Operation Manual 322 KL 8/07 von Oertzen GmbH Ferdinand-Harten-Str. 10 22949 Ammersbek Tel. +49 40 604110 Fax +49 40 6041149 www.oertzen-gmbh.de info@oertzen-gmbh.de
Table of Content 1. Introduction Page 3 2. Safety Instructions Page 4-5 3. Design/Configuration/Illustration Page 6-7 4. Start-up/Shut-down Page 8-11 5. Maintenance & Care Page 12-13 6. Electric Wiring Diagram Page 14 7. Technical Data Page 14 8. Trouble Shooting Page 15 9. Declaration of Conformity Page 16 322KL-08/07-ag 2
1. Introduction By buying this OERTZEN high pressure cleaner, you have obtained a most capable machine suitable to perfectly meet your cleaning tasks. All OERTZEN machines and accessories conform to the National and European Safety Regulations. The CE label guarantees for fulfilment of all relevant National and European Safety Regulations (EN). A CE Declaration of Conformity is attached to this manual. This operation manual to be made available to operating personnel and to be read completely before start-up. We clearly point out that we cannot be held responsible for any malfunction or damage resulting from disregarding. According to safety regulations the high pressure cleaner to pass an annual test in order to guarantee safe operation. Test results to be recorded and made available to authorities on their request. Packing materials (e.g. foil, wood, cardboard, nails) might lead to possible dangers and is therefore to be kept away from children and to be dumped as per safety regulations. This warning symbol appears in the operating manual at all operating safety instructions dealing with danger for personal entirety and life (DIN 4844). This warning symbol appears in the operating manual at all operating safety instructions dealing with danger due to electric power. This warning symbol appears in the operating manual at all operating and safety instructions dealing with the fulfilment of rules, regulations and instructions for the proper operation and to avoid damages or destroying of the machine. This operation manual is subject to technical alteration. All rights reserved. Any use in other than legally authorised cases requires the prior written approval of von Oertzen GmbH. 3
2. Safety Instructions The following instructions to be followed before, during and after work: This operation manual to be read before start-up. When strictly following the instructions, no danger should occur. This machine must only be operated by qualified persons who are fully familiar with the operation and possible danger. The operating instructions laid down in the Regulations for liquid blasters (ZH 1/406) as well as Working with liquid blasters strictly to be followed. The machine is not suitable for unattended operation and must only be run according to instructions laid down in this manual. During working protective clothing to be worn. The water stream leaving the spray pistol at high speed has a rather dangerous cutting effect. So, never direct the water stream onto persons or animals, nor direct it onto electrical units. When starting the machine, be aware of torque and recoil. Ensure of stable foothold. The max. pressure stated on the nameplate must not be exceeded. The safety valve opens as soon as the max. operating pressure is exceeded by 10 %. The safety/control valve is workshop adjusted and sealed. The adjustment must not be changed. Unsuitable or defective high pressure hoses very often cause accidents during operation of high pressure cleaners. Therefore, check the hoses for damages before any start-up. Defective hoses immediately to be replaced by original OERTZEN equipment. Using other materials than original OERTZEN equipment (hand nut respectively hose marked with OERTZEN ) or using materials which have not expressively been approved by OERTZEN in writing ceases warranty and product liability. Worn out high pressure hoses must never be repaired and re-used but must be replaced by new original OERTZEN equipment. Spray pistols with delayed closing mechanism must not be used, due to danger of injuries. Lever in open position must not be blocked or fixed in any other way. Use of spray wands of a length below 750 mm is prohibited. The unit must not be placed or operated in areas jeopardised by fire or explosions. During working at fuel stations the Technical Rules for flammable Liquids (TfbF) to be considered. 4
