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1. 7 3 Clean Machine Piping Standard Turntable Power Washer v 4 0 The MART Corporation The MART Corporation 5 Installation Operations and Maintenance Manual Install the wiring between the Clean Machine and the washer as follows Run the sealtite conduit located at the back of the washer near the pump to the control box on the Clean Machine Hook up the conduit to the box through the bottom of the box Install the 6 wires to the electrical box as follows Red Wire 10 Green Wire Ground Pink Wire SK White Wire Neutral Black Wire Contactor Black Wire Contactor 6 Place an approved 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 Setthe temperature controller aquastat located on the side of the Clean Machine s separator tank to 170 F 77 C The heater replaces heat lost when the solution is in the tank itis NOT designed to heat solution from ambient temperature NOTE Leave the heating loop ON for the Clean Machine s separator tank even when the washer is not in operation Verify that part of the Clean Machine s pump flow is directed to the washer to agitate the solution and keep contaminates in suspension Verify that the remainder of pump output is directed to the Clean Machine s separa
2. Jib Crane Washer mounted Standard Turntable Power Washer v 4 0 The MART Corporation 7 56 Installation Operations and Maintenance Manual 9 Insert the jib boom support angle shaft pin into the bottom of the boom Verify that there is a bronze bushing 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 the column 13 Unbolt the trolley stops at the front end of the jib boom 14 Slide the trolley onto the jib boom 15 Re bolt the trolley stops to the front of the jib boom ONE BRONZE BUSHING 2 REQ D TOP amp BOTTOM Fig 7 29 Jib Boom Bronze Bushing and Washer Locations The MART Corporation Standard Turntable Power Washer v 4 0 Options 10 3 Since the boom is a lifting device be sure to check the installation work Swing the boom manually and carefully to be sure it moves freely Check all bolts 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 cotter pin Operations WARNING Be sure you have anchored the washer to the floor BEFORE using the Jib Crane DO NOT OPERATE the Jib Crane if you have not anchored the washer to the floor the washer could
3. T y TOP OF MACHINE REF P TOP OF MACHINE RE 5 u A 7 5 T Z q hie ES v ete SIDE VIEW FRONT VIEW ASE FAN INSIDER DISCHARGE nN RAIN WEATHER CAP TO SUIT gee v CAVAILABLE FROM MART ON ee EN DUTLE RANSIT INLET NS 2a Sor ih P d K y O P Lean S Li y PPE SUPPOR 7 DRAIN wW TO SUIT pe T DRAIN COUPLING Pd i RA CARE PEE SS asd ROOF ER TU S BLOWER SUPPORT SUIT INSTALLATION CONDITIONS FLASHING per Rane VC Pe SUI TOP OF MACHINE REF TOP OF MACHINE REF l SIDE VIEW RONT VIEW ASE FAN OUTSIDEROOFE MOUNTED OPMANO74 Fig 7 24 HABO ASE Fan Installation The MART Corporation Standard Turntable Power Washer v 4 0 Options TOP SIDE VIEW OPMAN075 Fig 7 25 HABO ASE Fan Installation OF MACHINE ASE DRAIN LIN REF FAN BLOWER SUPPORT TO SUIT NUTLET TRANSITION iw INSTALLATION CONDITIONS lt lt AN ig i TUP OF MACHINE REF E A RONT VI RGE The HABO inside plenum located in the washer cabinet and shown in the following figure is always shipped installed The outside plenum which contains the blower unit the thermocouples 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 Turn the main power supply OFF 2 Mount the ou
4. Use one of these couplings to connect a drain line back into the ASE ducting below the fan This will allow condensed water vapor to drain back to the washer 2 The output of the ASE fan can be rotated to any direction Select a direction for the output that puts one of the two drain couplings on the fan in the DOWN position 3 Remove the fan housing and rotate it to the selected direction The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 47 4 During reassembly thoroughly caulk all joints of the fan with a good quality silicone caulk 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 of the nuisance dripping problems associated with steam condensing in the fan Tip If your planned piping route contains any 90 elbows install the fan at the elbow Standard Turntable Power Washer v 4 0 The MART Corporation 7 48 Installation Operations and Maintenance Manual L0 RAIN WEATHER CAP TO SUIT c AVAILABLE FROM MART ao BLOWER SUPPORT TO SUIT INSTALLATION CONDITIONS I PIPE HANGERS i TO SUIT N QUTLETAL EG INLET TRANSITION RANSTION wf Y _ S INJ Xe M F V k ps COUPLING M J D
5. concentration and conductivity After several weeks of testing and graphing you should see a pattern this is the correlation between chemical concentration and conductivity Given any conductivity reading on your graph you will most likely see a difference between the ideal 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 correlation between chemical concentration the results of titration and conductivity measurement testing you can use a conductivity measuring system to provide a close estimate of the strength of the chemical in the solution At this point conductivity measurement can be used for one of two purposes e Asan indicator of the need to titrate e Asan indicator of the need to add chemicals If the correlation between conductivity and titrated concentration is close enough for the purposes of the operator then titration should only be used as a periodic check on the conductivity measuring system 4 2 Installation The Chemical Conductivity Controller system is factory installed and shipped ready for use The electrode probe arrives installed in the washer based on your specifications The MART Corporation Standard Turntable Power Washer v 4 0 Options 4 3 Operations Follow this procedure 1 Check the conductivity reading on the controller panel
6. procedure 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 on the following problems e Pump pressure gauge does not work Problem Pump pressure gauge does not work Check This Probable Cause s Gauge pipe Clogged clean out Gauge Damaged replace Glycerin leakage replace Diaphragm seal Damaged replace Fig 7 34 Troubleshooting Pump Pressure Gauge Does Not Work Standard Turntable Power Washer v 4 0 The MART Corporation 7 68 Installation Operations and Maintenance Manual 14 Pump Pressure Gauge The optional pressure gauge indicates the amount of pressure in the piping from the wash pump to the power blast manifold PBM 14 1 Theory of Operation A coupling welded into piping between the pump and the PBM is used as a pressure tap point for a glycerin filled pressure gauge The pressure tap piping is a large diameter for easy clean 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 dial 14 2 Installation This option arrives factory installed 14 3 Operations There are no operator instructions The pump pressure gauge will indicate the pressure in the piping from the wash pump to the powe
7. 1 2 Load small parts into the basket Secure the id Place the basket on the center of the turntable Attach one end of the chain to a hook located on the inner surface of the turntable s outer rim Run the chain through both basket handles Attach the end of the chain or a link to a hook located on one end of the load binder Attach the hook on the other end of the load binder to a chain eyelet directly across 180 angle from the first hook Tighten the chain with the provided oad binder The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 73 PARTS BASKET y LC N j N dil c SEE 7 pran b CHAIN TIGHTENER rai 4 bu TOP OF TURNTABLE xor N v N N j a M 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 appropriate securing devices no problems should arise from these options Standard Turntable Power Washer v 4 0 The MART Corporation 7 74 Installation Operations and Maintenance Manual 16 Remote Grease Fittings The optional Remote Grease Fittings allow you to grease the turntable or the Power Blast Manifold PBM swivel bearings from the outside of the washer cabinet 16 1 Theory of Operation This option eliminates the need to disassemble any part of t
8. Probe The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 27 Chemical Management When a washer is first put into service it is easy to compute the concentration of the cleaning compound because you started with a fixed volume of water and added a known quantity of chemical After you begin using the washer however you can only estimate the chemical concentration until you drain the washer clean it out and recharge it with fresh water and chemical There are two commonly used estimating tools e Conductivity measuring systems e Titration kits Conductivity Measurement A conductivity measuring system measures the strength of a fixed electrical current flowing between two or more electrodes that are held at a fixed distance Since the addition of cleaning compounds chemical to water changes the capacity of water to conduct electricity conductivity measuring systems can provide an estimate of the strength of the chemical in the solution by measuring the relative conductivity of the solution Unfortunately compounds other than cleaning chemicals also affect 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 can be used as a control point this is done with the understanding that the oils greases metal particles and other contaminants that are b
9. Tubing For the system to function properly the concentration of your chemical must be proportional to its conductivity The system measures conductivity with electronics connected to a probe immersed in the washer s cleaning solution A concentrated chemical is added by a pump to maintain the conductivity of the solution at the selected set point The conductivity controller uses a set point for the minimum allowable conductivity When the electrode probe senses that conductivity 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 into the washer s reservoir Concentrate is only added during the wash cycle so that mixing occurs When the probe senses that conductivity has risen above the set point the controller relay opens This prevents the peristaltic pump from adding concentrate The peristaltic pump turns rollers which squeeze concentrate through the precision bore high tolerance tubing in a wave like motion acting like a positive displacement pump The concentrate comes in contact only with the tubing not the pump The pump is self priming and non siphoning The probe is mounted to the end of a tube This tube is used to insert the probe into the pump suction tube The probe can be removed without draining the washer PUMP SUCTION UBE Fig 7 12 Chemical Conductivity
