setting 0 00 0 50 1 00 1 50 2 00 Mix Ratio OZ GAL 10 PSI 20 PSI 30 PSI 40...

Страница 130: ...tor is factory pre set Adjust it to achieve rinse characteristics that meet your requirements To Get This Adjust the Regulator for Smaller drops more volume Higher gauge reading Larger drops less volu...

Страница 131: ...wn off mode Program run times for optional devices The clock is located on the face of the electrical control panel as shown in the following figure Circuit 1 controls the heating and water fill times...

Страница 132: ...switch controls some optional devices such as the Clean Machine and the Oil Skimmer and circuit 2 of the 7 day dual circuit clock located on the face of the electrical control panel In order for these...

Страница 133: ...e automatic steam exhaust ASE cycle removes steam from the washer cabinet During the wash cycle During the optional automatic rinse cycle ARC For the ASE timer set period of time after the automatic r...

Страница 134: ...e ASE cycle 3 Check to see if any steam remains in the cabinet after the ASE cycle has completed 4 Increase or decrease the ASE timer by one minute increments Generally if steam remains in the cabinet...

Страница 135: ...ter monitoring and indicate if any maintenance procedures need to be performed Refer to chapter Maintenance for maintenance procedures 6 1 Monitoring Lubrication Monitoring lubrication of the followin...

Страница 136: ...udge when there is about 4 inches 10 16 cm of it on the bottom of the front reservoir Pump Intake Filter Monitor daily Clean the pump intake filter every 8 hours of operation to remove sludge and othe...

Страница 137: ...nd long economical life of the washer Prerequisites Before you read this chapter we recommend that you read the following thoroughly Important Safety Instructions and Warnings in the front material Ch...

Страница 138: ...k manual be sure to re set the 7 day clock located inside the electrical control panel WARNING Do NOT OVERLOAD the false floor or other horizontal surfaces The false floor is intended as a chemical so...

Страница 139: ...Sludge Level monitor __________ _________ 40 Hours Weekly PBM Nozzles inspect monitor __________ _________ Chemical Concentration test __________ _________ Slip Clutch Torque Limiter inspect ________...

Страница 140: ...swivel joint grease Lubriplate 1444 PBM nozzles inspect monitor PBM swivel jam nut inspect adjust Amperage draw at wash pump measure Upper manifold bearing grease Mobilith AW2 Wash pump and pump moto...

Страница 141: ...The MART Corporation Fig 5 2 Cleaning the Pump Intake Filter Box 2 1 2 PBM Swivel Joint Grease Grease the PBM Swivel Joint with Lubriplate 1444 Refer to the following figure NOTE It is imperative that...

Страница 142: ...hich gives you the best cleaning results When you check for clogging be sure to check that all nozzles are correctly aligned as indicated in the following figure Monitor the amperage draw at the main...

Страница 143: ...ain power supply OFF 2 Remove the nozzle with a 9 16 inch 14 mm wrench 3 Remove any debris 4 Apply 6 7 turns of teflon tape to the threads 5 Re install the old nozzle or install a new one Thread nozzl...

Страница 144: ...ou need to adjust the jam nut The jam nut is located on the swivel at the bottom of the PBM manifold The swivel assembly allows for take up of the packing after it wears 5 Swivels with Jam Nuts only A...

Страница 145: ...on tag The tag indicates two things 1 Full load amperage draw at your specified voltage and 2 The service factor which is either 1 15 or 1 25 times the full load amperage depending on motor size and i...

Страница 146: ...of premature motor failure If you apply too much grease it is eventually forced out of the bearing housing and begins dripping on the motor windings The grease then attacks and destroys the insulatio...

Страница 147: ...each bearing 6 Replace the fittings and plugs 7 Turn the main power supply ON Fig 5 6 Wash Pump and Pump Motor s To grease the pump motor s follow this procedure refer to the previous figure 1 Turn th...

Страница 148: ...mp Couplings Inspect Inspect the wash pump s couplings for the following Wear Separation Misalignment Refer to Fig 5 6 as you inspect couplings for the following Wear If couplings are worn replace the...

Страница 149: ...lean the air intake on the burner blower motor natural gas L P gas or fuel oil fired burners only with a compressed air blower or a soft brush in order to remove dust and dirt Refer to the following f...

Страница 150: ...r replace 2 3 1 Float Assembly Inspect Clean Inspect Clean Inspect the float assembly periodically The single ball float system normally requires little or no cleaning however under some operating con...

Страница 151: ...urement you made is higher than the indicator you will need to move the cam up the float rod by the difference between the indicator and the measured value If the measurement is lower than the indicat...

Страница 152: ...at cam relative to the limit switches in the float box Refer to Fig 1 3 Float Level Mechanics If the cam is higher than the set point you will have to remove solution from the washer and allow the was...

