To be read completely before start-up! Operating Manual JuniorPower 12/04 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 Contents 1. Introduction page 3 2. Safety Instructions page 4 6 3. Description/Illustrations page 7 10 4. Start-up/Operation/Shut-down page 11 15 5. Maintenance and Care page 16 19 6. Electric Wiring Diagram page 20 7. Technical Data page 20 8. Trouble Shooting page 21 9. Declaration of Conformity page 22 JuniorPower-10/03-AG-VS-12/04 2
1. Introduction The OERTZEN high pressure cleaner model JUNIORPOWER is one of the most durable and reliable machines available on the market. Its balanced ratio of water flow (temperature) and working pressure meets all cleaning requirements. The OERTZEN high pressure cleaners conform to all and European safety regulations which is guaranteed by the CE symbol. This manual to be made available to the operating personnel and to be read completely before start-up. We underline that we cannot be held responsible for any damages or malfunctions as a result of ignoring this manual. OERTZEN offers training courses in order to enable the operating personnel to run the machine in accordance with the instructions laid down in this manual, to carry out all necessary maintenance work described herein and to eliminate minor repair work. This warning symbol appears in this operating manual at all operating and safety instructions dealing with the dangers for personal entirety and life (DIN 4844). 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 manual is subject to alteration. All rights reserved. Any use in other than legally authorised cases requires the prior written approval of ARNDT H. von OERTZEN (GmbH&Co). 3
2. Safety Instructions Before initial start-up this manual to be read completely and thoroughly. If all instructions laid down herein are strictly followed, no danger should occur. The machine must only be run by qualified and skilled personnel. All relevant national safety regulations to be followed. The machine is not suitable for unattended operation. Protective clothes to be worn. The water jet out of the spray pistol has a dangerous cutting effect! Water jet not to be directed onto persons, animals electrical components and must not be used for cleaning of clothes, shoes etc. When starting the machine, be aware of torque and recoil. Ensure secure foothold. Repair and/or maintenance work in the high pressure section (pump, HP-hoses, pipes) must only be carried out by qualified personnel. Before dismantling the machine in case of e.g. malfunctions unit to be stopped by means of the ON/OFF switch and to be disconnected from electric power source. The max. pressure stated on the type label not to be exceeded. The unloader valve opens in case the operating pressure is exceeded by 10 % and directs the water back to the suction side of the pump. The unloader valve is workshop-adjusted and sealed. The adjustment not to be changed. Unsuitable or defective hoses often cause accidents during operation with high pressure units. Defective hoses to be replaced immediately by Original OERTZEN equipment. Use of other hoses than those originally delivered or expressively approved by OERTZEN ceases warranty, product liability and validity of the Declaration of Conformity. Worn-out high pressure hoses must not be repaired and re-used but replaced immediately. Use of other detergents, spare parts and/or materials than those originally delivered or expressively approved by OERTZEN ceases warranty, product liability and validity of the Declaration of Conformity. Spray pistols with delayed closing mechanism are dangerous and must not be used. Lever in open position must not be blocked or fixed in any other way. During working with spray lances shorter than 750 mm particular dangers to be considered. After completion of work spray pistol to be secured against accidental/unauthorised operation by means of the safety lever. The unit must not be run in areas which are jeopardised by fire or explosions. All relevant safety regulations to be followed. 4