10. all Keep rinse wand use to a minimum to avoid this problem e Rinse wand water contains no chemical additives such as rust inhibitor Therefore excessive use of the wand could cause rusting of parts 17 4 Maintenance Lubricate the gun trigger periodically The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 77 17 5 Troubleshooting This section contains tables on the following problems e Nohand rinse Problem No hand rinse Check This Probable Cause s Light on control panel Solution level at HIGH HIGH maximum mark Solenoid Failed replace Nozzle Clogged remove and clean Fig 7 38 Troubleshooting Rinse Wand No Hand Rinse Standard Turntable Power Washer v 4 0 The MART Corporation 7 78 Installation Operations and Maintenance Manual 18 Sludge Scraper The Sludge Scraper removes sludge from the power washer s reservoir to a bin or barrel The materials to be removed by the sludge scraper can be any solid material or any material that is of a consistency that will not run off of the scraper bars The sludge scraper provides these benefits e Extension of cleaning solution life e Better cleaning results 18 1 Theory of Operation The washer is mounted on the sludge scraper assembly which replaces the original floor of the washer s reservoir Part of the assembly extends as a chute behind the washer at a 45 degree angle When the Sludge Scraper is operating angle scrapers mo
11. at the chemical concentration recommended by your chemical supplier 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 for instructions on changing ranges and setting set points Insert the peristaltic pump suction tube into a barrel of 50 diluted chemical concentrate 3 NOTE The peristaltic pump only pumps during wash cycles when chemical is needed Standard Turntable Power Washer v 4 0 The MART Corporation 7 30 Installation Operations and Maintenance Manual 4 4 Maintenance Every 160 hours of operation e Monitor chemical usage by the peristaltic pump Replace the empty barrel after the concentrate has been completely used e Test peristaltic pump operation 1 Set the controller LO set point 10 below the actual solution conductivity Run a wash cycle 3 Verify that the pump is pumping chemical into the reservoir Re set the LO set point to your control set point Peristaltic Pump and Tubing The pump has few moving parts and no seals or valves to clog clean or replace As tubing fatigues and eventually cracks move it to a section that has not been under the pump rollers Then continue pumping When you run low on tubing order a new spool Sludge Clean Out During sludge clean out clean the probe thoroughly Follow the vendor supplied instruction
12. is located at the bottom of the door The two position lock slots hold the door open at approximately a 60 angle and a 90 angle respectively from the front of the cabinet Securing the Door Always be sure that the open door is locked in position e Visually check the position lock slot or e Try to pull or push the door Refer to chapter Basic Operations for more general information on opening and closing the door The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 65 12 4 Maintenance Every 160 hours of operation e Check the filter regulator lubricator unit The lubricator has an oil reservoir and is located on the right side of the washer Add oil if required to the fill level Refer to your vendor supplied cutsheet for instructions 12 5 Troubleshooting This section contains tables on the following problems e Power assist does not activate Problem Power assist does not activate Check This Probable Cause s Control valve Stuck replace Position lock handle Defective limit switch Selector switch Defective Air pressure Not in the 75 100 PSI 1000 1400 kg sq cm range check air supply system Electric solenoid Burned out replace Fig 7 33 Troubleshooting Power Assist Does Not Activate Standard Turntable Power Washer v 4 0 The MART Corporation 7 66 Installation Operations and Maintenance Manual 13 Pump Pressure Control Valve and Gauge The optional pump press
13. until the manifold returns to the home position The lock functions automatically whenever the center manifold system is used in manual and automatic modes Power is required to unlock the door In the event of a power failure or if power is turned off to the machine the door lock solenoid will de energize and lock the door The lock can be manually by passed by pushing up the small pin that protrudes below the solenoid lock box and opening the door This will probably require the assistance of another person Be sure the manifold is in the home position before performing this procedure The MART Corporation Standard Turntable Power Washer v 4 0 Options 3 2 Installation This option arrives with the vertical manifold and superstructure disconnected To install the center manifold follow this procedure refer to the following figure 1 2 Place beads of sealant around the roof opening Place the superstructure frame and mechanism on the pad support on the roof Connect the superstructure plate to the pad on the roof Connect the wash and rinse lines to the connections on the roof Connect bracing if supplied Connect wires to the gear motor and to the brake assembly to the limit switch Standard Turntable Power Washer v 4 0 The MART Corporation LIFT CHAINS Installation Operations and Maintenance Manual T LIMIT SWITCI DRIVE CHAIN CHAIN TIGHTE
14. Corporation Standard Turntable Power Washer v 4 0 Options 7 33 5 4 Maintenance Clean the internal reservoir cover as required Pay particular attention to the expanded metal screen area be sure that no bolts or other parts gasket material or debris clog the screen NOTE If your internal reservoir cover has the optional chip baskets do not stand on or in the baskets If the expanded 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 Refer to section Troubleshooting 5 5 Troubleshooting This section contains tables on the following problems e Water leaks over doorframe Problem Water leaks over doorframe Check This Probable Cause s False floor screen area Expanded metal screen area clogged with bolts or other parts gasket material debris clean screen Fig 7 15 Troubleshooting False Floor Water Leaks Over Door Frame Standard Turntable Power Washer v 4 0 The MART Corporation 7 34 Installation Operations and Maintenance Manual 6 50Hertz Electrical Power This option is intended for installation sites that use 50 Hz electrical power instead of 60 Hz The pump system has been reconfigured using V belts to drive the pump enabling a washer powered by 50 Hz to deliver the same performance as one powered by 60 Hz This results in the same efficiency pressures a
15. F 93 C Exceeding 200 F 93 C may burn out the electric element or trip the over temp sensor system Set the HABO timer located inside the electrical control panel Each numbered increment on the timer increases HABO duration by 30 seconds The maximum run time is 300 seconds Examples are given in the following table HABO Timer Increments Number Seconds 30 60 90 4 300 Set the HABO auto off switch located on the control panel to auto This will activate the HABO system after the wash cycle unless your washer is equipped with the optional auto rinse cycle ARC If your washer is so equipped then the HABO system activates after the rinse cycle The MART Corporation Installation Operations and Maintenance Manual 6 Refer to the vendor supplied cutsheet for instructions on setting fan speed If your washer is equipped with HABO it is also equipped with auto steam exhaust ASE An added benefit of HABO is that you can also use the HABO steam exhaust fan speed control to adjust the amount of steam exhaust during ASE cycles NOTE If you set the ASE higher than the absolute minimum required for the desired rinse cycle the steam 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 provide an adequate rinse adjust it higher for longer rinse cycles 9 4
16. Maintenance Every 1100 hours of operation Oil the HABO blower motor with a standard electric motor oil suitable for small electric motors For example 10W 50 SAE oil Refer to the vendor supplied cutsheet for grease oil points Inspect and clean the electric heating coils e Turn the main power supply OFF e Remove the coils from the upper plenum e Carefully clean any debris from the coils e Insert the coils back in the upper plenum e Turn the main power supply ON The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 53 9 5 Troubleshooting This section contains tables on the following problems e HABO heating element begins to overheat Problem HABO heating element begins 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 to shut off power before checking Temperature controller Heat set point set too high do not exceed 200 F 93 C Over temp Tripped reset the over temp device Fig 7 27 Troubleshooting HABO Heating Element Begins to Overheat Standard Turntable Power Washer v 4 0 The MART Corporation 7 54 Installation Operations and Maintenance Manual 10 Jib Crane The optional Jib Crane is designed to pick up parts in front of the reservoir and place them on the turntable The crane is washer mounted with a hoist T
17. NER P4 FOR CLARITY UPPER GUIDE BUSHING 1 E ae p POM 7 i Se I PA I wN 9 LIFT CHAINS NC T I I I X Tea l x RES oS Pus a zi I rid y LIFT PIN jig 5 N ON LI Gd BUSHINGS Sake H i ERJA NORRIE a d i a ee Lr mj Lig y E IE apud ou LI INA u PEE ae m ae Hf N 1 r ri MEE bd Em 5 GEARMOTOR NOT SHOWN SUPERSTRUCTURE HEAS PAD SUPPORT A Kk IPMANO85 CABINE ROO Ny LOWER GUIDE BUSHING Fig 7 8 Center Manifold Mechanism and Superstructure The MART Corporation Standard Turntable Power Washer v 4 0 Options 3 3 Operations WARNING The minimum inside diameter of a part that can be cleaned by the center manifold is 5 inches To operate the center manifold follow this procedure 1 Verify that the manifold is up near the roof of the cabinet The center manifold has an automatic Home or up position controlled by a limit switch at the top of the superstructure 2 Place the part to be washed in the center of the turntable A special fixture may be needed to keep the part centered on