Страница 153: ...als Cyclone 30 s and Tornado 40 s Turntable roller bearings only Cyclone 30 s and Tornado 40 s have extended life bearings that require lubrication every 1100 hours of operation To lubricate the turnt...

Страница 154: ...bottom sprocket support plate Use a nut that is appropriate for your torque wrench 2 Use a torque wrench with 50 foot pound 6 9 kg m capability 3 Loosen the set screws on the large hexagon torque adju...

Страница 155: ...use phenolphthalen indicator P as a reactant and an acid hydrochloric or phosphoric as a neutralizer The indicator P turns red or pink or blue when added to a sample of the solution By counting the d...

Страница 156: ...proved testing accuracy 1 Prepare a control sample using fresh city water and chemical to the desired concentration 2 Titrate this control sample 3 Compare titrations of the wash solution to the resul...

Страница 157: ...Voltage at Power Distribution Block Measure Measure and record the incoming voltage to the washer with wash pump s running CAUTION Be sure that ONLY a qualified electrician performs this maintenance...

Страница 158: ...n than sludge clean out or cleaning of the heat exchanger and suction tube WARNING Do not stand or walk on the false floor inside the cabinet or on the reservoir cover 3 1 Sludge Monitoring To monitor...

Страница 159: ...ds by an approved waste disposal method 6 Pump the solution into holding barrels CAUTION Do NOT pump out the SLUDGE 7 Move the door position lock to allow the washer cabinet door to open to a 180 angl...

Страница 160: ...plies to electrically heated power washers only NOTE Maintenance of heating elements may need to be done more often than sludge clean out or cleaning of the heat exchanger and suction tube Follow this...

Страница 161: ...lse floor 8 Turn the main power supply ON 9 Allow solution to heat up to operating temperature before running a wash cycle Fig 5 11 Cleaning the Heating Elements 4 Maintenance of Options For instructi...

Страница 162: ...d correct the problem In many cases you can use procedures in chapters Installation Advanced Operations Process Control or Maintenance to correct a problem after you have diagnosed it In other instanc...

Страница 163: ...abinet when the main power supply is ON This could result in severe injury or death WARNING Be sure that people who perform repairs are qualified and trained for the task What You Will Learn In This C...

Страница 164: ...not start Check This Probable Cause s APE pressure switch Misadjusted Insufficient compressed air supply Clock override Set to OFF must be ON 7 day clock Not programmed program 1 must be ON Compressed...

Страница 165: ...rol or Maintenance to correct a problem after you have diagnosed it Or refer to your vendor supplied manuals or cut sheets for instructions on correcting problems Problem Ineffective cleaning of parts...

Страница 166: ...er solution Wash pump motor trips overload high amperage reading Seal leakage at wash pump mounting plate Wash pump or motor vibrates or is noisy Problem Wash pump motor won t start Check This Probabl...

Страница 167: ...le Cause s Pump or motor Mechanical defects rotate pump shaft by hand to verify if one of the following is causing the problem Bent shaft Loose impeller Pump casing unbolted Throttle bushing failure S...

Страница 168: ...Wash pump or motor vibrates or is noisy Check This Probable Cause s Pump or motor Bearings Need lubrication Need to be replaced Damaged Pump Throttle bushing failure Pump motor Coupling Loose dropped...

Страница 169: ...at specified pressures Blower motor not running Check for fan obstruction No ignition blower motor must be running Flameproving rods Corroded replace Igniter rods Corroded replace Burner controller d...

Страница 170: ...rect setting Fig 6 10 Troubleshooting Water Does Not Heat Steam Problem Water does not heat electric Check This Probable Cause s Electric heaters Defective element Replace Defective wires loose burned...

Страница 171: ...s This section contains tables on the following problems Turntable does not rotate Problem Turntable does not rotate Check This Probable Cause s Drive gear motor Not operating Fuse overload Blown trip...

Страница 172: ...supplied manuals or cut sheets for instructions on correcting problems This section contains tables on the following problems Nozzles ineffective cleaning Problem Nozzles Ineffective cleaning Check T...

Страница 173: ...er you have diagnosed it Or refer to your vendor supplied manuals or cut sheets for instructions on correcting problems Problem Foaming Check This Probable Cause s Operating temperature Too low raise...

Страница 174: ...cut sheets for instructions on correcting problems This section contains tables on the following problems PBM not oscillating Problem PBM not oscillating Check This Probable Cause s Linkage Not conne...

Страница 175: ...ctions on correcting problems This section contains tables on the following problems Water not filling reservoir Water overflowing reservoir System not heating Problem Water not filling reservoir Wate...

Страница 176: ...on contains tables on the following problems Washer will not start Problem Washer will not start Check This Probable Cause s Door limit switch Door not closed does not activate Loose bolts switch has...

Страница 177: ...tion contains tables on the following problems No rinse cycle Problem No rinse cycle Check This Probable Cause s Rinse timer Not set above 0 Steam exhaust fan Not operating Rinse solenoid Not energizi...

