Industrial Hot Water Fully Electric OWNER'

Industrial Hot Water Fully Electric
OWNER’S MANUAL
Special Inspection
Call 1-800-315-5533
Email sales@easykleen.com
Website: www.easykleen.com
BEFORE YOU BEGIN!
HIGH-PRESSURE WASH EQUIPMENT AND THE SPRAYS THAT THEY GENERATE
CAN CAUSE SERIOUS INJURY.
THINK SAFETY FIRST!
The forces generated by high-pressure sprays can penetrate clothing or skin and cause severe
personal injury. Additionally, the high-pressure spray and material dislodged by it may be
deflected back toward you and / or persons or objects nearby. Water or water combined with
cleaning agents or soap can make floors and other surfaces slippery, creating the possibility of
persons or objects falling. Power cords and high-pressure hoses create a further hazard and should
always be stored neatly when not in use. During any cleaning operation, hoses and power cords
should be laid flat on the ground and away from areas where they may become entangled in objects
or cause tripping of persons passing by. Always consider the surrounding environment and
conditions before beginning any cleaning operation.
Eye protection, safety footwear and protective clothing should always be worn when using this
equipment.
Never place any part of your body in front of the high-pressure nozzle.
Never direct the high-pressure spray at yourself or any other person.
Never allow children to operate the pressure washer.
Hold the trigger gun/wand assembly securely with both hands when operating the pressure washer.
Never direct the high-pressure spray at any electrical device or the pressure washer itself.
Never operate electrically powered pressure washers where they will be exposed to rain or other
forms of precipitation or spray.
Never operate the pressure washer with damaged parts or components.
Never allow the machine or accessories to freeze.
Do not drive over or crush high-pressure hoses or allow them to come in contact with sharp objects.
Do not operate electrically heated system without first supplying water to the heat exchanger tank.
Fill the water tank with clean water to safe levels of operation.
Do not attempt to move or pull the machine (portable equipment) by the high-pressure hose or
electrical cord.
When not in use, turn the machine OFF and depress the trigger gun to remove residual system
pressure
Do not operate the system without a water supply.
Do not allow the machine to operate (by-pass) for extended periods with the trigger gun closed or
without discharging water.
Avoid rapid triggering and releasing of the gun. Smooth triggering will extend the life expectancy of
the system components.
High-pressure wash system components are sensitive to solid matter and debris that may be present
in the fluid moving through them. Additionally, material allowed to enter hoses and various
connections when the equipment is improperly moved or stored can increase the potential for
failure. To avoid component fouling, poor system performance and costly downtime, always ensure
that a clean water supply and when possible, a clean environment is provided to the machine
Easy-Kleen Pressure Systems
1-800-315-5533
This manual contains operational information that is specific for
The EH Industrial Hot Water Fully Electric Models
Read the following instructions carefully before attempting to assemble,
install, operate or service this pressure washer. Failure to comply with these
instructions could result in personal injury and/or property damage.