18. Options 7 1 7 Options Purpose This chapter contains information on any options you have that purchased from MART The material in this chapter is meant to be used with material in other chapters for example chapters Installation Operations and Maintenance Prerequisites Before you read this chapter we recommend that you read the following thoroughly e Important Safety Instructions and Warnings in the front material e Chapter 1 Overview Safety Precautions Before you install operate or maintain any option read and follow these recommended safety precaution instructions WARNING NEVER get inside the washer cabinet when the main power supply is ON This could result in severe injury or death WARNING Be sure that people who install and maintain the washer and options are qualified and trained for the task Standard Turntable Power Washer v 4 0 The MART Corporation 7 2 Installation Operations and Maintenance Manual What You Will Learn In This Chapter In this chapter you will learn the following about each option Theory of operation Installation Operations Maintenance Troubleshooting The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 3 1 Automatic Turntable Swivel Bearings Lubrication The automatic turntable and swivel bearings lubrication system helps ensure that these critical bearings are lubricated every set number of wash cycles 1 1 Theory of Operation T
19. Washer v 4 0 Options 7 45 9 Hot Air Blow Off HABO The optional Hot Air Blow Off HABO system flash dries parts by high velocity direct blasts of air that blow most of the water off parts Heat evaporates any remaining water All HABO systems are delivered with the following features e Heater contactor wired in line with blower e Over temperature protection e Duct heater e TEFC fan motor e Direct coupled aluminum balanced fan blade e High velocity conversion nozzles 3 inches 7 6 cm from the edge of the turntable 9 1 Theory of Operation The HABO system activates after wash and rinse cycles have completed The fan turns on while the turntable continues to rotate Air is inducted from outside 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 travels through the plenum and out the nozzles to blow water off parts on the turntable The heating units are sized to provide a minimum of 110 F 43 C rise above ambient to operating air temperature Steam Exhaust Fan NOTE The HABO system removes steam using a variable speed DC drive centrifugal steam exhaust fan which replaces the standard ASE unit The centrifugal fan differs from the standard unit in two keyways e The inlet is at a 90 angle from the outlet e The outlet ducting is square and connects to a round
20. a sludge collection bin from which the sludge must be periodically removed e Solution then flows into a chamber where the entrained air brings oils and greases to the surface by coalescing action A powered rotating skimmer removes the oils and greases that collect on the solution surface A scraper removes the collected material from the skimmer and deposits it in a collection device for further treatment processing or disposal The Clean Machine segregates the waste streams generated by washing allowing you to e Collect waste oils and greases easily and recycle them off site e Dispose properly of particulate matter Standard Turntable Power Washer v 4 0 The MART Corporation 7 10 Installation Operations and Maintenance Manual 2 2 Installation Install the power washer as described in chapter Installation When you charge the power washer with chemical remember to add enough chemical to take into account the 135 gallons 511 liters of solution that will fill the Clean Machine s separator tank Clean Machine Physical Dimensions and Capacity 5 feet 3 inches 1 60 m 2 feet 3 inches 69 m 6 feet 2inches 1 88 m Capacity 135 gallons 511 liters Follow this procedure 1 Setthe separator tank by the right side of the washer Leave enough room for access to the burner heating elements and opening the cabinet door Be sure that when it is fully open the door will not touch the Clean Machine 2 Level t
21. al Power Squealing Sounds from Pump Area Problem 50 Hz electrical power No wash cycle no water pumped simplex pump system Check This Probable Cause s Belt s Broken replace Fig 7 17 Troubleshooting 50 Hz Electrical Power No Wash Cycle No Water Pumped Simplex Pump System The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 37 Problem 50 Hz electrical 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 50 Hz Electrical Power Poor Cleaning Results or Abnormal Pump Noise Duplex Pump System Standard Turntable Power Washer v 4 0 The MART Corporation 7 38 Installation Operations and Maintenance Manual 7 Filters The optional Filters remove particles as small as 1 micron from the wash solution If you have purchased this option your MART representative will have worked with you to select a micron rating that best suits your washer s configuration and your applications When you purchase replacement filters be sure the micron rating is appropriate for your washer s configuration A filter with extremely fine pores could significantly increase the pressure differential and overload the capacity of the filter housing affecting pump pressure and flow rate 7 1 Theory of Operation The two filter types are e Bag
22. 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 position lock handle which is located at the bottom of the door The handle works like a throttle to increase and decrease speed 12 2 Installation The Power Assisted Door is shipped installed on the cabinet The speed control valves are factory pre set for a moderate opening and closing speed range 12 3 Operations WARNING NEVER put hands legs or head inside the door This could result in severe injury or death WARNING Before you attempt to open or close the power assisted door be sure you have enough clearance for the full arc travel of the door as it swings Standard Turntable Power Washer v 4 0 The MART Corporation 7 64 Installation Operations and Maintenance Manual WARNING NEVER swing the power assisted door open to a position lock at an accelerated speed Control the speed of the door by the position lock handle located at the bottom of the door Use the handle like a throttle to adjust speed To operate the door follow this procedure 1 Select open or close on the power assist selector 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 assist The position lock handle
23. bottom of the superstructure 5 Check the adjustment of the drive chain at the gear motor Remove any excess play with the chain tightener Every 250 Hours of Operation Teflon Bearing Plates Inspect the Teflon bearing plates in the double bearing housing Look for excessive sideways movement of the center manifold or for bearing wear hole is oblong Replace the plates The MART Corporation Standard Turntable Power Washer v 4 0 Options 3 5 Troubleshooting This section contains tables on the following problems e Water leaks onto cabinet roof e Center manifold assembly does not work e Center manifold light does not illuminate Problem Water leaks onto cabinet roof Check This Probable Cause s Manifold hose Cracked 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 Superstructure Damaged Limit switch Damaged replace Electric solenoid Burned out replace Fuses Blown turn power OFF and pull out of electrical control panel to check Relay s Need to be tightened or replaced Overload Tripped reset Chain jammed Brake not releasing Fig 7 10 Troubleshooting Center Manifold Assembly Does Not Work Standard Turntable Power Washer v 4 0 The MART Corporation 7 24 Installation Operations and Maintenance Manual Problem Center manifold light does n
24. dge chamber underneath Because the hydrocyclone also discharges some water during operation the sludge holding tank initially fills with water up to the return outlet As operation continues sludge that is removed from the washer displaces water in the sludge holding tank Clean out the sludge when it reaches the bottom of the water return outlet Follow this procedure 1 Place an approved container under the 5 inch 13 cm cap 2 Remove the cap from the sludge holding tank 3 Push s udge out through the opening into the container 4 Replace and tighten the cap Standard Turntable Power Washer v 4 0 The MART Corporation 7 16 Installation Operations and Maintenance Manual 2 5 Troubleshooting CAUTION Never run the oil skimmer in a tank where there is no oil on the solution surface The absence of oil creates excess drag on the skimmer motor This will damage the motor This section contains tables on the following problems Clean machine does not heat Hydrocyclone does not separate Oil skimmer tank overflows into cyclone separator tank Skimmer wheel drain trough backs up Problem Clean machine does not heat Check This Probable Cause s Incorrect temperature set controller to 170 F 77 C Low draw Wires may be loose Heating element may need to be replaced Blown power OFF then pull out of electrical box to check Fig 7 4 Troubleshooting Clean Machine Does Not Heat Problem Hydrocyclone
25. does not separate Check This Probable Cause s Ball valve Ball valve on the discharge line from the pump needs adjustment Cyclonic separator Clogged remove bottom clamp amp clean out debris Pressure at cyclone Too low 15 PSI minimum Fig 7 5 Troubleshooting Hydrocyclone Does Not Achieve Cone Effect The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 17 Problem Oil skimmer tank overflows into cyclone separator tank Check This Probable Cause s Discharge line Clogged overflow pipe Ball valve setting Improper adjustment adjust 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 Bend to adjust Replace if worn Wheel Not turning check tighten shaft nuts Motor Motor not turning 115 V Fuse needs to be replaced Wires need to be tightened Motor needs to be replaced Fig 7 7 Troubleshooting Skimmer Wheel Drain Trough Backs Up Standard Turntable Power Washer v 4 0 The MART Corporation 7 18 Installation Operations and Maintenance Manual 3 Center Manifold The optional center manifold is used to clean very narrow diameter hollow long parts whose interior is inaccessible to the washing solution Examples of such parts include gun barrels long pipes and turbine pumps The center manifold oscillates vertically i