Consumables to be handled thoroughly. Technical safety regulations and environmental rules to be followed. Make sure that power cable, plug connections switches are in proper condition, otherwise the machine must not be started. Extension cables to have a diameter according to VDE regulations. Extension cables on reels to be reeled off completely, in order to avoid overheating of the cable reel. Plugs, couplings to be water-proof. A faulty current protection switch is recommended. Electric power can cause severe injuries. Electric components thoroughly and frequently to be checked for damages and malfunctions, in order to avoid any cause for accidents. All repair work to be carried out by qualified personnel. Disconnect the unit from the electrical network during all repair/maintenance work. (ZH 1/95). Ensure that the unit cannot move. The unit is equipped with a brake which must be activated during working in steep areas. Repair work within the high pressure section of the machine (pump, hoses, piping) only to be carried out by qualified personnel. During loading suitable lifting eyes to be foreseen. Balanced load to be ensured. After work spray pistol to be locked by means of the safety lever in order to avoid unauthorised/accidental operation. Using other materials than original OERTZEN equipment or using materials which have not expressively been approved by OERTZEN in writing ceases EC conformity, warranty and product liability. 5
3. Design/Configuration/Illustration The cold water cleaners of this series mainly comprise a low speed high pressure inline plunger pump which is directly flanged to and driven by a high performance electric motor. The feed water is directed via a filter to the high pressure pump which, together with the diameter of the determined spray nozzle, boosts it to the required working pressure. Downstreams of the high pressure pump a sealed safety/control valve is installed which opens as soon as the max. operating pressure is exceeded by 10 % and returns the water which cannot be taken by the nozzle to the suction line of the pump. A hose reel which is incorporated in the system allows easy rolling off and up of the high pressure hose. The double lance allows continuous pressure regulation and detergent injection in low pressure mode, if required. The double lance can easily be changed against the Vario lance with Vario spray head, which provides the opportunity to work with intensive point jet or abrasive turbo jet alternatively. The machine is equipped with a START/STOP TIMER. When closing the spray pistol the machine keeps on running in circulation mode for approx. 20 seconds value workshop set (stand-by mode) and is then switched off. When releasing the spray pistol again, the machine restarts and pressure is generated immediately so that work can be continued without delay. A wide range of accessories which allow to increase the efficiency of the machine is available. Contact OERTZEN or your local dealer for details. 6
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4. Start-up/Shut-down Before Start-up Read operation manual and follow instructions. In order to guarantee proper condition of the machine and trouble-free operation, carry out the following checks before start-up: General condition of the unit (connections, seals, etc.) Power cables/connections Check all hoses for damage Air supply to be ensured Fill in all consumables required Check correct oil level of high pressure pump (dip stick), only oil qualities approved by OERTZEN to be used (OERTZEN OSP special pump oil). Check high pressure pump/pump connections for leaks Machine only to be run with absolutely clean water. Thoroughly flush water supply hose before connection. Depending on water quality, filter to be checked in regular short intervals and replaced whenever needed. Machine to be run horizontally (+/- 5 ) In order to guarantee proper condition of the machine and trouble-free operation, carry out the following checks during operation: Observe control indications/devices whether functioning Observe pressure whether varying Observe high pressure pump, hoses, connections whether leaking Observe unnormal noise In case of malfunctions switch off machine immediately, eliminate cause according to chapter "Trouble Shooting", call qualified service. Connections Water Connection Water inlet (6) of the unit to be connected to the water distribution network by means of an internally clean, min. water hose (diameter: see table below). For connections to the potable water distribution network DIN 1988 to be considered (for short-time connection a back-flow preventer with non-return protection and ventilation to be used). Flow Pressure Flow Rate minimum * minimum: 2 bar maximum: 8 bar 15 l/min. " supply hose * see Technical Data Water shortage may cause severe damages on the pump unit (cavitation). 8