Consumables to be handled thoroughly strictly in accordance with relevant technical and environmental safety regulations. Electric power can cause severe injuries. Defective electrical components to be replaced immediately and possible causes for accidents to be eliminated. Repair work to be carried out by qualified personnel. Disconnect the machine from electric power source during repair/maintenance work. Only correctly dimensioned cables according to VDE regulations to be used. Cables on reels to be reeled off totally during operation in order to avoid overheating of the reel. Plugs and couplings to be water-proof. A faulty current protection switch to be foreseen. Machine not to be started in case power cable, plugs, switches, etc. are defective. Machine must not move. It is equipped with a brake which must be activated when working in steep areas. During loading proper hoisting device to be used. Ensure balanced load. When using pipe cleaning hoses observe markings during moving hose in or out (approx. 50 cm). Strictly follow the instructions as per chapter Operation Pipe Cleaning. Exhaust evacuation line gets hot. Do not touch. Indoor operation of oil-heated high pressure units without proper ventilation and exhaust evacuation is forbidden! Exhaust fumes are hazardous! 5
3. Description/Illustrations The hot water model JuniorPower mainly consists of an inline high pressure pump with safety-shut-down system, as well as a high performance, double shell vertical heat exchanger. The inline high pressure pump is directly flanged to the electric motor. It sucks the feed water from an integrated level-controlled storage tank and directs it under high pressure via a safety/control valve into a heating coil which heats up the passing water to operating temperature. The sealed safety/control valve which is arranged between high pressure pump and heating coil opens as soon as the working pressure is exceeded by more than 10 % and returns the water which is not taken by the nozzle to the suction line of the high pressure pump. By activating the burner/temperature adjusting switch the fuel pump sucks fuel oil from the fuel oil storage tank via a filter system and injects it under defined pressure through the oil nozzle into the burner chamber. The blower presses the oxygen which is needed for the combustion process into the burner chamber, where the mixture is atomised and ignited by ignition electrodes which are continuously energised by a high-voltage transformer. The heating flame burns in the burner chamber without touching the shells and without soot formation at high efficiency. Infrared radiation generated by this process and hot exhaust fumes cause an economic heating of the water passing through the heating coil up to the working temperature adjusted on the thermostat. At the high pressure outlet the hot water enters high pressure hose, spray lance and spray nozzle. Working pressure is achieved by the fixed diameter of the spray nozzle and can continuously be adjusted as required by turning the rotary handle at the double lance. The steam mode allows operation with hot water of more than 100 C at reduced flow. If required, a suitable detergent can be sucked from the detergent tank via filter and non-return valve and applied onto the cleaning object by the water jet by opening the detergent dosing valve. In order to protect the machine against formation of scale deposits, it is equipped with an anti-scalant/liquid softening system which continuously doses softening liquid into the water storage tank. This high pressure cleaner is equipped with an automatic start-/stop system. When closing the spray pistol the machine remains in circulation mode for approx. 15 seconds and then switches over into "stand-by mode". In parallel the a safety/control unit interrupts the fuel supply to the burner which is so stopped. When activating the spray pistol again, the machine and burner system start and pressure is generated immediately, so that the cleaning procedure can be continued without delay. The machine can be used more effectively by adding proven accessories. Please contact your OERTZEN dealer for further information. 6
Symbols water inlet fuel oil/diesel electric shock softening liquid earthing detergent burner mode high press. outlet Legend for Illustrations on Page 8 1 Electric motor 13 Oil sight glass 2 ON/OFF switch 16 Detergent dosing valve 3 Safety-/control valve 17 Detergent tank 4 Pressure indicator 19 Fuel tank 6 Water inlet/pre-filter 21 Blower 8 High pressure pump 22 Fuel pump/micro-filter 9 Water storage tank 23 Burner/thermostat switch 11 High pressure water outlet 24 Boiler outlet 12 Oil filling hole/dip stick 28 Liquid softener tank 7