26. dure 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 wear of the sheaves and belts 4 Be sure that the sheaves are at the same height in the same plane so that the belts run true Every 250 hours of operation Visually inspect belt s for wear and adjust tension as needed General Maintenance Keep belts clean Never use belt dressing This will damage belts and cause early failure Be sure that air can circulate freely around the V belt drive and that temperatures are moderate This will extend belt life Never cover the expanded metal guards vents that protect the V belt drive Standard Turntable Power Washer v 4 0 The MART Corporation 7 36 Installation Operations and Maintenance Manual e Replace belts with original manufacturer s equipment or equivalent e Keep extra belts stored in a cool dark dry place 6 5 Troubleshooting This section contains tables on the following problems e Squealing sounds from pump area e No wash cycle no water pumped simplex pump system e 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 frayed replace Sheaves Walls worn with resulting belt slippage replace Fig 7 16 Troubleshooting 50 Hz Electric
27. dure 1 Unpack the skimmer assembly from the turntable inside the washer cabinet 2 Setthe assembly into the skimmer box 3 Tighten the wing nut 4 Attach the grounded plug to the outlet on the washer 11 3 Operations The Oil Skimmer is designed to operate when the washer is in use or after hours when the washer is in shut down off mode To operate the Oil Skimmer follow this procedure 1 Set the skimmer s selector switch located on the washer s control panel to one of the following e Manual Activates the skimmer It will run continuously e Off Turns the skimmer off e Auto Automatically activates and runs the skimmer according to the program set for circuit 2 of the 7 day clock NOTE You must program the 7 day clock s circuit 2 for ON OFF times and set the skimmer s selector switch to auto NOTE Oil skimming works best when the emulsified oils are allowed time to float and collect on the surface of the solution Program your 7 day clock circuit 2 to run the Oil Skimmer several hours after washer shutdown in order to achieve the best oil skimming results Also some defoamers float on the surface at higher temperatures By skimming when the solution is cooler less defoamer will be skimmed off with the oils Standard Turntable Power Washer v 4 0 The MART Corporation 7 62 Installation Operations and Maintenance Manual 11 4 Maintenance Every 1100 hours of operation e Oil the skimmer moto
28. e Cartridge Filter Types Bag filters are generally recommended for 50 100 microns although they can filter down to 1 micron at lower flow rates Bag filters are less expensive than cartridge filters easier to change and re usable One filter at a time is inserted into the housing Bags are constructed of polypropylene especially selected for reliable performance in a hot caustic environment Cartridge filters are rated for 1 50 microns Multiple filters may be inserted into the housing Filter housings have a swing away lid Filter elements are inserted into the housing from the top The housing lid is tightened with swing bolts The following table shows micron comparisons to guide you in selecting filters The MART Corporation Standard Turntable Power Washer v 3 0 Options 7 39 Micron Comparisons Substance Microns Red blood cell Bacteria cocci Fig 7 19 Micron Comparisons 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 Wash pump gt Filler gt Manifold PBM Or Filter pump gt Filter gt Eductor nozzles in reservoir The filter pump driven system allows for continuous filtering operation 7 2 Installation The filters are delivered installed according to the configuration you specified Standard Turntable Power Washer v 4 0 The MART Co
29. e lubrication duration Set the Lube Cycle Counter to 1 so 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 The control panel has an off auto switch for controlling power to the auto lube system To run the system turn the switch to auto The auto lube system will function automatically until this switch is turned off Manual Operation To run the lubrication system at times other than those programmed open the control panel door for the auto lube system and press the manual button on the controller The auto lube system will start an automatic lubrication cycle Indicator Lights There are two indicator lights on the control panel The Lubrication Cycle light will flash during the auto lube cycle The Lubrication Fault light will light should the controller detect a fault during an auto lube cycle The MART Corporation Standard Turntable Power Washer v 4 0 Options 1 4 Maintenance Every 8 hours of operation e Check the grease reservoir fill level Refill as required according to the grease pump reservoir manufacturer s instructions e Check the Auto lube control panel for a fault indication If the fault indicator is ON your Auto lube system is not providing grease to the bearings Discontinue washer operations until the problem is corrected Refer to section Troublesho
30. e proper manifold with the selector valve Refer to the selector valve schematic diagram below and on the front of the Power Washer door for manifold selection To deploy the SHIM reposition the PBM selector valve handle remove the locking pin in the fold down arm section pivot the arm to its horizontal position and replace the locking pin to hold the horizontal SHIM arm in place Be sure the fold down arm is locked in the proper position for the height of the wash load A tall wash load may hit the fold down arm and damage the PBM drive Do not walk on the internal reservoir cover to raise or lower the fold down arm or to switch the selector valve Stand on the outside reservoir lid and reach into cabinet to make adjustments SHORT SHIM MANIFOLD FULL MANIFOLD FIGURE 7 42 SHIM MANIFOLD SELECTOR VALVE SCHEMATIC The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 85 Upper PBM Arm Upper SHIM Arm Raised When SHIM is Upper SHIM Arm Deactivated in Horizontal Position SHIM Deployed Locking pin SHIM I Fold Down Selector n t i d SHIM Valve Fig 7 43 SHIM Manifold System Tornado 40 HP 19 3 Maintenance 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 Standard Turntable Power Washer v 4 0 The MART Corporation 7 86 Installation Operations and Maintenance Man
31. e remote mounted be sure a qualified electrician does the work The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 43 8 3 Operations Refer to the vendor supplied manual for instructions on configuring the Frequency Drive input output and performance parameters in order to adjust the percent of full load which adjusts pressure and flow The following figure shows frequency drive results One benefit of reduced pressure is the ability to clean delicate parts FREQUENCY DRIVE RESULTS As of rated Pressure amp Flow 100 90 80 70 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 LOAD Flow Pressure Note Results are for main pump only Pressure or Flow Fig 7 22 Frequency Drive Results 8 4 Maintenance Follow the manufacturer s recommended maintenance schedule and procedures for cleaning and oiling the fan Standard Turntable Power Washer v 4 0 The MART Corporation 7 44 Installation Operations and Maintenance Manual 8 5 Troubleshooting This section contains tables on the following problems e 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 check power LED fault diagnostic indicator lit refer to the vendor supplied manual Fig 7 23 Troubleshooting Pump Motor Does Not Run The MART Corporation Standard Turntable Power
32. he automatic lubrication system consists of the following refer to the following figure Grease reservoir Pneumatically driven grease pump Grease dividing valve Pneumatic control valve Filter regulator lubricator Control Panel _ Grease Pump Divider amp Valve Solenoid Filter amp Regulator Fig 7 1 Automatic Lubrication System Block Diagram Standard Turntable Power Washer v 4 0 The MART Corporation 7 4 Installation Operations and Maintenance Manual The air solenoid valve repeatedly cycles open and closed for a timed duration Each opening and closing of the solenoid valve causes the grease pump to make one stroke The grease is pumped from the reservoir to the grease dividing valve The dividing valve proportions the proper amount of grease flow from the pump to each bearing Grease lines carry the grease flow from the dividing valve to each of the lubrication points e Turntable upper and lower bearings e 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 the controller counts washer cleaning cycles and initiates a lubrication cycle after a preset number of cleaning cycles The factory pre set is 1 cycle which means that the automatic lubrication system will start every wash load The duration of the lubrication cycle which controls the number of cycles of the dividing valve and
33. he crane is sized by washer with a load capacity compatible with that of the washer turntable The maximum load capacity is stenciled on the boom NOTE The jib crane kit with trolley is supplied by MART The hoist is provided by others not by MART 10 1 Theory of Operation The operator pivots the horizontal lifting 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 the boom 10 2 Installation WARNING Never cut or weld or add anything to the column or jib crane structure Follow this procedure refer to the following two figures 1 Mount the column on the bolts provided The bolts are located at the rear center of the washer There are 2 bolts at the top of the washer cabinet and 2 bolts at the bottom 2 Tighten the nuts and lock washers on the bolts 3 Mount the boom track on the bolts located over the top of the doorframe 4 Make sure the wheel stops are at the back of the washer not the front near the column 5 Do nottighten the boom track bolts yet The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 55 6 Mount the center brace on the column and the boom track T Bolt the center brace to the column and the beam 8 Tighten the boom track bolts BOOM E1 TROLLEY CENTER BRACE COLUMN A1 BOOM TRACK B1 Fig 7 28