Страница 178: ...will not operate ASE leaks liquid Problem ASE will not operate Check This Probable Cause s Wires Not tight enough Fuses Blown Blower fan Wheel off shaft Corroded ASE motor Not operating overload tripp...

Страница 179: ...power supply OFF before working on the electrical control system NOTE Use your electrical schematics to work on the electrical control system NOTE If a part or assembly on the power washer will not wo...

Страница 180: ...ore you read this chapter we recommend that you read the following thoroughly Important Safety Instructions and Warnings in the front material Chapter 1 Overview Safety Precautions Before you install...

Страница 181: ...nce Manual The MART Corporation Standard Turntable Power Washer v 4 0 What You Will Learn In This Chapter In this chapter you will learn the following about each option Theory of operation Installatio...

Страница 182: ...every set number of wash cycles 1 1 Theory of Operation The automatic lubrication system consists of the following refer to the following figure Grease reservoir Pneumatically driven grease pump Grea...

Страница 183: ...able upper and lower bearings PBM swivel bearings An electronic programmable controller inside the control panel mounted next to the grease pump controls the automatic lubrication system A counter in...

Страница 184: ...output Step 8 0 Idle mode no lube on power up Step 9 1 Normally energized fault relay goes off during power loss Step 10 1 Places controller in the operating mode These settings set the controller fo...

Страница 185: ...o that a lubrication cycle is run every washer cleaning cycle Check the system for proper operation See the Operations section for instructions on changing the controller program Automatic Operation T...

Страница 186: ...s ON your Auto lube system is not providing grease to the bearings Discontinue washer operations until the problem is corrected Refer to section Troubleshooting NOTE Use Lubriplate 1444 grease ONLY Ev...

Страница 187: ...er Time set too short program Fig 7 2 Troubleshooting Automatic Lubrication System Fault Light Is ON NOTE Bearing Lubrication Bearing lubrication is critical Before making any changes to the lubricati...

Страница 188: ...settling and building up Two processes are used in the Clean Machine to separate oils greases and particulate matter from the cleaning solution A hydrocyclone removes heavy particles and entrains air...

Страница 189: ...n Machine 2 Level the separator tank if necessary Refer to chapter Installation Leveling 3 Anchor the separator using 5 8 18 bolts through the welded nuts on the feet of the tank Refer to chapter Inst...

Страница 190: ...11 Standard Turntable Power Washer v 4 0 The MART Corporation NOTE Use a minimum of elbows and bends in the piping configuration Refer to chapter Installation for more information Fig 7 3 Clean Machi...

Страница 191: ...container at the outlet of the skimmer assembly to collect waste and tramp oils WARNING Fill the Clean Machine s separator tank BEFORE you turn on the heat 7 Set the temperature controller aquastat lo...

Страница 192: ...of the 7 day clock NOTE You must program the 7 day clock s circuit 2 for ON OFF times and set the Clean Machine s selector switch to auto 2 After you activate the Clean Machine verify the following Th...

Страница 193: ...ght Soils Operate the Clean Machine every other day NOTE If sludge builds up on the front floor of the washer reservoir operate the Clean Machine more often 2 3 2 Clean Machine Chemical Management Use...

Страница 194: ...of the particle the actual particle size and the pressure at the cyclone entrance The hydrocyclone expels sludge from its apex into the sludge chamber underneath Because the hydrocyclone also discharg...

Страница 195: ...tank Skimmer wheel drain trough backs up Problem Clean machine does not heat Check This Probable Cause s Aquastat Incorrect temperature set controller to 170 F 77 C Amperage Low draw Wires may be loos...

Страница 196: ...Fig 7 6 Troubleshooting Oil Skimmer Tank Overflows into Cyclone Separator Tank Problem Skimmer wheel drain trough backs up Check This Probable Cause s Drain trough Clogged Blades Not contacting wheel...

Страница 197: ...f the cabinet roof Optionally an extra tube may be attached to the vertical manifold tube for carrying rinse water to a pair of rinse nozzles on the lower end of the manifold Flexible tubing is connec...

Страница 198: ...this procedure refer to the following figure 1 Place beads of sealant around the roof opening 2 Place the superstructure frame and mechanism on the pad support on the roof 3 Connect the superstructure...

Страница 199: ...7 20 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 8 Center Manifold Mechanism and Superstructure...

Страница 200: ...h the center manifold WARNING Be sure the part is centered properly so that the center manifold does not hit the part 3 Set the center manifold mode selector switch located on the washer s control pan...

Страница 201: ...is up near the top of the cabinet roof in the Home position 3 Inspect the lift chain lift pin and bushings for wear and looseness 4 If loose tighten the lift chain by using the adjuster located near...

