Operation Manual HOT BOX 200 HOT BOX 500

Read Operation Manual completely before initial start-up!

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

2

Table of Content

1. Introduction Page 3 2. Safety Instructions Page 4 - 5 3. Configuration, Mode of Operation Page 6 - 8 4. Start-up/Shut-down Page 9 – 11 5. Maintenance Page 11 – 13 6. Electric Wiring Diagram Page 14 7. Technical Data Page 15 8. Trouble Shooting Page 16 9. Declaration of Conformity Page 17

1. Introduction

3

Buying this OERTZEN accessory, you have obtained one of the most durable and modern machines on the market. It conforms to the National and European Safety Regulations. It must only be used in connection with an OERTZEN hot water high pressure cleaner with the adequate operating parameters. The operating instructions of the relevant high pressure cleaner, especially its safety instructions must be considered. The CE label stands for fulfilment of all relevant National and European Safety Regulations (EN). Important Notes This operation manual should thoroughly and completely be read and considered prior to start-up of the unit. We expressively point out that we cannot be held responsible for any damages and/or malfunctions which may be caused by ignoring this instruction manual. This manual is subject to technical alterations. This manual to be made available to the operating personnel. According to the rules and regulations for liquid blasters (item 6) the machine to be inspected yearly by experts, in order to guarantee safe operation. Inspection results to be recorded in writing and to be made available to the authorities on request. OERTZEN service engineers are experts according to RFL and carry out all inspections at moderate prices.

This warning symbol appears in the operating manual at all operating safety instructions dealing with dangers for per-sonal 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 opera- tion and to avoid damages or destroying of the machine.

All rights reserved. Any use in other than legally authorised cases requires the prior written approval of ARNDT H. von OERTZEN (GmbH&Co).

ATTENTION

4

2. Safety Instructions This operation manual should thoroughly and completely be studied and considered prior to initial start-up of the unit. When strictly following the instructions, no dangers should occur. This machine must only be operated by qualified persons who are fully familiar with the operation and possible dangers. The operating instructions laid down in the “Regulations for liquid blasters (ZH 1/406)” as well as “Working with liquid blasters” (BGV D 15) strictly to be followed. The machine is not suitable for unattended operation. Protective clothing to be worn during working. When opening the machine in case of malfunction or emergency, the unit to be switched off by means of the ON/OFF switch and to be disconnected from the electrical network. The water jet leaving the spray pistol at high speed has a rather dangerous cutting effect. So, never direct the water jet onto persons or animals, nor direct it onto electrical units. When starting the machine, be aware of torque and recoil. Take care 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 equip-ment (union respectively hose marked with “OERTZEN”) or using materials which have not expressively been approved by OERTZEN in writing ceases all warranties and product liability. 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. After work the spray pistol to be protected against accidental/unauthorised use by means of the safety lever. When using spray lances below 750 mm length be aware of special hazards. 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.

5

Consumables to be handled thoroughly. All relevant safety regulation and environmental rules to be considered. Electrical energy can cause severe injuries. Electrical 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 form the electrical network during all repair/maintenance work. (ZH 1/95). 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. Indoor operation of oil-heated high pressure cleaners is not permitted in case proper ventilation and exhaust evacuation is not guaranteed. Exhaust gas is harmful! Repair work within the high pressure section of the machine (pump, hoses, piping) only to be carried out by qualified personnel. The exhaust evacuation area is hot! Do not touch! Make sure that the unit cannot move. In case the unit is equipped with a break, it should be activated during working in steep areas.

According to safety rules (BlmSchV) the oil-heated high pressure cleaner/HOT BOX to be inspected within 4 weeks after delivery. Exhaust gas measurements to be taken and to be repeated yearly.

ATTENTION

6

3. Configuration and Mode of Operation

Greasy dirt layers as well as thermo-plastic coatings can easily and quickly be removed with overheated water (> 100 °C) which is most advantageous for painting and restoration contractors. The HOT BOX modules are oil-heated heater systems which – once connected to a cold water high pressure cleaner – heats up the water which is flowing through to a value adjusted by means of a thermostat. This design concept allows to achieve an adjustable temperature increase to max. 120 °C, depending on the flow rate (l/min.) of the cold water high pressure cleaner. When using cold water high pressure cleaners with higher flow rates (l/min.), the max. temperature of 120 °C can be reached by connecting several HOT BOX units in parallel (see diagram on page 15). The installation of a flow distributor kit (order No. 10.000.066) between cold water high pressure unit and HOT BOX module(s) is a must in order to achieve a balanced flow level of the heating modules (see diagram on page 8). The high pressure pump directs the water into the HOT BOX where it s heated up to the temperature adjusted at the thermostat. A safety control device (flow switch, thermostat, safety temperature limiter) ensures safe and trouble-free operation of the oil burner by activating and deactivating the burner which is fed with fuel from a 20 l NATO vessel incorporated in the steel structure. A relief valve which is arranged in the water inlet of the heating coil and protected against unauthorised modification of adjustment guarantees pressure reduction and unloading of the boiler system in case of overload. We seriously recommend to carry out a “test cleaning procedure” in order to make sure that the surface of the building/object will not be damaged by abrasive or thermal effect. Contact OERTZEN personnel for detailed advice.