34. he 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 Installation Anchoring 4 Referto the following figure to install piping between the washer and the Clean Machine NOTE Use schedule 40 black iron pipe stainless steel flex hose or any other material suitable for 5096 sodium hydroxide at 200 F 93 C All connections must be leakproof e install line 1 1 1 2 inch diameter pipe from the 2 inch diameter ball valve to the cyclone inlet e Install line 2 2 inch diameter pipe from the 2 inch diameter coupling at the Clean Machine sludge tank to the 2 inch diameter coupling at the right rear of the washer e Install line 3 3 inch diameter pipe from the 3 inch diameter coupling on the Clean Machine tank to the 3 inch diameter coupling at the right rear of the washer NOTE Return pipelines to the power washer are gravity feed and must run downhill The MART Corporation Standard Turntable Power Washer v 4 0 Options NOTE Use a minimum of elbows and bends in the piping configuration Refer to chapter Installation for more information to the Cyclone inlet from the 2 diameter coupling at the sludge tonk to the 2 diameter TON WES ORIS Ap um cog 8 n the Clean Machine tank to the 3 Neuf IMPORTANT 3 and bends OPMANO22 Fig
35. he washer or to get inside the cabinet in order to grease the 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 Remote Grease Fittings are delivered installed according to your specifications 16 3 Operations The Remote Grease Fittings are located on the nearest outside surface of the washer to the bearing They are placed at a convenient height for the operator The remote turntable grease point is on the cabinet door The remote swivel grease point is on the wash manifold side of the washer near the door 16 4 Maintenance None 16 5 Troubleshooting None The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 75 17 Rinse Wand The Rinse Wand is an optional addition to the standard rinse system Its purpose is to manually rinse spot areas after a wash cycle The Rinse Wand consists of a gun shaped handle with an extended tube that has a spray nozzle at its apex The spray wand is hand operated Whenever the operator depresses the trigger water from the supply line is released through the nozzle at line pressure NOTE The water from the wand is not heated and contains no chemicals 17 1 Theory of Operation Supply line water pressure powers the spray The wand uses a two gallon a minute fan shaped nozzle Since water from spray is normally re
36. late 1444 grease ONLY Bearings are receiving too much grease Adjust the lubrication duration Adjust the Lube Cycle Counter to a higher number of cycles See the Operations section for instructions on changing the controller program Bearings are receiving too little grease Lengthen the lubrication duration Set the Lube Cycle Counter to 1 so 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 The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 9 2 Clean Machine The Clean Machine reduces clean out and re charging of the cabinet reservoir It automatically separates and collects sludge metal particles tramp oils and other contaminants during the wash cycle 2 1 Theory of Operation The Clean Machine can be set to operate manually or on a timer and can operate whether or not the washer is in operation When the Clean Machine is in operation washer solution is pumped from the washer reservoir through the Clean Machine and back into the reservoir Eductors connected to the return line churn the reservoir solution to prevent sludge from settling and building up Two processes are used in the Clean Machine to separate oils greases and particulate matter from the cleaning solution e A hydrocyclone removes heavy particles and entrains air into the solution Heavy particles settle out in
37. nd flows All other systems and components are the same 6 1 Theory of Operation The pump motor is 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 motor the smaller on the pump The pump motor is mounted on an adjustable base at the side of the reservoir This allows for aligning the belt drive as well as tensioning the belt s Depending on the horsepower of the pump the V belt drive uses 1to 3 belts 6 2 Installation This option arrives factory installed 6 3 Operations Operations are the same as those for a standard washer 6 4 Maintenance After the first 8 hours of operation check belt tension and sheave alignment To adjust belt tension follow this procedure 1 Remove the belt guard The MART Corporation Standard Turntable Power Washer v 4 0 Options 2 Turn the upper and lower adjusting bolts on the motor s adjustable base to tighten or loosen belts Turn each of the bolts exactly the same number of turns to maintain belt alignment Use a belt tension checker to verify proper tension NOTE Follow belt tensioner directions for proper tension adjustment NOTE When a properly tensioned belt is running the tight side of the belt forms a straight line from sheave to sheave The slack side slightly bows To verify sheave alignment follow this proce
38. not set properly Fuse needs to be replaced Wires need to be tightened Replace brushes Motor needs to be replaced Fig 7 41 Troubleshooting Sludge Scraper Drag Chain Does Not Move Standard Turntable Power Washer v 4 0 The MART Corporation 7 84 Installation Operations and Maintenance Manual 19 Short High Impact Manifold SHIM System The Short High Impact Manifold SHIM is designed to give you the advantage of two machines in one A standard work height machine and a shorter work height ultra high impact machine When retracted you have the benefit of the entire Cabinet height to wash tall parts and when deployed all the blasting energy is concentrated into a smaller work area for shorter loads and baskets of parts 19 1 Theory of Operation Two Power Blast Manifolds are coupled together and a set of valves directs the flow to one of the Manifolds The Standard PBM is full height and SHIM when deployed reduces the work height by approximately one half The SHIM Manifold has a fold down horizontal upper arm The vertical sections of the standard and SHIM manifold have the same number of nozzles 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 more than doubling the impact pressure for shorter wash loads A SHIM manifold is shown in the following figure 19 2 Operations Choose th
39. nside the part as the part rotates in the center of the turntable The center manifold cleans the interior as the power blast manifold PBM cleans the exterior 3 1 Theory of Operation A superstructure on the reinforced roof of the washer cabinet houses the center manifold as shown in the following figure The center manifold consists of a vertical manifold tube the length of the work height of the washer with 2 wash nozzles located horizontally and connected to the lower end The tube is guided through a pair of bushings in the cabinet roof The tube is raised and lowered by a roller chain and carriage which are driven by a gear motor Wash solution is piped to the vertical manifold tube through a hose attached to the back of 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 connected to the hose to carry rinse water The fluid flow for the center manifold is provided from a tap off the flow to the power blast manifold PBM Door Lock The center manifold system incorporates an additional feature on the standard washer to help prevent accidental damage to the vertical manifold tube or parts on the turntable An electrically actuated solenoid locks the washer cabinet door closed during operating cycles to prevent accidental opening with the center manifold in the down position The door remains locked
40. ot illuminate Check This Probable Cause s Selector switch Not set to auto or manual manifold at home position Switch light bulb Burned out replace Fig 7 11 Troubleshooting Center Manifold Light Does Not Illuminate The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 25 4 Chemical Conductivity Controller After you have determined an effective chemical concentration as described in chapters Overview and Advanced Operations Process Control you must monitor and maintain that concentration to provide consistent cleaning performance The optional Chemical Conductivity Controller automatically monitors and maintains chemical concentration by electronically measuring the electrolytic conductivity of the cleaning solution This is a useful technique for figuring out when to add more detergent to a high ionic strength cleaning solution such as those based on salts Potassium hydroxide sodium hydroxide or sodium metasilicate This is not a useful technique for monitoring high emulsifying cleaners that rely on surfactants for a significant part of the cleaning mechanism Electrolytes are ionic compounds such as salts acids or bases Added to water or a water based aqueous solution they increase its conductivity Conductivity is defined as the ability of a substance to conduct electric current All aqueous solutions conduct electricity to some degree The addition of electrolytes increases conduc
41. oting NOTE Use Lubriplate 1444 grease ONLY Every 160 hours of operation e Check the filter regulator lubricator unit The lubricator has an oil reservoir and is located on the right side of the washer Add oil if required to the fill level Refer to your vendor supplied cutsheet for instructions NOTE If the system runs out of grease you will have to prime the system Standard Turntable Power Washer v 4 0 The MART Corporation 7 8 Installation Operations and Maintenance Manual 1 5 Troubleshooting This section contains tables on the following problems e Automatic lubrication system fault light is ON e Automatic lubrication system fault light is ON Check This Probable Cause s Grease Pump Empty refill grease reservoir Control valve Stuck replace Air pressure Not in the 75 100 PSI 1000 1400 kg sq cm range check air supply system Electric solenoid Burned out replace Grease dividing valve Air bubble bled all air out of the system Stuck disassemble clean amp bleed Power Verify that the controller has power Step 4 in controller 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 lubrication cycle refer to chapter Advanced Operations Process Control and to chapter Maintenance for information on required lubrication NOTE Use Lubrip