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4. Start-up /Shut-down Before start-up: Before starting an OERTZEN hot water machine, the following to be noted: Proper ventilation and exhaust evacuation to be guaranteed. Due to the electric configuration the correct direction of rotation of the burner motor to be guaranteed. Changes to be carried out by qualified electrical engineers. Operating manual to be read completely, instructions to be followed. Correct oil level of high pressure pump to be checked (sight glass (13) / dip stick (12)) Only oil qualities approved by OERTZEN to be used. Machine only to be run with clean water. Water supply hose to be flushed before connection. Water filter to be checked in short regular intervals. Machine only to be run horizontally (± 5 ). In order to ensure proper condition and trouble-free operation the following checks to be carried out before, during and after work: General condition of the machine (screw fixings, protection caps, etc). Power cable/electric connections. Indicator lamps. Pump/connections leaking? High pressure hoses, supply hoses, etc. damaged? Water supply, water filter. Air supply. Tanks filled? Abnormal noise? The JuniorPower is equipped with an automatic start/stop system with timer-controlled lag. During extended shut-down periods the machine in general to be switched off by means of the ON/OFF switch (2). Spray pistol to be de-pressurised and secured by means of the safety lever. In case of malfunctions machine to be switched off immediately. Eliminate cause according to chapter "Trouble-Shooting", respectively call qualified service. 9
Connections Water Connection Water inlet (6) to be connected to the water source with a clean supply hose (diameter as per table below). Water supply hose to be flushed with clean water before connection. If machine to be connected to the potable water distribution system, a backflow preventer with non-return protection and ventilation to be installed). Water flow pressure Min. flow * Minimum: 2 bar 15 l/min " supply hose Maximum: 8 bar 21 l/min 1" supply hose 30 l/min 1 " supply hose * s. Techn. Data Insufficient water supply will cause severe damage on the high pressure pump (cavitation). Electric Connection Unit to be connected to a 400 V power source, protected by 3 x 16 A fuse (slow). Only correctly dimensioned cables according to DIN to be used. Cables on reels to be reeled off totally during operation in order to avoid overheating of the reel. A faulty current protection switch to be foreseen. VDE regulations to be followed. High Pressure Connection High pressure hose to be connected by means of the hand nut hand tight to the high pressure outlet (11) without using tools. Fuel Tank The fuel tank (19) to be filled with clean fuel oil according to DIN 51603, part 1 or Diesel. Ensure absolute cleanliness during transport and filling. After filling the tank to be closed properly. Softening tank Tank (28) to be filled with OERTZEN softening liquid ORM 30. Machine never to be run with empty tank. After filling tank to be closed properly. Detergent Tank Detergent tank (17) to be to be filled with a detergent approved by OERTZEN. Detergent powders to be diluted in water without lumps before being filled into detergent tank. After filling tank to be closed properly. 10
Operation Open water cock. Unlock and release spray pistol, bleed machine until water emerges without blistering. Turn ON/OFF switch (2) into Pos. I. Adjust burner thermostat (23) to required working temperature. Carry out cleaning job. Be aware of torque and recoil. Be aware of hot exhaust fumes. Steam Mode Turn ON/OFF/burner switch (23 a) to maximum working temperature. Pull steam valve (26) upwards and block it by turn clockwise. Be aware of hot steam emerging from the machine. Pressure Regulation (in general) Pressure can continuously be adjusted as required by turning the rotary handle at the double lance. Counter-clockwise: Clockwise: pressure decrease pressure increase In case machine is being moved while burner is in operation, be aware of hot exhaust fumes emerging from the boiler outlet! 11
Detergent Mode Only approved, harmless detergents to be used. Use of not approved, hazardous detergents ceases warranty obligations. Detergents can be used in cold and hot water mode. Manufacturers instructions to be followed. Adjusting knob on detergent dosing valve (16) to be adjusted to required concentration. Detergent to be applied onto cleaning object from the bottom to the top. Detergent to work in, but must not dry. Turn detergent dosing valve (16) into position 0. Wash cleaning object with high pressure stream from the bottom to the top. Keep a distance of 10 20 cm. Detergent residues to be rinsed properly from the cleaning object. Detergent must not be applied on hot surfaces or in direct sunlight. Detergent must not dry. After completion of work detergent dosing valve to be closed and detergent line to be flushed until no detergent residues can be detected in the water stream. 12