7

Diagrams

8

9

4. Start-up/Shut-down

During indoor operation ensure proper ventilation and exhaust gas evacuation.

During operation under exhaust gas chimneys rele- vant rules and regulations to be considered.

According to safety rules (BlmSchV) the oil-heated high pressure cleaner/HOT BOX to be inspected within 4 weeks after delivery. Exhaust gas measurements to be taken and to be repeated yearly.

Before Start-up

Make sure that the technical parameters of the cold water high pressure cleaner connected to the HOT BOX will never exceed the limits of the HOT BOX.

Connect the high pressure cleaner according to operating manual. Fill NATO vessel (20 l) with clean fuel oil according to DIN 51603, part 1 or Diesel. Ensure cleanliness during trans-port and filling. Properly close the fuel tank after filling. Consider safety regulations during handling of fuel. Connect the original OERTZEN high pressure hose (included in our scope of supply) manually to the high pressure outlet of the high pressure cleaner (the other end is fixed to the HOT BOX inlet). Original OERTZEN spray equipment to be connected manually to the pressure outlet of the HOT BOX. Never mix up pressure in- and outlet of the HOT BOX. Connect the unit with the connection cable to the electrical net-work or to a main switch which have to be equipped with a 16 A fuse. Extension cables to have a diameter according to VDE rules. Extension cables on reels to be reeled off completely during operation, in order to avoid overheating of the cable reel. A faulty current protection switch is recommended. VDE regulations to be considered.

ATTENTION

ATTENTION

10

Operation Switch on the high pressure cleaner according to operating in- structions. Unlock and activate the spray pistol, vent the unit. Be aware of recoil/ensure stable foothold. Turn HOT BOX ON/OFF switch (3) into position 1 – red control lamp (2) is illuminated. Adjust HOT BOX thermostat (3) to the required operating tempe- rature. Never direct water stream onto persons, animals or electrical units.

Never touch high voltage components, ignition electrodes, plugs/ cables during operation or emergency in case ON/OFF switch (1) is in position 1 (red control lamp illuminated).

In case the burner trips and does not restart automatically, the temperature limiter may be activated. In order to release same, cool down HOT BOX, remove cap from reset button (2) and push reset button. Re-install cap.

After Completion of Work Turn HOT BOX ON/OFF switch (1) into position 0 – red control lamp (2) is off.

Operate the unit for approx. 2 minutes with cold water so that the boiler system can cool down, in order to avoid overheating. Close spray pistol. Stop high pressure cleaner as per operation manual.

De-pressurise and lock the spray pistol.

ATTENTION

11

Disconnect the unit from the electrical/water distribution network.

After cooling down completely, dismantle the connection hose 2 m and the spray device.

Reel up the high pressure hose properly.

Unit and equipment to be stored in a dry, frost-protected area. Drain completely in case of extended shut-down periods.

Unit to be protected against frost (see maintenance instructions), as otherwise severe damages may occur.

The oil pump installed in the HOT BOX must never be operated without fuel oil, as otherwise proper lubrication is not guaranteed. In such a case the HOT BOX to be

switched off immediately by means of the ON/OFF switch (1) and fuel oil tank to be refilled. Ignoring this instruction voids all warranty and liability.

5. Maintenance

Every machine is only as reliable as its maintenance personnel. Disregarding of the maintenance instructions and intervals cease warranty.

It is most important that the operator carries out the following maintenance work in shorter time periods than the normal maintenance intervals:

Fuel Tank Immediately remove deposits in the fuel tank (8) and water in the fuel filter (6), if any. Fuel Filter Between fuel pump and fuel tank there is a filter installed. This filter to be cleaned monthly, respectively daily in case contaminated fuel is being used.