Table of Contents
MODEL SPECIFICATIONS................................................................................4
PROTECTING THE SYSTEM FROM FREEZING .................................................5
EQUIPMENT PREVENTATIVE MAINTENANCE ................................................6
ELECTRIC HEAT EXCHANGER..........................................................................7
MAINTENANCE ..............................................................................................9
GENERAL INFORMATION..............................................................................10
HEAT EXCHANGER DIAGRAM.......................................................................11
CIRCUIT DIAGRAM........................................................................................13
MANUFACTURER'S WARRANTY....................................................................14
SERVICE MANUAL.........................................................................................15
3 of 23
Rev. 4/8/2016
SPECIFICATIONS
Industrial Hot water Fully Electrically Heated
HEATER
MODEL
GPM
PSI
INPUT
EH411E24A
EH411E24A
EH411E48A
EH420E24A
EH420E448A
EH420E472A
EH430E424A
EH430E448A
EH430E472A
EH440E448A
EH440E472A
EH450E448A
EH450E472A
EH550E448A
EH550E472A
EH535E448A
EH535E472A
EH562E448A
EH562E472A
EH612E448A
EH620E448A
EH620E472A
EH812E2448A
EH812E2472A
EH820E2448A
EH820E2472A
EH830E2448A
EH830E2472A
EH1030E2472A
*
EH1030E2496A
*
4
4
4
4
4
4
4
4
4
4
4
4
4
5
5
5
5
5.6
5.6
6
6
6
8
8
8
8
8
8
10
10
1200
1200
1200
2000
2000
2000
3000
3000
3000
4000
4000
5000
5000
5000
5000
3500
3500
2000
2000
1200
2000
2000
1200
1200
2000
2000
3000
3000
3000
3000
24KW
24KW
48KW
24KW
48KW
72KW
24KW
48KW
72KW
48KW
72KW
48KW
72KW
48KW
72KW
48KW
72KW
48KW
72KW
48KW
48KW
72KW
48KW
72KW
48KW
72KW
48KW
72KW
72KW
96KW
MOTOR
HP
3
3
3
5
5
5
7.5
7.5
7.5
10
10
15
15
20
20
10
10
7.5
7.5
5
10
10
7.5
7.5
10
10
15
15
20
20
4 of 23
TOTAL AMP 3PH
208
208
72.5
134.8
77.1
139.6
N/A
85
147.5
N/A
154
N/A
N/A
N/A
N/A
N/A
154
N/A
147.5
N/A
139.6
147.5
N/A
147.5
N/A
154
N/A
165
N/A
N/A
N/A
460
460
33.3
62.2
35.5
64.4
93.3
39.1
68
96.5
70.9
99.8
75.9
104.8
82.8
112.2
70.9
99.8
68
96.9
64.4
68
96.9
68
96.9
70.9
99.8
75.9
104.8
112.2
141.3
575
575
26.6
49.7
28.4
51.8
74.4
31.3
54.4
76.9
56.7
79.9
60.7
83.9
66.5
89.8
56.7
79.9
54.4
77.6
51.8
54.4
77.6
54.4
77.6
56.7
79.9
60.7
83.9
89.8
113.1
DIMENSIONS
L" x W" x H"
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
38x28x55
38x28x55
38x28x55
38x28x55
32x24x52
32x24x52
32x24x52
32x24x52
32x24x52
53x48x40
53x48x40
53x48x40
53x48x40
53x48x40
53x48x40
53x48x40
53x48x40
53x48x40
53x48x40
Rev. 4/8/2016
PROTECTING THE SYSTEM FROM FREEZING
If the equipment will be used or stored in areas where it will be exposed to temperatures below 0° Celsius
(32° Fahrenheit) for any period of time, precautions must be taken to prevent damage due to freezing.
Draining the system does not offer adequate protection. Use of a high quality plumbing antifreeze or
automotive windshield washer antifreeze is recommended. Glycol based antifreeze may be used, but be
sure to follow the manufacturer’s directions for correct mixture and for proper disposal after use. The
following method may be used to protect the system when not in use.
1. Disconnect the power supply to the machine and turn off all control switches (Turn off engine on gas
powered machines)
2. Turn off the water supply.
3. Relieve any trapped pressure in the system by squeezing the trigger gun but leave high pressure hose(s)
attached to the discharge.
4. Remove supply hose.
5. Fill a clean container of sufficient size to supply the machine with enough antifreeze solution for
approximately two minutes operation (i.e. 8 gallons for a 4 GPM system).
6. Connect a short hose to the inlet of the system and submerge the open end in the antifreeze close to the
bottom of the container.
7. Restore power to the machine and turn control switch to MANUAL position. (Start engine on gas
powered machines)
8. Open and hold trigger gun until antifreeze is discharged from nozzle. (Most antifreeze compounds will
foam slightly when discharged from system). Discharged antifreeze may be directed back into container for
reuse or proper disposal.