After Work Burner thermostat switch (23) to be turned into Pos. 0. Machine to be run in cold water mode for several minutes. Close spray pistol. Switch of machine by means of the ON/OFF switch (2 in Pos. 0). De-pressurise spray pistol shortly opening and closing. Lock spray pistol. Disconnect machine from power and water source. High pressure hose to be cleaned thoroughly. In case of damages (cracks, kinks, etc.) hose to be replaced by original OERTZEN equipment. Use of other hoses than those originally delivered or expressively approved by OERTZEN ceases warranty, product liability and validity of the Declaration of Conformity. High pressure hose to be reeled up properly. Machine and accessories to be stored in a dry and frost-protected area. In case of extended shut-down periods pump to be drained completely. Note in particular: In case of malfunctions switch off machine immediately. Eliminate cause according to chapter "Trouble-Shooting" respectively call qualified service. During extended working breaks and after completion of work machine to be switched off by means of the ON/OFF switch (2). Frost protection is essential, as otherwise severe damage on the pump may occur. After work protect the spray pistol against accidental/unauthorised use by means of the safety lever. 13
5. Maintenance and Care Every machine is only as reliable as maintenance instructions are followed. The following maintenance work to be carried out in regular intervals: Ignoring the maintenance instructions described below ceases all warranty obligations. High Pressure Pump First oil change to be carried out after 50 operating hours, followed by further oil changes every 500 operating hours. In case the oil is getting milky due to condensation, switch off machine immediately and change oil. In the event of recurrence all seals of the pump to be changed. For OERTZEN high pressure pumps only OERTZEN OSP special pump oil to be used. Use of oil qualities not approved by OERTZEN ceases all warranty obligations. OERTZEN OSP special pump oil can be obtained from your local OERTZEN service point. 14
Water Filter In the water inlet there is a pre-filter (6) arranged which must be checked before start-up and replaced, whenever required. Operation with polluted feed water and/or clogged water filter can cause severe damage on high pressure pump and control elements. Fuel Filter Between fuel pump and fuel tank there is a filter installed, which must be replaced whenever required. Fuel Pump Strainer of the fuel pump (22) to be cleaned or replaced whenever required. Fuel Tank Dirt and water deposits inside the fuel tank (19) to be regularly removed. Boiler Cleaning In case the machine gives off sooty smoke, it must be stopped immediately (danger of explosion). Heating coil and pre-heater to be cleaned whenever required, at least as soon as soot deposits can be detected on the heating coil. Boiler cleaning only to be carried out by qualified personnel. De-Scaling The JuniorPower is equipped with an anti-scalant system which avoids formation of scale deposits to a great extent. In order to guarantee proper functioning of the anti-scalant device the tank to be checked and refilled whenever required. Only OERTZEN ORM 30 softening liquid to be used. In case of high water hardness, at least every 300 operating hours the water-boiler-system to be flushed with an anti-scalant during normal maintenance work. 15
Maintenance Intervals Works to be carried out Pump oil OSP First oil change H.P. pump Further oil changes H.P. pump To be checked/cleaned by operators To be carried out by qualified service personnel, min. every... operating hrs 50 hrs 100 hrs 200 hrs 500 hrs/once per year Water filter Fuel filter Fuel pump (strainer) Fuel tank Boiler Heating coil Water tank Ignition electrodes Burner nozzle Total safety check = replacement = cleaning = to be carried out All maintenance intervals stated apply under the condition that the machine is run with clean water according to instructions. Otherwise shorter intervals are needed Ignoring the maintenance instructions described before ceases all warranty obligations. Therefore, strictly following maintenance instructions is of vital interest. 16