Страница 202: ...d replace Loose tighten Rinse pipefittings Broken tubing replace Loose fittings tighten Fig 7 9 Troubleshooting Water Leaks Onto Cabinet Roof Problem Center manifold assembly does not work Check This...

Страница 203: ...d Turntable Power Washer v 4 0 Problem Center manifold light does not illuminate Check This Probable Cause s Selector switch Not set to auto or manual manifold at home position Switch light bulb Burne...

Страница 204: ...electric current All aqueous solutions conduct electricity to some degree The addition of electrolytes increases conductivity Since conductive liquids consist of ionic compounds electrolytes dissolve...

Страница 205: ...uctivity has fallen below the set point you have selected it closes a relay If the relay closes while the wash pump is operating the peristaltic pump activates and pumps concentrated chemical solution...

Страница 206: ...the conductivity of the solution in the washer These compounds include iron oxide rust and carbon both commonly found in most washing applications This means that while conductivity measuring systems...

Страница 207: ...al and the actual chemical concentration of the solution Use this compensation factor to know how to adjust chemical concentration based on conductivity readings Conclusion After you have developed a...

Страница 208: ...plier or developed through process control testing refer to chapter Advanced Operations Process Control 2 Adjust the LO set point to this reading NOTE Refer to the controller vendor supplied manual fo...

Страница 209: ...the actual solution conductivity 2 Run a wash cycle 3 Verify that the pump is pumping chemical into the reservoir 4 Re set the LO set point to your control set point Peristaltic Pump and Tubing The pu...

Страница 210: ...ntinuity Overloads Not all of them are re set Probe Dirty clean Set point Too high set below readout level Pump motor Defective replace Fig 7 13 Troubleshooting Peristaltic Pump Does Not Pump Problem...

Страница 211: ...al reservoir cover is steel sheet supported by angles welded to the cabinet walls above the wash solution reservoir and below the turntable It funnels all liquid back through an expanded metal screen...

Страница 212: ...panded metal screen or the optional chip baskets becomes clogged the pump s may flood the false floor resulting in cleaning solution or rinse water pouring over the doorframe into the front reservoir...

Страница 213: ...s no longer directly coupled to the pump This option uses a V belt drive to recover the loss in rpm and turn the pump at the same rpm it would turn at 60 Hz The bigger sheave pulley is on the pump mot...

Страница 214: ...ows To verify sheave alignment follow this procedure 1 Remove the belt guard 2 Adjust belt tension 3 Use a level to verify that the motor shaft and the pump shaft are parallel This prevents excessive...

Страница 215: ...system Poor cleaning results or abnormal pump noise duplex pump system Problem 50 Hz electrical power Squealing sounds from pump area Check This Probable Cause s Belt s Slippage tighten Worn and fray...

Страница 216: ...lectrical power Poor cleaning results or abnormal pump noise duplex pump system Check This Probable Cause s Main pump belt s Broken replace Booster pump belt s Broken replace Fig 7 18 Troubleshooting...

Страница 217: ...filter housing affecting pump pressure and flow rate 7 1 Theory of Operation The two filter types are Bag Cartridge Filter Types Bag filters are generally recommended for 50 100 microns although they...

Страница 218: ...arisons NOTE The lower limit of visibility to the naked human eye is 40 microns Filtering System Configurations There are two filtering system configurations The following diagram shows solution flow...

Страница 219: ...standard 5 hour timer is numbered 1 10 each number represents a 1 2 hour increment The timer controls the length of time the filter pump operates in auto mode if you set the selector switch to auto i...

Страница 220: ...l pressure differential gauge replace the filter when the pressure differential has increased by 10 PSI 142 kg cm2 or more 7 5 Troubleshooting This section contains tables on the following problems Wa...

Страница 221: ...ed on the washer cabinet or in another more convenient location If the unit is remote mounted the power lines run from the washer s control panel to the Frequency Drive and then to the pump motor Refe...

Страница 222: ...ure and flow The following figure shows frequency drive results One benefit of reduced pressure is the ability to clean delicate parts 0 10 20 30 40 50 60 70 80 90 100 Pressure or Flow 0 10 20 30 40 5...

Страница 223: ...g This section contains tables on the following problems Pump motor does not run Problem Pump motor does not run Check This Probable Cause s Power Not ON Frequency drive LED power indicator not lit ch...

Страница 224: ...e the washer cabinet by the fan and blown through the electric heating coils The air picks up heat as it passes around the heating coils Finally the heated air is accelerated to high velocity as it tr...

Страница 225: ...g system works in conjunction with a high level shutdown system to de activate the HABO system if the heating element should overheat Refer to section Troubleshooting 9 2 Installation If you have a HA...

Страница 226: ...aulk Tip Seal all joints with a 100 pure silicone caulking compound to prevent dripping and leaking from the steam in the exhaust Tip If at all possible install the ASE fan outside to eliminate many o...

Страница 227: ...7 48 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 24 HABO ASE Fan Installation...