9. Close the trigger gun momentarily to force solution through by-pass loop.
10. Repeat steps 1, 3, and 4
If desired, compressed air may be connected to the inlet connection of the system to force the remaining
antifreeze solution from the system; however, air pressure should be regulated to no more than 80 PSI.
5 of 23
Rev. 4/8/2016
EQUIPMENT PREVENTATIVE MAINTENANCE
Regular inspection and maintenance of your system is the best defense against equipment
failure and costly downtime. Additionally, the high-pressure wash systems can create safety
hazards. Simple checks, performed by the operator of the equipment or maintenance personnel on a
regular basis, will help to ensure safe operation and that the system’s maximum performance and life
cycle is achieved. The guidelines below pertain to the basic system and components only.
Further consideration should be given to optional accessories when included.
Daily Maintenance should include the following:
Check that all water supply and high pressure discharge hoses as well as all power cords do not
create an obstruction that may cause anyone to trip or fall.
Check that all controls, switches and disconnects are readily accessible and can be reached
quickly in case of emergency.
Check inlet water supply valves and hoses for signs of leakage and correct where needed.
Check inlet water supply hose for kinks or other forms of restriction that can interrupt
proper flow in to the system.
Check that all electrical cords and wires are properly secured/connected and do not pose a
potential hazard for electrocution. All electrical supply and motor connections must include a
ground wire.
Check that the area around the unit is clear and dry.
Check that all moving parts such as belts, pulleys, motor fans etc., are clear of debris that could
become entangled or otherwise come in contact with them.
Check the pump oil sight glass or dipstick for the correct oil level and signs of contaminants
(water or metallic particles).
Untangle the high presser hose if needed.
Check the hose for nicks, cuts and abrasions that can lead to leaks.
Check that the nozzle is clear of debris and operates correctly.
Check for adequate water to the unit.
Check that the chemical tank is full
Check that the Chemical tube is clear and in the tank.
Weekly Maintenance should include the following:
Check and clean inlet filters and screens
Check and clean the chemical filter/screen
Check for signs of water and / or oil leaking around the pump
Monthly Maintenance should include the following:
Update your record of inspections, problems or any potential problems
Check for any oil leaks at the crankcase, crankshaft or piston seals
Check controls are working within specifications
Quarterly Maintenance should include the following:
Change the pump oil every 3 months or 500 hours of use, whichever occurs first
Check the inlet and discharge valve assemblies and O-rings should be checked or changed
every 3 months
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Rev. 4/8/2016
ELECTRIC HEAT EXCHANGER
Functional Description
The function of our heat exchangers is to enhance an existing high pressure cold water wash system by
enabling it to create hot water downstream of the height pressure pump. It also allows the system to operate
automatically, virtually eliminating the problems that are often associated with “hands-on” controls. High
pressure cold water is circulated through a tubular coil which is submerged in hot water in an unpressurized
tank. The cold water is then heated by the surrounding hot water.
Motor controls as well as other system controls and safety features are provided with the heat exchanger,
and are enclosed within the unit eliminating the need for separate pump control.
Our heat exchangers have been designed with the maximum efficiency in mind. There is no need for messy
and potentially dangerous fuel storage and no need for venting. The unit may be located in any convenient
location. High pressure hot water is only the squeeze of a trigger away, and our heat exchangers deliver it to
you instantaneously; NO WARM UP PERIOD.
Cold Inlet Water Connection
Inlet connection to the heat exchanger is made by connecting a high pressure discharge hose
(optional) from the discharge port of the high pressure pump unit to one of the fittings provided on top of
the heat exchanger. DO NOT EXCEED MAXIMUM SYSTEM PRESSURE (See specifications on the
third page).
Hot Discharge Water Connection
Discharge connection is made from the fitting opposite the inlet to the hose/gun/lance assembly, or to
plumbing for remote station(s) operation.
Automatic Controls
Automatic controls include water temperature control, low heat exchanger water level shut off, and
pump motor control circuit complete with time delay stop. Motor circuit fusing and overload protection are
also provided. In addition all heat exchanger control circuits have provisions for connecting a flow switch
and optional pump thermal protector.