Frost Protection Frost protection is a must, because frost may cause severe damage on the machine and hazardous operation as otherwise heavy damage on the entire water system may be the result. The best frost protection is to store machine and accessories in a frost protected area. Frost protection to be carried out as follows: Machine to be started, spray pistol to be opened, water source to be closed. Wait until pressure drops and stop the machine. Fill approx. 3 l of a commercial frost protection liquid (Glysantin) into the water storage tank. Start the machine, open and close the spray pistol several times until frost protection liquid emerges. Stop the machine. The system is now protected against temperatures of 25 C Ignoring frost protection instructions can cause severe damage on the entire system. 17
6. Electric Wiring Diagram 7. Technical Data Technical Data JuniorPower Flow rate / adjustable 800 l/h Unloading pressure * 180 bar Max. working pressure / adjustable 160 bar Water temperature / adjustable **** 30 140 C Normal current (50 Hz) 3 ~ 400 V Total connected load 5,3 kw Power consumption 8,5 A Heating capacity 40 kw Fuel consumption 3,9 kg/h Spray nozzle 2545 Ssyst. Recoil ** 42 N Noise level Lp *** / Lw *** 75 / 93 db(a) Abmessungen (L x B x H mm) 980 x 670 x 810 Weight 88 kg Order-No. 10.000.012 * Setpoint of unloading control ** Depending on length and angle of spray lance, torque occurs which has to be controlled by a tight grip. *** according to DIN ISO 3744 **** max. 140 C, 32 bar, at fully opened safety/control valve Standard Equipment: 10 m high pressure safety hose, insulated spray pistol, insulated double lance Subject to technical alteration. 18
8. Trouble Shooting Electric power can cause severe injuries. Defective electrical components to be replaced immediately and possible causes for accidents to be eliminated. Repair work to be carried out by qualified personnel. Disconnect the machine from electric power source during repair/maintenance work. Only original OERTZEN spare parts and accessories to be used. Use of other materials ceases all warranty obligations. Malfunction Cause Remedy Machine does not start. - Machine not connected to electric power source. Machine suddenly stops. - Fuse burnt. - Phase missing. - Overload protection activated. - Fuse defective. - Overload protection activated. - Water shortage (control lamps illuminated) - Press motor protection switch. - Insert electric plug, Activate main switch. - Change fuse. - Mount phase according to electric wiring diagram. - Cool down motor. - Change fuse. - Cool down motor. - Ensure water supply, restart machine by means of ON/OFF switch. Electric motor noises during start-up. Working pressure not achieved/varies - Micro leakage. (contr. lamp illuminated) - Low voltage. - Motor protection switch defective. - Operating pressure too high. - Fuse burnt (phase missing). - Fault in electric network - Air in machine - Water shortage - Tighten leakage. - Ensure correct voltage. - Call qualified service. - Clean / replace nozzle (see Technical Data). - Change fuse. - Check. - Bleed machine Open pressure regulation handle/pistol until continuous pressure is achieved. - Diameter of supply hose incorrect. (see table on page 12) - Nozzle worn - Incorrect nozzle - Nozzle clogged - Water filter clogged - Unloader valve leaking - Suction side leaking - Replace nozzle. - Install correct nozzle. - Clean nozzle - Clean filter - Call qualified service - Properly fix hose clamps on suction hose - Clean valves. - Suction valves sticking/dirty. Vibrations on high pressure hose/pistol - Air in machine - Bleed machine Open pressure regulation handle/pistol until continuous pressure is achieved. - Clean water filter. Machine does not start after Total Stop. (control lamp illuminated) No detergent injection Burner does not start. Temperature not achieved. - Total Stop function activated. - Restart according to instructions on page 8 - Detergent tank empty. - Fill tank. - Pressure regulation handle closed. - Open handle. - Detergent dosing valve closed. - Open valve. - Incorrect direction of rotation burner motor - Fuel tank empty. - Thermostat incorrectly adjusted. - Fuel filter clogged - Direction of rotation to be corrected by qualified electrical engineers - Fill tank. - Adjust correctly. - Clean filter. Excessive exhaust formation. - incorrect burning procedure. - Clean fuel filter. - Call qualified service. 19
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