Страница 228: ...ocouples and the heating element is shipped installed on smaller washers You must install the outside plenum on larger washers To install the outside plenum on larger washers follow this procedure 1 T...

Страница 229: ...7 50 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 26 Hot Air Blow Off HABO Inside Plenum...

Страница 230: ...r is located inside the electrical control panel WARNING Do NOT set the HABO temperature controller above a maximum set point of 200 F 93 C Exceeding 200 F 93 C may burn out the electric element or tr...

Страница 231: ...exhaust wastes energy and raises operating costs Initially set the ASE speed control to the lowest setting that will satisfactorily keep steam in the washer during operation If this setting does not...

Страница 232: ...gins to overheat Check This Probable Cause s Fan Not activating check HABO selector switch fuses Fan motor Burned out Blown fuse Fuses Blown pull out of electrical control panel to check and Be sure t...

Страница 233: ...g jib boom about a column located in the rear center of the washer A roller on the jib boom rides on a support over the top of the doorframe Stops at each end of the support limit the arc travel of th...

Страница 234: ...urntable Power Washer v 4 0 The MART Corporation 6 Mount the center brace on the column and the boom track 7 Bolt the center brace to the column and the beam 8 Tighten the boom track bolts Fig 7 28 Ji...

Страница 235: ...in the angle 10 Fit the bronze washer onto the top of the boom shaft 11 Fit the top support angle onto the shaft and the washer Verify that there is a bronze bushing in the angle 12 Bolt the angle to...

Страница 236: ...ORE using the Jib Crane DO NOT OPERATE the Jib Crane if you have not anchored the washer to the floor the washer could tip over and severely injure or kill the operator WARNING Be sure the washer rese...

Страница 237: ...part To unload a part from the washer using the Jib Crane follow this procedure 1 Pull the door open slowly until it locks in the first position 90 angle from cabinet frame 2 Use the jog button locate...

Страница 238: ...nd parts for tightness Check the jib boom wheel located at the top front of the cabinet above the door to be sure that the shaft pin is actually all the way through the wheel and held in place by the...

Страница 239: ...the side of the power washer cabinet Refer to the following figure Skimmer Assembly The skimmer is electrically connected to the washer by a standard 120V 3 prong grounded plug It is operated by a sin...

Страница 240: ...ol panel to one of the following Manual Activates the skimmer It will run continuously Off Turns the skimmer off Auto Automatically activates and runs the skimmer according to the program set for circ...

Страница 241: ...move the skimmer assembly and box cover to clean sludge out of the box Refer to chapter Maintenance for more information on sludge clean out 11 5 Troubleshooting This section contains tables on the fo...

Страница 242: ...the cabinet can be adjusted to regulate the general range of opening and closing speed You can fine tune your control of the speed at which the door opens and closes by raising and lowering the posit...

Страница 243: ...switch located on the front of the door 2 Unlatch the door if it is latched 3 Lift and hold the position lock handle up to keep the power assist activated 4 Release the handle to stop the power assis...

Страница 244: ...ur vendor supplied cutsheet for instructions 12 5 Troubleshooting This section contains tables on the following problems Power assist does not activate Problem Power assist does not activate Check Thi...

Страница 245: ...sure remains exactly as adjusted NOTE When the control valve is fully closed the water line still carries the minimum water flow necessary to avoid damage to the pump A coupling welded into piping bet...

Страница 246: ...re 1 Unscrew the diaphragm seal and gauge together 2 Clean the gauge pipe out 3 If the problem persists replace the gauge and diaphragm seal assembly 13 5 Troubleshooting This section contains tables...

Страница 247: ...out The pressure gauge assembly includes a diaphragm seal that prevents solution from entering the gauge Pressure on the diaphragm is transmitted through the glycerin inside the gauge to the reading...

Страница 248: ...eal assembly 14 5 Troubleshooting This section contains tables on the following problems Pump pressure gauge does not work Problem Pump pressure gauge does not work Check This Probable Cause s Gauge p...

Страница 249: ...ecuring Parts for information on using securing devices 15 1 Theory of Operation The rack and fixture set and small parts basket are optionally available from MART Refer to the following two figures Y...

Страница 250: ...Options 7 71 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 7 36 Rack and Fixture Set...

Страница 251: ...p of the centering vertical post facing the center of the turntable 4 Load the part vertically inside the head rack or fixture 5 Attach securing devices as described in chapter Basic Operations Loadin...

Страница 252: ...tion Fig 7 37 Small Parts Basket 15 4 Maintenance Clean racks fixtures and baskets as required 15 5 Troubleshooting If you properly secure all parts using racks fixtures small parts baskets and approp...

Страница 253: ...turntable or the Power Blast Manifold PBM swivel bearings It improves accessibility reducing maintenance time This option is available for any bearing in the washer 16 2 Installation The optional Rem...