The thermostat maintains tank water temperature at approximately 180 degrees F (82 degrees C). A level
switch in the tank will open if, the water level should drop to a point where operation of the unit is affected
Electrical Supply Hookup
Electrical service for the system is run to the terminal block on the electrical panel labeled L1, L2,
L3. A ground lug is also provided. This unit must be properly grounded to prevent electrical shock. A fused
disconnect is to be provided according to local codes. Refer to ID plate for voltage and total connected load.
ALL ELECTRICAL WORK TO BE PERFORMED BY A QUALIFIED ELECTRICIAN.
WARNING: This controller must be provided with suitable overload and overcurrent protection in
accordance with the Canadian Electrical Code part 1.
UNIT TO BE CONNECTED TO A (GFCI) OR TWIST LOCK PLUG OR PERMANENT
CONNECTION
7 of 23
Rev. 4/8/2016
Motor/Motor Control Connection
The high pressure pump motor is to be connected to the motor contactor overload connections labeled T4,
T5, T6. Be sure that the motor current ( see FLA rating on motor plate) is within the current rating of the
motor overload, and that the overload is set to the proper current level. A ground lug is also provided for the
motor circuit. Electrical leads from a flow switch (optional) are to be connected to the terminal strip labeled
FLOW SWITCH CONNECT, at terminals 7 & 8. An optional thermo probe may be connected at terminals
9 & 10. The purpose of this probe is to protect the high pressure pump from overheating. A thermally
activated switch within the probe will open when the pump temperature is too high, stopping the unit. The
system will start again only when the temperature has been restored. On units that are not equipped with this
feature, a jumper wire (installed at the factory), must connect terminals 9 & 10 and it is suggested that
another type of thermal protector be used.
Startup and Adjustment Procedures:
Installation
Install the Electrically Heated System in accordance with pumping package and heat exchanger directions.
See pump and heat exchanger directions. This equipment should be installed and serviced by qualified
personnel.
Turning Power On
Do not turn power on until the heat exchanger is filled with water as severe damage may occur if water is
not above heater elements. To fill heat exchanger, remove 1 ¼” pipe plug from the elbow fill pipe located on
the heat exchanger. Insert water hose and fill. Heater tank will require approximately 70 gallons (265 litters)
of water on initial fill. After a water level has reached the fill elbow the power may now be turned on. It will
take 15 to 20 minutes for the heat exchanger to reach operating temperature. WATER WILL EXIT THE
FILL PIPE WHILE THE HEATER TEMPERATURE IS RISING. This is due to the heat expansion of
the cold water just added. This will stop after the heater has reached its operating temperature. Replace and
hand tighten the 1 ¼” fill pipe plug. After initial heating of the tank leave the main power on to the
equipment. This will ensure hot cleaning solution instantly on pump start up.
Turning Water On
Turn the inlet water supply on after the pumping package has been installed. See pumping package
section for details.
CAUTION!
Before pumping package is started for the first time, or after maintenance has been performed on any supply
or discharge water lines, all air must be purged from the system. Failure to do so may result in system
damage.
System Operation
Caution: Pressure cleaning gun must be HELD ONTO SECURELY when the pump is turned on as
serious personal injury may be inflicted if spray wand is allowed to move freely. High pressure spray can
cause SERIOUS BODILY HARM- HANDLE WITH CARE- NEVER POINT SPRAY AT ANY
PART OF THE BODY. Proper protective equipment should be worn if corrosive chemicals are used. With
pumping unit off pull the gun trigger to ensure that the water is running through the nozzle. Check the
supply line to ensure there are no kinks in the hose. Release the gun trigger. Place the operators switch
located on the heat exchanger in the “A” automatic position. You are now ready to clean.
8 of 23
Rev. 4/8/2016
Pressure Regulation
This unit has been adjusted at the factory and preset at the designed specifications. DO NOT READJUST
IN AN ATTEMPT TO INCREASE PUMP PRESSURE. This will only increase the regulation
pressure which will cause internal pump damage or motor overload.