ATTENTION

ATTENTION

ATTENTION

ATTENTION

12

Removal of Mineral Deposits In spite of constant load of the heating surface at a low level water heating results in a certain formation of mineral deposits (scaling) which should frequently be removed. Therefore, weekly dismantle the spray nozzle from the spray lance and operate the unit without nozzle. If the pressure on the pressure gauge exceeds 5 bar, carry out the following procedure: Fill the clean tank with 5 l anti-scalant ORM 1 (acid) and 5 l water. Relevant safety regulations to be considered. Dip the suction hose of the high pressure cleaner into the tank. Start the burner of the HOT BOX by turning the main switch (1) into position 1 and adjust the thermostat (3) to 70 °C. Start the high pressure cleaner. The acid solution is now directed through the heating coil of the HOT BOX. The removal of the deposits can be seen from dirty water emerging from the unit.

After the acid solution has been soaked in completely, fill the tank with clean water and observe the pressure gauge. If the pressure has not decreased as required, repeat the procedure until only clean water is leaving the heating coil and the pressure has dropped below 5 bar.

After finishing the cleaning procedure, run the high pressure unit with clean water for further 5 minutes. Collect the cleaning liquid and dump it according to safety regulations. The anti-scalant is an acid, i.e. corrosive! Therefore, protective clothing to be put on!

ATTENTION

13

Frost Protection All water piping and units, so, consequently also your HOT BOX to be protected against frost. The most effective frost protection is achieved by storing the unit in a continu-ous dry and frost-proof room, however not near air-shafts, open windows and the like. In case the unit is connected to an exhaust gas evacuator, disconnect it in case of frost, as otherwise it could be damaged. If no frost-proof room is available, strictly follow the instructions below:

Connect high pressure unit to HOT BOX and HOT BOX to spray device (see chapters “Before Start-up / Start-up/Shut-down”). Mix 5 l of a 1 : 1 water-frost protection liquid in a clean vessel. Dip the suction pipe into the vessel, start the high pressure cleaner and dip the spray device into the liquid. Open the spray pistol and direct the frost protection liquid back into the vessel, in order to circulate the liquid. After approx. 4 minutes open and close the spray pistol several times, in order to fill all control elements of the HOT BOX as well as all safety components and pressure gauges of the high pressure unit with the protection liquid. High pressure unit to be switched off and all hoses to be disconnected. High pressure unit and HOT BOX are now protected against tempera-tures down to -30 °C. Ignoring above instructions can cause heavy damages on all wetted parts. Damages due to frost are excluded from our guarantee obligations. For environment-protective reasons the frost-protection liquid should be re-used various times and afterwards to be dumped according to environmental regulations.

ATTENTION

ATTENTION

14

15

7. Technical Data

Technical Data HOT BOX 200 HOT BOX 500

Feed water quantity 500 – 1000 l/h 500 – 1000 l/h Max. operating pressure (up to 99 °C) 220 bar 500 bar Max. operating pressure (up to 120 °C) 220 bar 350 bar Water temperature – adjustable 60 – 98 °C 60 – 98 °C (120 °C) (120 °C) Net heating capacity 61000 kcal/h 61000 kcal/h Voltage 230 V/1~50 Hz 230 V/1~50 Hz Dimensions (L x B x H mm) *) 620 (760) x 610 x 950 Weight (net) 74 kg 85 kg Order No. 10.000.092 10.000.094 *) Length inclusive of fuel tank Subject to technical alterations. Serial Equipment: Exchangeable fuel tank (20 l), 2 m PANZERJET high pressure connecting hose (fixed on one end), 4 m electric cable with European plug. Heater Diagram HOT BOX

16

8. Trouble Shooting

Electrical energy can cause severe injuries. Electrical components tho- roughly and frequently to be checked for damages and malfunctions, in order to avoid any cause for accidents. Trouble Shooting: - only to be carried out by experts/trained persons - preferably by OERTZEN service personnel. Disconnect the unit from the electrical network during all repair/mainte-nance work (ZH 1/95)

Malfunction Cause/Solution

Unit does not start. Switch on main switch. Insert plug. Check fuse. Stop the unit – call qualified service.

Unit stops during operation. Check/replace fuse. Switch on main switch again. Safety temperature limiter – push reset button Stop the unit – call qualified service.

Unit suddenly generates steam. Check water supply. Remove scaling. Clean/replace spray nozzle. Stop the unit – call qualified service.

Burner does not start. Fill up fuel tank. Readjust burner/thermostat switch, if required. Adjust thermostat to a higher value. Clean fuel filter. Seal fuel filter. Stop the unit – call qualified service.

Burner stops automatically Fill up fuel tank. resp. repeatedly. Readjust burner/thermostat switch, if required. Safety temperature limiter – push reset button Stop the unit – call qualified service.

Burner gets sooty/smokes. Fill up fuel tank. Clean fuel tank, in case water inside. Clean fuel filter. Stop the unit – call qualified service.

Burner is running with closed Stop unit – call qualified service. pistol.

17