42. pipe Therefore you must modify the standard installation procedures given in chapter Installation in this manual to account for these two differences Refer to the following section nstallation for more information Standard Turntable Power Washer v 4 0 The MART Corporation 7 46 Installation Operations and Maintenance Manual The centrifugal fan runs at two speeds e Low speed provides normal steam exhaust It works similar to the auto steam exhaust ASE feature e High speed minimizes steam leakage from the cabinet during HABO Refer to the vendor supplied cutsheet for instructions on setting fan speed Controlling HABO Heat Thermocouples in the outside plenum on top of the washer cabinet and a temperature controller inside the electrical control panel control HABO heat NOTE The outside plenum contains the blower unit the thermocouples and the heating element A redundant back up heat source measuring 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 HABO system you must modify standard ASE installation procedures Refer to the following figures MART has available as an option flanged transition pieces to adapt the ASE fan to round ducting To install the HABO follow these quidelines 1 There are two couplings welded into the ASE fan blade housing
43. r information on the controller To adjust the number of wash cycles before an automatic lubrication cycle or to change the duration of the lubrication cycle read the vendor supplied controller manual and adjust the controller steps as follows e Adjust Step 3 to change the number of machine cycles required to initiate an automatic lubrication cycle e Adjust Step 4 to 1 3 times the lube cycle duration This depends on your setting for Step 5 determine the amount of time Step 5 requires then adjust Step 4 For example if the lube Step 5 takes 10 minutes set Step 4 to 13 minutes e Adjust Step 5 to change the amount of grease pumped per automatic lubrication cycle NOTE Step 3 Step 4 and Step 5 are the only program changes that should ever be made in the field Standard Turntable Power Washer v 4 0 The MART Corporation 7 6 Installation Operations and Maintenance Manual NOTE Bearing Lubrication Bearing lubrication is critical Before making any changes to the lubrication cycle refer to chapter Advanced Operations Process Control and to chapter Maintenance for information on required lubrication NOTE Use Lubriplate 1444 grease ONLY Bearings are receiving too much grease Adjust the lubrication duration Adjust the Lube Cycle Counter to a higher number of cycles See the Operations section for instructions on changing the controller program Bearings are receiving too little grease Lengthen th
44. r blast manifold PBM 14 4 Maintenance WARNING NEVER disconnect the pressure gauge from the diaphragm seal Glycerin will leak out and damage the gauge assembly If the gauge does not read pressure follow this procedure 1 Unscrew the diaphragm seal and gauge together The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 69 2 Clean the gauge pipe out 3 If the problem persists replace the gauge and diaphragm seal assembly 14 5 Troubleshooting This section contains tables on the following problems e Pump pressure gauge does not work Problem Pump pressure gauge does not work Check This Probable Cause s Gauge pipe Clogged clean out Gauge Damaged replace Glycerin leakage replace Diaphragm seal Damaged replace Fig 7 35 Troubleshooting Pump Pressure Gauge Does Not Work Standard Turntable Power Washer v 4 0 The MART Corporation 7 TO Installation Operations and Maintenance Manual 15 Rack and Fixture Set or Small Parts Basket All parts must be secured to the turntable during the cleaning cycle To do this use the following e Rack and fixture set e Small parts basket Refer to chapter Basic Operations Loading and Securing 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 You may want to discuss yo
45. r with a standard electric motor oil suitable for small electric motors For example 10W 50 SAE oil Refer to the vendor supplied cutsheet for oil points During sludge clean out e Clean the wheel and frame If necessary remove 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 following problems e Skimmer wheel does not skim Problem Skimmer wheel does not skim Check This Probable Cause s Drain trough Clogged Blades Not contacting wheel Bend to adjust Replace if worn Wheel Not turning check tighten shaft nuts Motor Motor not turning 115 V Fuse needs to be replaced Wires need to be tightened Motor needs to be replaced Fig 7 32 Troubleshooting Skimmer Wheel Does Not Skim The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 63 12 Power Assisted Door The optional Power Assisted Door supplies power to the door of the washer cabinet which makes heavier weight loads easier to handle the operator can easily open and close the door weighted with up to 20 000 pounds 9070 kg of load NOTE The door can be operated manually without power assist 12 1 Theory of Operation The Power Assisted Door is pneumatically powered A tandem air hydraulic cylinder dampens and smoothes door operation Speed control valves on top of the cabinet can
46. rporation 7 40 Installation Operations and Maintenance Manual 7 3 Operations The wash pump driven configuration is fully automatic and runs during the wash cycle To operate the filter pump driven configuration follow this procedure 1 Set the filter pump timer located in the washer s electrical control panel The 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 in the following step 2 Setthe filter pump s selector switch located on the washer s control panel to one of the following e Manual Activates the filter pump It will run continuously e Off Turns the filter pump off e Auto Automatically activates the filter pump at the beginning of a wash cycle and runs the filter pump for the time indicated on the filter pump timer The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 41 7 4 Maintenance Every 40 hours of operation e Check the filter elements Replace dirty elements If you notice that cleaning results are not as good as usual or that more time is necessary check the filter elements If they are dirty replace them If your washer is equipped with the optional pressure differential gauge replace the filter when the pressure differential has increased by 10 PSI 142 kg cm or more 7 5 Troubleshooting This section contains table
47. s The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 31 4 5 Troubleshooting This section contains tables on the following problems e Peristaltic pump does not pump e Concentration cannot be maintained Problem Peristaltic pump does not pump Check This Probable Cause s Pump tubing Cracked move or replace Barrel Empty of concentrate replace Power Not ON Fuses Not intact remove and measure continuity 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 Conductivity cannot be maintained Check This Probable Cause s Peristaltic pump tubing Cracked move or replace Barrel Empty of concentrate replace Conductivity controller Set point incorrectly set Defective Chemical Concentration Wrong type of chemical Wrong concentration recommended or developed Concentration not proportional to conductivity Fig 7 14 Troubleshooting Conductivity Cannot Be Maintained Standard Turntable Power Washer v 4 0 The MART Corporation 7 32 Installation Operations and Maintenance Manual 5 Internal Reservoir Cover The internal reservoir cover provides the following benefits e Safety Provides a barrier covering the wash solution reservoir This isolates the operator from accidental contact with the hot wash solution as might occur if
48. s on the following problems e Wash load not clean e Solution leaks from filter cover Problem Wash load not clean Check This Probable Cause s Filter Dirty change filter Fig 7 20 Troubleshooting Wash Load Not Clean Problem Solution leaks from filter cover Check This Probable Cause s Cover gasket Dirty clean Cover clamps Loose tighten Fig 7 21 Troubleshooting Solution Leaks from Filter Cover Standard Turntable Power Washer v 4 0 The MART Corporation 7 42 Installation Operations and Maintenance Manual 8 Frequency Drive The optional Frequency Drive is an electronic device that controls pump motor speed The result is control of pressure and flow output 8 1 Theory of Operation The Frequency Drive is programmable for a variety of input output and performance configurations in industrial applications It can be mounted 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 Refer to the vendor supplied manual for more information 8 2 Installation If you specify that your Frequency Drive be mounted on the washer cabinet no further installation is required If you intend to remote mount the Frequency Drive follow the manufacturer s installation instructions and make appropriate electrical connections WARNING If you have the Frequency Driv
49. someone was to slip and fall e Catch Catches small parts that may loosen during the cleaning cycle and fall from the turntable The floor prevents the parts from falling into the solution and being lost in the reservoir e Insulation Provides a thermal insulation cover over the reservoir tank This slows down the heat loss from the reservoir saves energy especially when the cabinet door is open 5 1 Theory of Operation The internal 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 area to the reservoir The internal reservoir cover is removable for sludge clean out and other maintenance procedures It is held in place by thumbscrews which are easily removed and replaced 5 2 Installation If you purchase the optional internal reservoir cover your power washer is delivered with the internal reservoir cover factory installed and ready to use 5 3 Operations There are no operational procedures for the internal reservoir cover WARNING Do NOT OVERLOAD the internal reservoir cover or other horizontal surfaces The internal reservoir cover is intended as a chemical solution cover ONLY Horizontal surfaces are NOT designed for walking or standing Walking on the internal reservoir cover tank cover or other horizontal surfaces could result in serious injury or death The MART
50. t the first position lock wider than a 90 angle from the washer frame Lower the part to the transporter Remove the hoist from the part The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 59 10 4 Maintenance Inspect the jib crane according to OSHA 29CFR Section 1910 179 Every 160 hours of operation e Inspect the bronze washer on the boom shaft to be sure it is in good condition Replace the washer if it is worn Every year inspect the jib crane for the following e Swing the boom manually and carefully to be sure it moves freely e Check all bolts and parts for tightness e 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 cotter pin e Verify that there are no permanent distortions or cracked or corroded members Repair or replace parts as needed 10 5 Troubleshooting This section contains tables on the following problems e Boom does not swing freely Problem Boom does not swing freely Check This Probable Cause s Bronze washer Bronze washer on boom shaft has worn replace Jib boom wheel track Dirty Fig 7 30 Troubleshooting Boom Does Not Swing Freely Standard Turntable Power Washer v 4 0 The MART Corporation 7 60 Installation Operations and Maintenance Manual 11 Oil Skimmer The optional Oil Skimmer removes from the surface of the po