Electric Connection Connect the unit to a 400 V power source which is protected by 3 x 16 A (slow). Extension cables to have a diameter according to VDE regulations. Extension cables on reels to be reeled off completely, in order to avoid overheating of the cable reel. Plugs, couplings to be water-proof. A faulty current protection switch is recommended. VDE regulations apply. Spray Lances Required spray lance to be connected to the machine by means of the hand nut on the spray pistol without using tools. Detergent Tank Filling Fill detergent tank (17) with non-hazardous detergent. When using powders, these have to be mixed in a separate tank before being filled into the detergent tank of the machine. Operation Important Notes Model 322 KL is equipped with a START/STOP TIMER which stops the machine after the workshop-set time sequence has passed. As soon as the spray pistol is released again, the machine is restarted. The machine always to be switched off by means of the rotary multi-functional control knob ON/OFF/detergent mode (2) after completion of work, de-pressurise the spray device. If detergents to be injected, turn rotary control knob continuously clockwise, until required detergent concentration is achieved. Machine is equipped with thermal overload protection; if activated, cool down and re-start machine. Operation Open water source. Unreel high pressure hose completely. Unlock and release spray pistol, bleed the unit. Start the unit by means of the multi-functional control knob (2). Be aware of recoil / ensure stable foothold. Carry out cleaning task. 9
Pressure Adjustment The working pressure can be continuously be adjusted by opening/closing the rotary handle at the double lance. Counter-clockwise rotation: Clockwise rotation: pressure decrease pressure increase Pressure/Flow Adjustment Pressure and water flow can be adjusted as required by mans of the rotary knob on the safety/control valve (3). Counter-clockwise rotation: Clockwise rotation: continuous pressure and flow reduction continuous pressure and flow increase up to maximum Detergent Dosing Only detergents approved by OERTZEN to be used. Use of hazardous detergents or detergents not approved by OERTZEN ceases warranty and product liability. Open the detergent dosing valve. Turn rotary handle on the double lance counter-clockwise. Detergent is drawn in in low pressure mode and applied it onto the surface of the cleaning object. Detergent to work in, but must not dry. By turning the rotary handle of the double lance clockwise detergent dosing is stopped. Cleaning object can be washed with high pressure beam. After use of detergents, operate the machine with clean water for a couple of minutes, in order to completely flush all detergent residues out of the system. Vario Lance to remove heavy dirt layers Loosen hand nut on spray pistol and connect Vario lance hand-tight. Counter-clockwise rotation: Clockwise rotation: intensive point jet abrasive turbo jet 10
After Completion of Work The unit to be switched off by means of the multi-functional control knob (2). De-pressurise the spray pistol by shortly opening and closing. Lock spray pistol. Disconnect the unit from the water and power sources. Reel off high pressure hose and thoroughly clean it. In case of damage replace it for safety reasons. Using other materials than original OERTZEN equipment (hand nut respectively hose marked with OERTZEN ) or using materials which have not expressively been approved by OERTZEN in writing ceases warranty and product liability. Reel up high pressure hose properly, without loops. Store equipment in a dry, frost-protected area. In case of extended shut-down periods drain pump completely. Particularly Note In case of malfunctions switch off machine immediately, eliminate cause according to chapter "Trouble Shooting", call qualified service. If frost is likely, frost protection of the machine is a must, as otherwise severe damage could occur. 11
5. Maintenance and Care Every Machine is only as reliable as maintenance is carried out. According to safety regulations the high pressure cleaner to pass an annual test in order to guarantee safe operation. Test results to be recorded and made available to authorities on their request. Moreover, it is of vital interest to carry out the following maintenance work in shorter than then normal maintenance intervals: Disregarding maintenance work/intervals ceases warranty. High Pressure Pump First oil change after 50 operating hours. Further oil changes every 500 operating hours or min. once a year in connection with maintenance carried out by authorised OERTZEN service personnel. In case the pump oil is becoming turbid, initiate oil change. In case oil is becoming turbid again or is being lost, call qualified service. Only OERTZEN OSP special pump oil to be used. Use of oil qualities not approved by OERTZEN ceases warranty. 12