Страница 254: ...ed nozzle Since water from spray is normally returned to the water reservoir a solenoid valve connected to the solution level control system disallows spray wand use whenever the solution level is at...

Страница 255: ...r is not heated It will not flash dry as quickly as rinse water in the washer Wand water returns to the reservoir and uses part of the rinse bank rinse bank is the available volume for rinse water The...

Страница 256: ...g This section contains tables on the following problems No hand rinse Problem No hand rinse Check This Probable Cause s Light on control panel Solution level at HIGH HIGH maximum mark Solenoid Failed...

Страница 257: ...ervoir Part of the assembly extends as a chute behind the washer at a 45 degree angle When the Sludge Scraper is operating angle scrapers move across the bottom of the reservoir collecting sludge and...

Страница 258: ...Options 7 79 Standard Turntable Power Washer v 4 0 The MART Corporation Fig 7 39 Sludge Scraper External View 18 2 Installation The Sludge Scraper is factory installed...

Страница 259: ...The timer controls the length of time the scraper operates in auto mode if you set the selector switch to auto in the following step 2 Set the scraper s selector switch located on the washer s contro...

Страница 260: ...ive sprocket moves back and up Adjust both sides of the chain Adjust the drive chain from the motor to the torque limiter by sliding the motor Follow the manufacturer s recommendations for adjusting t...

Страница 261: ...7 82 Installation Operations and Maintenance Manual The MART Corporation Standard Turntable Power Washer v 4 0 Fig 7 40 Sludge Scraper Diagram of Parts...

Страница 262: ...e Check This Probable Cause s Chain Caught on something Use reverse jog Broken Drive sprocket too loose adjust tension tighten Sprockets Chain is not on sprockets Torque limiter Not adjusted correctly...

Страница 263: ...zzles so that the nozzles in the SHIM are packed more tightly together The nozzles in the standard Manifold have a 25 degree blast pattern while the SHIM has narrower15 degree pattern nozzles thus mor...

Страница 264: ...nce Lubricate Fold down Arm Swivel every 8 hours of operation or as required Replace worn nozzles in both manifolds as required to prevent overloading of pumping system SHIM Selector Valve Upper SHIM...

Страница 265: ...d manuals or cut sheets for instructions on correcting problems This section contains tables on the following problems PBM not oscillating Problem PBM not oscillating Check This Probable Cause s Linka...

Страница 266: ...g power washer 2 13 APE Timer 1 22 cycling test in power up 2 45 startup 1 23 Applications cleaning 1 9 Aqueous Alkaline Cleaner 1 8 ARC and ASE 4 19 overview 1 15 ASE and ARC 4 19 blower motor 1 22 m...

Страница 267: ...th chemical 4 9 Chemical charging power washer 4 9 cleaning results 1 8 concentration 4 5 and foaming 4 7 and supersaturation 4 8 maintenance 5 21 conductivity test 4 6 corrosion prevention 4 3 genera...

Страница 268: ...2 45 D Devices securing parts 3 9 Diaphragm Seal pump pressure gauge assembly 7 66 7 68 Documentation unpacking 2 9 Door closing 3 10 latch 3 7 3 10 3 13 limit switch problems 6 15 locking 3 10 openi...

Страница 269: ...on monoxide 2 31 configurations 2 31 connection 2 31 construction of 2 31 oxygen 2 31 placement planning 2 2 roof clearance 2 2 termination location 2 32 Foaming chemical 4 7 problems 6 12 troubleshoo...

Страница 270: ...on connections 2 34 electrical connections 2 36 power washer 1 24 J Jib Crane maintenance bronze washer 7 59 yearly inspection list 7 59 option 7 54 Jog button 3 13 L Latch door 3 7 3 10 3 13 Leveling...

Страница 271: ...Controls power washer 1 20 Options 50 hertz electrical power 7 34 7 day dual circuit clock 4 18 and 7 day clock 4 18 automatic turntable swivel bearings lubrication 7 3 center manifold 7 18 chemical c...

Страница 272: ...rol components 1 21 operator controls 1 20 placement 2 8 power up installation 2 37 sequence of operation 1 22 starting 3 12 startup procedure 2 35 unpacking 2 9 verifying correct function 3 12 Power...

Страница 273: ...3 13 parts 3 9 parts with fixtures 3 9 Sequence of Operation power washer 1 22 Sequestrant 1 9 Service Access placement planning 2 2 Service Schedule 5 3 and monitoring 4 21 Services By Others SBO ins...

Страница 274: ...for operations 3 5 cleaning results 1 8 controller 4 10 4 12 guidelines 4 11 power up procedure 2 45 verifying wash t 3 10 Time actual wash time 3 11 cleaning results 1 10 Timer ape single pump 1 22 1...