51. the drag chain tighten the bolts on the take up frame so that the drive 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 the torque limiter Lubricate the take up bearings The grease fittings are located at the chute end of the sludge scraper Every year Check the DC motor brushes for wear Replace as needed A diagram of the scraper is shown in the following figure Standard Turntable Power Washer v 4 0 The MART Corporation G CHAIN SPROCKET Installation Operations and Maintenance Manual DRIVE MOTOR DRAG CHAIN TENSION ADJUSTMENT TORQUE LIMITER SPROCKET ACCESS PAN DISCHARGE CHUTE DRAG CHAIN SCRAPER BLADI PMANDBA WEAR PLATE MACHINE FLOOR Fig 7 40 Sludge Scraper Diagram of Parts The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 83 18 5 Troubleshooting This section contains tables on the following problems e Sludge scraper drag chain does not move Problem Sludge scraper drag chain does not move 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 Motor Motor not turning Selector switch OFF 7 day clock
52. the turntable and properly aligned with the center manifold WARNING Be sure the part is centered properly so that the center manifold does not hit the part 3 Setthe center manifold mode selector switch located on the washer s control panel to one of the following e Man Turns auto mode OFF Activates the manifold jog push button which lets you manually control the down up position of the center manifold e Auto Returns the manifold to the home position and sets automatic cycle as part of the wash rinse cycle A light on the control panel illuminates each time the center manifold strokes during operation The center manifold works with the power blast manifold PBM e OFF Returns the manifold to the home position and disables auto cycle Refer to chapter Basic Operations for more information on loading and unloading parts Standard Turntable Power Washer v 4 0 The MART Corporation 7 22 Installation Operations and Maintenance Manual 3 4 Maintenance Refer to the previous figure to help locate parts during maintenance procedures Every 40 Hours of Operation Oil the chains and lift pin bushings in the carriage Follow this procedure 1 Turn the main power supply OFF 2 Verify that the manifold 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 Ifloose tighten the lift chain by using the adjuster located near the
53. therefore the amount of grease pumped during a lubrication cycle is programmable in the controller The factory preset is for 5 cycles 1 2 Installation The automatic lubrication system arrives factory installed The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 5 1 3 Operations Lubrication system operations are performed automatically They may also be started manually The controller is programmed at the factory for an auto lube cycle every machine wash cycle The duration of the auto lube cycle is factory preset for 5 cycles These settings are initial startup settings only You may want to change them depending on your needs The complete controller program with the factory presets is as follows Program Setting Description Step Step 1 Machine Counts Step 2 Counts X 1 Each machine cycle counts 1 Step 3 Run lube after every machine cycle Step 4 Number of minutes before fault occurs during lube Step 5 Number of switch transitions of cycle switch during lube cycle Step 6 Pulsed output to pump solenoid valve Step 7 Seconds of power on time for pulsed output Step 8 Idle mode no lube on power up Step 9 Normally energized fault relay goes off during power loss Step 10 Places controller in the operating mode These settings set the controller for machine cycle mode For further information on changing program settings and on the controller refer to the supplied vendo
54. tip over and severely injure or kill the operator WARNING Be sure the washer reservoir is filled to capacity with solution BEFORE using the Jib Crane DO NOT OPERATE the Jib Crane if you have not filled the reservoir to capacity with solution the washer could tip over and severely injure or kill the operator To load a part using the Jib Crane follow this procedure 1 Hold the door position lock handle up and push the door slowly away from the cabinet past the first position lock wider than a 90 angle from the washer frame Move parts up to the front reservoir Attach the hoist to a part Standard Turntable Power Washer v 4 0 The MART Corporation Installation Operations and Maintenance Manual Lift the part Rotate and hold the door position lock handle up and push the door slowly toward the cabinet until it locks in the first 90 angle position Move the part over the center of the turntable Lower the part to the turntable Remove the hoist from the part To unload a part from the washer using the Jib Crane follow this procedure 1 Pull the door open s owly until it locks in the first position 90 angle from cabinet frame Use the jog button located on the control panel to rotate the turntable for easy access to the part you wish to unload Attach the hoist to a part Lift the part Rotate and hold the door position lock handle up and push the door slowly away from the cabinet pas
55. tivity Since conductive liquids consist of ionic compounds electrolytes dissolved in water more ions in the solution indicate higher conductivity In applications using very pure to very concentrated chemical solutions a rising conductivity reading indicates a generally increasing chemical concentration Thus a simple electronic conductivity test can measure the makeup of a ionic solution and indicate its approximate chemical concentration Unfortunately compounds other than cleaning chemicals affect the conductivity of the solution These compounds include iron oxide rust and carbon both commonly found in most washing applications And some cleaning compounds are not conductive Conductivity measuring systems provide an estimate of the strength of the chemical in the solution by measuring the relative conductivity of the solution Conductivity is expressed in millionths of a Siemen microSiemens cm or uS cm One mS cm equals 1000 uS cm Contact your chemical supplier for a chart of conductivity vs concentration for your chemical and to determine if conductivity measurement is an appropriate technique for controlling the concentration of your solution Standard Turntable Power Washer v 4 0 The MART Corporation 7 26 Installation Operations and Maintenance Manual 4 1 Theory of Operation The Chemical Conductivity Controller system consists of the following e Conductivity controller e Electrode probe e Peristaltic pump e
56. to protect the gauge 2 3 1 Clean Machine Operation Frequency The amount of contaminants on the parts to be washed will determine how often you should operate the Clean Machine Standard Turntable Power Washer v 4 0 The MART Corporation 7 14 Installation Operations and Maintenance Manual Recommendations Heavy Soils Operate the Clean Machine on a daily continuous basis Light 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 the same chemical management principles for the Clean Machine that you use for the power washer Refer to section Chemical concentration Management in chapter Advanced Operations Process Control The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 15 2 4 Maintenance Sludge removal is the principal maintenance required on the Clean Machine NOTE You do not have to drain the washer or the oil skimming tank to remove accumulated sludge in the Clean Machine s sludge holding tank The hydrocyclone removes contaminates larger than 50 microns table salt is approximately 100 microns in diameter The exact rating is dependent on a number of factors including the specific gravity of the particle the actual particle size and the pressure at the cyclone entrance The hydrocyclone expels sludge from its apex into the slu
57. tor tank Standard Turntable Power Washer v 4 0 Options 7 13 2 3 Operations The Clean Machine system is designed to operate when the washer is in use or after hours when the washer is in shut down off mode NOTE The maximum separation of sludge and oils will occur after a few days of washing heavily soiled parts To operate the Clean Machine follow this procedure 1 Set the Clean Machine s selector switch located on the washer s control panel to one of the following e Manual Activates the Clean Machine s pump It will run continuously e Off Turns the Clean Machine s pump off e Auto Automatically activates and runs the Clean Machine according to the program set for circuit 2 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 e The oil skimmer is rotating clockwise e Water is being discharged from the bottom of the hydrocyclone NOTE To adjust the control valve on the Clean Machine pump open the valve completely Then if you notice that water overflows from the oil skimmer tank into the sludge tank slowly close the 1 1 2 inch diameter 3 8 cm valve just until water no longer overflows Open the gauge valve on the cyclone and note the pressure reading The reading should be more than 15 PSI for the best separation Close the gauge valve
58. tside plenum on the washer cabinet 3 Bolt the plenum to connection points on the cabinet 4 Connect heating element wires and blower motor wires to the conduit on the washer Match corresponding wire abels 5 Turn the main power supply ON Standard Turntable Power Washer v 4 0 The MART Corporation Installation Operations and Maintenance Manual So N X Te yo N i Fi fe ES Ne t WASHER ROOFS ort N 22 DUCT ott EMPI EATER UR THERMOCOUP RA LIMIT DUC HEATER EE EMPERATURE HERMOCOUPL E INSIDE W SH CABINE OPMANO79 Fig 7 26 Hot Air Blow Off HABO Inside Plenum The MART Corporation Standard Turntable Power Washer v 4 0 Options 9 3 Operations Refer to chapter Basic Operations for general washer operating procedures WARNING Turn the washer s main power supply OFF before opening the electrical control panel Follow this procedure 1 Standard Turntable Power Washer v 4 0 Position parts on the turntable so they will drain as best as possible Deep pockets or hidden areas will retain water Place parts as close to the nozzles as possible Air velocity is highest near the outer edge of the turntable Set the HABO temperature controller to the desired temperature The controller is located inside the electrical control panel WARNING Do NOT set the HABO temperature controller above a maximum set point of 200