Strainer A strainer (6) is installed at the water inlet of the machine which must be checked and cleaned, respectively replaced whenever needed. Severe damage on pump set and control units can be caused by running the machine with polluted feed water and/or clogged strainer. Frost Protection Frost-protection of the machine is of vital interest, as frost can cause severe damage on the entire system. The best frost protection is to store the machine/accessories in a permanently frost-protected area. If there is a risk of temperatures below freezing point during storage and/or transportation, the machine to be frost-protected as follows: 2 l of a 1 : 1 water/anti-freeze liquid (e.g. Glysantin) to be mixed in a clean vessel. Put water supply hose into the vessel and start the high pressure pump. Spray pistol/stop valve to be opened in order to circulate the anti-freeze liquid. Spray pistol/stop valve to be opened and closed several times in order to also fill safety/control valve with anti-freeze liquied. Stop high pressure pump and disconnect all hoses. Machine is now protected against temperatures of 30 C. Disregarding of frost-protection instructions can cause severe damage on the entire system. Anti-freeze liquid to be collected for re-use, respectively to be dumped properly according to safety regulations. 13
6. Electric Wiring Diagram 7. Technical Data Technical Data 322 KL Flow rate/adjustable 960 l/h Unloading pressure 210 bar Max. working pressure 190 bar Max. recoil 49 N Max. water temperature 50 C Electric current 3~400 V/50 Hz Fuse (slow) 3 x 16 A Power consumption 5,1 kw Shut-off system start-stop timer Detergent tank volume 15 l Spray nozzle 25045 Noise pressure/power level Lp/Lw 77/92 db(a) acc. to DIN EN ISO 3744 Dimensions (L x W x H) 750 x 480 x 880 mm Weight 75 kg Order No. 10.000.140 14
8. Trouble Shooting Electric power can cause severe injuries. Defective electrical components to be immediately replaced, possible causes for accidents to be eliminated without delay. Any repair work must only be carried out by qualified service personnel. Only original equipment expressively approved by the manufacturer to be installed, as otherwise warranty and Declaration of Conformity will cease, health and safety standards are not guaranteed. During repair or maintenance work, unit to be disconnected from electrical network. Malfunction Cause Remedy Electric motor does not start. - Machine not connected to power source. - Multi-functional control knob not in position "ON". - Fuse burnt. Electric motor suddenly stops, motor protection switch trips. Electric motor noisy upon start-up. Operating pressure not achieved/varies Vibrations on high pressure hose and spray pistol No detergent supply - Phase missing. - Motor protection switch defective. - Fuse burnt. (phase missing). - Low voltage/thermal overload. - Motor protection switch defective. - Operating pressure high. - Fuse burnt. (phase missing). - Fault in electrical network - Air in unit - Poor water supply. - Nozzle worn. - Incorrect nozzle. - Nozzle partly clogged. - Water filter dirty. - Unloader valve leaking - Suction valves sticking/dirty. - Connect machine to power source, switch on main switch. - Turn into position "ON". - Replace fuse. If it burns again, call qualified service. - Phase to be mounted as per electric wiring diagram. - Call qualified service. - Replace fuse. If it burns again or motor is noisy, call qualified service. - Ensure correct power supply, cool down/re-start machine. - Call qualified service. - Clean/replace nozzle (see Technical Data). - Replace fuse. If it burns again, call qualified service. - Check phases in electric plug. - Bleed unit. Open pressure regulating handle and pistol, until continuous pressure is reached. - Water supply hose diameter too small. (see table page 8). - Replace nozzle. - Install correct nozzle. - Remove/clean/re-install nozzle. - Clean water filter. - Call qualified service. - Remove/clean/re-install valves. - Air in unit - Bleed unit. Open pressure regulating handle and pistol, until continuous pressure is reached. - Detergent tank empty. - Regulation handle closed. - Low pressure nozzle clogged. - Non-return valve blocked. - Refill tank. - Open handle. - Remove/clean nozzle. - Blow through detergent hose with compressed air 15
von OERTZEN GmbH Ferd.-Harten-Str. 10 D-22949 Ammersbek Tel. (040) 60411-0 Fax (040) 60411 49 Internet: www.oertzen.info 16