MAINTENANCE
Daily
To ensure a problem free- system simple visual checks can be performed. Check for leaks in inlet
supply, pumping system, pump to heater hose, gun(s) and high pressure hose. Check and refill chemical
concentrate. Check pump oil level/ condition. Check nozzle condition. If badly worn or leaking conditions
are found, qualified personnel should repair or place components with new original or equivalent
manufacturers parts.
Check equipment for proper operation. Nozzle spray should be uniform in flow, angle, and pressure. Clean
if nozzle is plugged and replace if worn. If a heavy pulsation is the hose or spray is observed, repair of the
pumping system is required.
Weekly
After the first week of operation it is recommended 1litre of motor oil be added to be beat exchanger
tank through the 1 ¼ fill pipe. This oil creates a vapor barrier and slows evaporation of water in the tank.
Check heat exchanger water level. The level must be up to the filler pipe neck. Add water if necessary. If
cold water has been added, heating may cause the expanding water to escape through the filler plug. This
will stop after operating temperature has been reached.
Monthly
Check system for operation. Automatic start/stop, hot high pressure water, and smooth operation should be
noted. Check tank water level; refill if necessary. Should the tank ever be completely emptied, 450 g of
perafilm P must be added to the tank. This prevents corrosion.
Change oil in pump crankcase. Note the condition of the oil when drained. If found to be creamy, the water
seals in pump may have to removed and replaced. Fallow the pump manual directions.
FAILURE TO MAINTAIN YOUR PRESSURE WASHER/EQUIPMENT, INCLUDING REGULAR
MAINTENANCE OF PUMP AND SYSTEM COMPONENTS, WILL VOID MANUFACTURER'S
WARRANTY.
Symptom
Pulsation
Possible Cause
Solution
Excessive pressure and/or temperature of fluid
being pump.
Check pressures and/or temperature.
Reduce to acceptable level. Reduce
pressure.
Unloader/regulator set too high of pressure.
Running pump dry.
Reduce Pressure
Faulty Pulsation Dampener.
DO not run pump without water.
Check pre-charge, if low, re-charge it
or install a new one.
9 of 23
Rev. 4/8/2016
GENERAL INFORMATION
Introduction
The electrical Single heater consists of a, single coil heat exchanger, control components, thermo probe,
float switch, high pressure hose(s) connections.
THIS MACHINE SHOULD BE PROTECTED FROM FREEZING AT ALL TIMES. (SEE
MAINTENANCE)
Installation Location
Place system in any suitable location. Adjusting the leg bolts levels the unit. It is recommended to provide
ample room and support for installation, maintenance, and operation of elevated systems. Drainage should
be provided near the unit.
The pumping unit is designed to be located on top of the heat exchanger although it may be located beside
it.
System Functions
In every Electrically Heated System the following standard features can be found:
1. Automatic start circuit complete with manual override
2. Automatic time delay stop circuit
3. Automatic temperature controlled heat exchanger
4. Thermal safety shutdown on pumping system to protect pump components
5. Low water shutdown circuit to protect heating elements from lack
of water in the heat exchanger
6. Corrosion resistant incoloy heating elements (tube type)
7. Fifty feet of 3/8” steel braided hose
8. High pressure trigger gun
9. Lance complete with chemical valve
10. Chemical injection system
11. Complete motor fusing and overload protections
Note: Some of this features may not applied to your build. Check with serial and model number for
features that come with your pressure washer.
10 of 23
Rev. 4/8/2016
HEAT EXCHANGER DIAGRAM
The design feature of our Heat Exchanger allows high pressure cold water to be heated in an
unpressurized tank. Cold water entering the heat exchanger passes through a coil submerged in heated
water. Electrical controls for the exchanger and pumping package are mounted on the outside of the tank.
The protective outer wrap and front panel enclose the controls.
After filling the water tank to the level indicated in Fig3, turn the heat exchanger switch to the “ON”
position. Once the heater has reached the set temperature, water may drip through a small hole in the 90
deg. to prevent pressure from building up which can naturally occur when water is heated to high
temperature.