Страница 275: ...ntenance 5 10 problems 6 5 troubleshooting 6 5 Wash Pump Intake Filter maintenance 5 4 Wash Pump Motor maintenance 5 10 Wash Rinse Relay 1 22 Wash Cycle Timer setting 3 11 Wash Delay Timer 1 22 startu...

Страница 276: ...t morning You want to turn ON an output at 10 00 on Monday and turn it OFF at 17 00 on Friday Multiple day operation is recommended You want the Time Switch to turn outputs ON OFF at the same interval...

Страница 277: ...rcuit number indicators FROM TO indicators COPY indicator HOLIDAY indicator AM PM indicator Summer time DST indicator Main display Pulse width unit indicator Total value alarm indicator Sub display AM...

Страница 278: ...lue Pressing decrements the value of the Key that was last pressed Note On first power up or after a reset Section 8 the time adjustment display appears on the screen Adjust the time by following the...

Страница 279: ...o confirm the settings P1 P2 RUN SUN MON TUE WED THU FRI SAT 8 30 17 15 8 30 17 15 8 30 17 15 8 30 17 15 8 30 17 15 Number of remaining steps The color indicates flashing SUN MON TUE WED THU FRI SAT S...

Страница 280: ...y pressing in program setting mode When the Mode Switch is set to P1 or P2 to PRGM for 4 channel type the Time Switch stop automatic operation To forcibly turn ON or OFF the output use the OUT ON OFF...

Страница 281: ...on the bar at the Friday position Set the OFF time with and 2 MON MON FRI SUN MON TUE WED THU FRI SAT The color indicates flashing Set the Mode Switch to P1 or P2 1 See Section 4 5 for 4 channel type...

Страница 282: ...THU FRI SAT P1 P2 RUN PULSE TIMER The color indicates flashing SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT h m Press Press to turn off the bar at the Monday po...

Страница 283: ...g SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT SUN MON TUE WED THU FRI SAT Set the Mode Switch to P1 or P2 1 See Section 4 5 for 4 channel type P1 P2 RUN PULSE TIMER Press the DAY Keys to t...

Страница 284: ...d by pressing in program setting mode When the Mode Switch is set to P1 or P2 to PRGM for 4 channel type the Time Switch stops automatic operation To forcibly turn ON or OFF the output use the OUT ON...

Страница 285: ...ircuit 1 or circuit 2 ON for 5 minutes and OFF for 1 hour 55 minutes repeatedly from 8 00 to 19 00 on Sunday Press to turn on the bar at the Sunday position Set the start time to 8 00 with and 2 4 4 C...

Страница 286: ...ons in individual circuits The set data will be cleared if the OUTPUT setting switch is moved between the TIMER and PULSE positions after the data has been set SUN MON TUE WED THU FRI SAT SUN MON TUE...

Страница 287: ...ncelled Each operation clears the following combination of settings Timer operation weekly Both the ON OFF times Pulse output operation weekly Both the ON time and pulse width Cyclic operation weekly...

Страница 288: ...mode holiday settings or day override settings cannot be cleared in the same manner Yearly programs are also cleared with the yearly types The color indicates flashing SUN MON TUE WED THU FRI SAT Set...

Страница 289: ...s not turned ON or OFF according to displays in program check mode but according to settings and the current time Program check mode can be entered from run mode only Holiday settings Section 5 1 day...

Страница 290: ...omatically returns to run mode Note This mode can be entered from run mode only Output is not turned ON or OFF according to displays but according to settings and the current time Holiday settings Sec...

Страница 291: ...le in run mode only If summer time adjustment Section 6 6 6 is set to automatic for the yearly types manual adjustment is disabled The settings are not changed by summer time adjustment 5 5 SummerTime...

Страница 292: ...y 4 chnls 5 7 Display Switching Current time Current month and day Factory setting Current time Next operation Total time hour Total count cnt Weekly 2 chnls Yearly 2 chnls Yearly 4 chnls 5 7 Display...

Страница 293: ...Key for 1 s or more Except for slide switches and DIP switches A next operation is not displayed during the power off Override and automatic return operation is not available Weekly 2 chnls Yearly 2 c...

Страница 294: ...de and automatic return operation Isn t the Time Switch set for day override operation Weekly type only Isn t the Time Switch set for yearly operation Yearly types only Are banks weekly type only or s...

Страница 295: ...MART REVISION 06 06 06 Revision 03 OWNER S MANUAL for MART VERTICAL POWER WASHER PUMP...

Страница 296: ...mp 3 C Stopping the Pump 4 VI MAINTENANCE 4 A Backhead 4 B Bearing Temperature 4 C Bearing Lubrication 4 VII TROUBLESHOOTING 4 VIII DISASSEMBLY AND REASSEMBLY 6 A Disassembly 6 B Parts Inspection 8 C...

Страница 297: ...ber on the lines below Pump Serial Number ___________________________________ Model Number ________________________________________ D SAFETY PRECAUTIONS This manual contains descriptions and instructi...