59. turned to the water reservoir a solenoid valve connected to the solution level control system disallows spray wand use whenever the solution level is at the HIGH HIGH maximum mark A light on the control panel indicates this condition 17 2 Installation This option is factory installed 17 3 Operations After a cleaning cycle has completed open the washer door to the first door position lock stop Use the jog button to rotate the turntable as you inspect the wash load for any area that may need additional rinsing If you find such an area release the jog button to stop the turntable WARNING Be sure to wear protective gear face shield gauntlet gloves rubber apron Spray could be deflected back at you and could contain chemical residue that could cause serious chemical and scald type burns to eyes and skin Standard Turntable Power Washer v 4 0 The MART Corporation 7 76 Installation Operations and Maintenance Manual Follow these operating quidelines 1 Stand back several feet from the washer 2 Aim the wand at the part 3 Pull the trigger and direct the spray to the area that needs to be rinsed Remember the following e Wand water is not heated It will not flash dry as quickly as rinse water in the washer e Wand water returns to the reservoir and uses part of the rinse bank rinse bank is the available volume for rinse water Therefore use of the wand could result in shortened rinses or no rinse at
60. ual 19 4 Troubleshooting Use procedures in chapters Installation Advanced Operations Process Control 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 This section contains tables on the following problems e PBM not oscillating Check This Probable Cause s Problem PBM not oscillating Linkage Not connected Out of adjustment Loose Not connected to shaft Bearings Failed Swivel Not properly adjusted Not lubricated Not moving freely PBM gear motor Not rotating check wires fuses overload tripped PBM mounting plate Motor not securely attached to it Fig 7 44 Troubleshooting PBM Not Oscillating The MART Corporation Standard Turntable Power Washer v 4 0
61. ur hands into the scraper chute This could result in severe injury To operate the Sludge Scraper follow this procedure WARNING Disconnect power before opening the control panel 1 Set the Sludge Scraper timer located in the washer s electrical control panel The standard 10 hour timer is numbered 1 10 each number represents a 1 hour increment 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 control panel to one of the following e Manual Allows manual operation of the sludge scraper using the jog buttons e Off Turns the scraper off e Auto Automatically activates and runs the scraper for the time indicated on the scraper timer The scraper will restart start when a wash cycle begins and continues for the time set after the last wash cycle If another wash cycle is started before the timer times out the timer is reset with the last wash cycle To operate the jog function follow this procedure 1 Set the selector switch on the control panel to manual 2 Goto the sludge scraper s discharge area and press the forward or reverse jog button located in the small sludge scraper control panel The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 81 18 4 Maintenance Every 40 hours of operation Check chain tension If you need to adjust the tension of
62. ur requirements with your MART representative especially before you alter or add to the basic configuration to customize it for an application 15 2 Installation There is no installation required The rack and fixture set and small parts basket arrive ready to use NOTE Large racks or fixtures may need to be assembled The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 T1 HEAD RACK VERTICAL SUPPORT POST Fig 7 36 Rack and Fixture Set Standard Turntable Power Washer v 4 0 The MART Corporation 7 72 Installation Operations and Maintenance Manual 15 3 Operations Refer to chapter Basic Operations Loading and Securing Parts for information on using securing devices with the rack and fixture set To use the rack and fixture set follow this procedure 1 2 Select the appropriate 16 inch 40 6 cm or 32 inch 81 3 cm vertical post Insert it into a turntable socket that will position the oad nearest the center of the turntable and ensure that no part of the load will hang outside the turntable Attach a head rack or other fixture to the top of the centering vertical post facing the center of the turntable Load the part vertically inside the head rack or fixture Attach securing devices as described in chapter Basic Operations Loading and Securing Parts To use the small parts basket follow this procedure refer to the following figure
63. ure control valve allows the operator to adjust water flow and pressure to the power blast manifold PBM The pressure gauge indicates the amount of pressure 13 1 Theory of Operation The operator turns the control valve clockwise to close it decreasing water flow to the PBM The reduced flow results in lower pressure through the PBM nozzles The valve will not slip so pressure 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 between the pump and the PBM is used as a pressure tap point for a glycerin filled pressure gauge The pressure tap piping is a large diameter for easy clean 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 dial 13 2 Installation This option arrives factory installed 13 3 Operations While the wash pump is running turn the control valve until the pressure you wish is indicated on the pressure gauge The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 67 13 4 Maintenance WARNING NEVER disconnect the pressure gauge from the diaphragm seal Glycerin will leak out and damage the gauge assembly If the gauge does not read pressure and the control valve is open follow this
64. ve across the bottom of the reservoir collecting sludge and carrying it up the chute At the end of the chute the sludge drops into a bin or barrel The scrapers then move back down the chute into the washer reservoir and begin to scrape the bottom of the reservoir The scrapers are attached to a sprocket mounted drag chain that continuously rotates The drag chain is chain driven by a gear motor through a sprocket torque limiter The gear motor is a variable speed DC drive motor with a speed controller located in the washer s electrical control panel You can set the motor from low to high speed An external view of the sludge scraper is shown in the following figure The MART Corporation Standard Turntable Power Washer v 4 0 Options 7 79 i rp DRIVE MOTOR DRIVE CHAIN GUARD MAIN WASH DRAG CHAIN CABINE ADJUSTMENT SCRAPER A TROUGH DISCHARGE CHUTE OPMANO8 Fig 7 39 Sludge Scraper External View 18 2 Installation The Sludge Scraper is factory installed Standard Turntable Power Washer v 4 0 The MART Corporation 7 80 Installation Operations and Maintenance Manual 18 3 Operations The Sludge Scraper is designed to operate when the washer is in use or after hours when the washer is in shut down off mode A forward and reverse jog feature is provided to help free any scraper jams WARNING NEVER put yo
65. wer washer s sump floating oils greases sludge fatty acids and other contaminants that cling to the wheel These contaminants cling to the rotating skimmer wheel and are then scraped off into a container by spring loaded wiper blades Water is not removed The skimmer provides these benefits e Extension of cleaning solution life e Better cleaning results e Reclamation of oil in many cases 11 1 Theory of Operation The Oil Skimmer is mounted in a small box on 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 single phase 60 cycle gear motor The skimmer is lightweight and has only one moving part The skimmer s manual off auto switch is located on the washer s control panel Skimmer Function The lower part of the skimmer wheel is submerged in the solution As the wheel rotates it picks up oil and other clinging contaminants from the surface of the solution The contaminants are collected in the run off trough and directed to a suitable disposal container The skimmer will remove up to 1 1 2 gallons 5 7 liters of contaminants each hour Skimmer Skimmer Outlet a Wheel Skimmer Blades Skimmer Trough Skimmer Mounting Box Fig 7 31 Oil Skimmer Assembly The MART Corporation Standard Turntable Power Washer v 4 0 SPUR CE 11 2 Installation Follow this proce
66. yproducts of the cleaning process affect conductivity Thus the only true measure of chemical concentration is to use titration tests in conjunction with conductivity measurements to determine a correlation Once you know the correlation you can get a fairly accurate estimate of chemical concentration in the solution by using a conductivity measuring system Titration Titration is the estimation of the strength of a compound by measuring the amount of another compound of known strength that is required to produce an observable reaction Almost all titration kits supplied with cleaning compounds use phenolphthalein 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 drops of acid it takes to turn the solution back to its original color you can arrive at a good estimate of the chemical concentration Standard Turntable Power Washer v 4 0 The MART Corporation 7 28 Installation Operations and Maintenance Manual Correlating Titration Results and Conductivity Measurements To measure the chemical concentration in your washer s cleaning solution titrate the solution once a week and perform a conductivity test at the same time Your objective is to learn how chemical concentration and conductivity vary from wash to wash Set up a graph that shows the correct concentration and then graph the actual variance in

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