Страница 298: ...y depending on climatic environment length of storage and equipment For storage periods of three months or longer contact a representative from Carver Pump Company for specific instructions Improper s...

Страница 299: ...pecially the following instructions 2 Before starting the pump rotate shaft by hand to assure all moving parts are free 3 Before starting the pump install closed guards around all exposed rotating par...

Страница 300: ...bearings C BEARING LUBRICATION Lubrication frequency depends on operating conditions Normal duty calls for relubrication every 1000 hours of operation Bearings are lubricated at Carver Pump Company wi...

Страница 301: ...Check inspect replace 10 Worn swivel joint 10 Check inspect replace Pump surges 1 Liquid level in tank too low 1 Add liquid to system 2 Solution is too hot 2 Lower solution temperature 3 Solution is t...

Страница 302: ...screen or reduce operating temperature if problem persists disassemble pump and inspect Rapid wear of coupling spider 1 Misalignment 1 Align pump and motor as outlined in section IV Alignment 2 Bent s...

Страница 303: ...1 from casing 2 and inserting lifting eyes into pipe plug holes 12 Remove capscrews 10 and washers 38 securing backhead 6 to casing 2 Remove casing 2 from pumping unit 13 Remove capscrews 35 and washe...

Страница 304: ...meter of impeller 1 wear surface exceeds double the maximum clearances given in Table 2 replace suction head 3 and impeller 1 5 On bearing column 30 measure the inside diameter at the lower bearing G3...

Страница 305: ...pe wrench or try to jam the impeller with a screw driver while tightening Holding the impeller by the vanes may break it NOTE Use Loctite 262 Red when installing capscrew 15 Install new suction head g...

Страница 306: ...me type is on your pump There are two frames for MART pumping systems 12V or 1530 Use one of the ways below to determine which pump frame type you have 1 Count the bolt holes on the upper pump frame b...

Страница 307: ...Page 18 For 1530 See Page 20 for 12V Main Pump See Page 12 for 1530 with Hardened Steel Bushing See Page 14 for 1530 with Composite Bushing See Page 16 for 12V Main Pump See Page 12 for 1530 with Hard...

Страница 308: ...12 Fig 1 Main Pump Cut Away 1530 Frame Hardened Steel Throttle Bushing...

Страница 309: ...column base 60 Baseplate 61 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor i...

Страница 310: ...14 Fig 2 Main Pump Cut Away 1530 Frame Composite Throttle Bushing...

Страница 311: ...Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor intermediate 70 72556 71919 Coupli...

Страница 312: ...16 Fig 3 Main Pump Cut Away 12V Frame Composite Throttle Bushing...

Страница 313: ...r column base 42 Lockwasher column base 60 Baseplate 61 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermedi...

Страница 314: ...18 Fig 4 Boost Pump Cut Away 1530 Frame Composite Throttle Bushing...

Страница 315: ...1 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor intermediate 70 72555 Coupl...

Страница 316: ...20 Fig 4 Boost Pump Cut Away 12V Frame Composite Throttle Bushing...

Страница 317: ...n base 60 Baseplate 61 52395 Intermediate 15HP 20HP 52390 Intermediate 30HP 52392 Intermediate 40HP 50HP 63 Hex head bolt frame intermediate 64 Hex nut frame intermediate 65 Hex head bolt motor interm...

Страница 318: ...Washer Torque Capscrew turn FIGURE 1 IMPELLER CAP SCREW TORQUE METHOD Follow these instructions for installation of the impeller cap screw 1 Install the flange head capscrew with washer into the shaft...

Страница 319: ...1530 12V 30281 C Kit Main Pump 15 50 hp Oil Seal 1 Oil Seal 2 Radial Bearing 1 Thrust Bearing 1 Bearing Locking Nut 1 1530 51173 12V 30310 Main Pump 20 50 hp Stainless Steel Sleeve Shaft 1530 53203 15...

Страница 320: ...otor Couplings for 1530 Frame with Leeson Motor Assy Pump Coupling 15 20hp 1 Coupling 1 3 8 1 Coupling 1 5 8 1 Insert 72555 Assy Pump Coupling 30hp Simplex 1 Coupling 1 3 8 1 Coupling 1 5 8 1 Insert 1...

Страница 321: ...p Motor Couplings for 12V Frame with US Motor Assy Pump Coupling 15 20hp 1 Coupling 1 7 16 1 Coupling 1 5 8 1 Insert 71934 Assy Pump Coupling 30 40 50 hp 1 Coupling 1 7 16 1 Coupling 1 7 8 1 Insert 1...

Страница 322: ...26 2450 Adie Road Suite 100 Maryland Heights MO 63043 Tele 1 800 543 6278 Fax 314 567 6318 Website www marttechservices com Copyright 2005 Arcus Corporation All Rights Reserved Made in the USA...

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