Figure 3
Heat Exchanger
11 of 23
Rev. 4/8/2016
8
12 of 23
Rev. 4/8/2016
MANUFACTURER’S WARRANTY
The manufacturer warrants all original equipment of the manufacturer to be free
from defects in material and workmanship as follows:
Pump Head
Pump Crankcase
Internal Pump Parts
Heating Coil
Honda Engine* Kohler Engine* Others
Electric Motor*
Frame and Body Materials
Burner Assemblies
Wheels and Castors
Accessories, Unloader, Safety Valves
Hoses, Fittings, O’Ring, and Elastomers
Pressure Gauges
10 years
5 years
90 days
5 years, 1 prorated
3 years, 1 year
1 year
10 years
1 year
90 days
90 days
90 days
90 days
Within the periods stated above and at the discretion and approval of Easy-Kleen, if there is
shown to be a defect in material or workmanship, the defective parts will be repaired or replaced
at the manufacturers place of business or an original manufacturers repair depot when returned
PREPAID. This warranty will not cover labor if warranty work is conducted at the customer’s place
of business. Road service will be charged at the normal rate in these situations. Damage resulting
from freezing, accident, neglect, tampering, abuse, alteration, or improper installation and
operation will automatically void this warranty.
All labor repairs are to have an Easy-Kleen pre-authorized repair number (PARN). In order to
receive a PARN, please email a copy of your invoice to our service department and make sure to
clearly indicate the date of purchase and the serial number of the machine. A pre-determined
service time will then be appointed to you. If new parts are needed, they will be invoiced to you as
normal. Defective parts are to be sent to us prepaid for warranty and consideration. If a part is
found to be defective, a credit will be issued to cover the costs of parts and shipping.
Note: This warranty will not extend to consequential damage or liability that occurs as a
result of original defect.
* Due to original equipment manufacturer’s requirements, Easy-Kleen is not permitted to perform
warranty repairs or claims for electrical motors, gas, or, diesel engines. If you require warranty
information for these please call our service department and they will put you in touch with your
local warranty representative.
If you have any questions or comments regarding this warranty please call 1-800-315-5533.
Easy-Kleen Pressure Systems Ltd
41 Earnhardt Rd
Sussex Corner, NB, Canada
E4E 6A1
E-mail: sales@easykleen.com
website: www.easykleen.com
14 of 23
Rev. 4/8/2016
SERVICE MANUAL
EASY KLEEN PRESSURE SYSTEMS
This manual is intended for technical personnel to assist in the diagnosis and repair of
issues with pressure washers.
This manual is not intended for use by non-technical personnel.
It is advised to always refer to competent technical personnel for repairs to avoid equipment
damage or potential injury.
If you have any technical questions please do not hesitate to call us at 1-800-315-5533.
15 of 23
Rev. 4/8/2016
No Flow
PROBLEM
Low pressure, adequate
flow
Low pressure, low flow
Low pressure, low flow Bogs
FLUID SYSTEM DIAGNOSTICS - Flow and Pressure
POSSIBLE CAUSE
No power
Trigger gun valve
No water source
Clogged spray nozzle
Clogged inlet filter
Float Valve stuck (optional)
Faulty unloader valve
Incorrect or no spray nozzle
Worn spray nozzle
Debris in valves
Lance on low pressure
Unloader is not adjusted correctly
Pressure gauge inaccurate
Pump packings bad
Volume Improperly adjusted
Discharge leaks
Downstream chemical injector
(Dema)
Loose drive belts
Pump not running at rated speed
Stripped pump drive coupling
Defective easy start valve
(optional)
Malfunctioning motor or gear
Unloader stuck in bypass
Outlet restriction
Clogged nozzle
Nozzle too small
Hose restriction
Debris in the system
SOLUTION
Make sure pump is operating. Check drive belts and couplings, make necessary adjustments.
Check trigger gun, repair or replace.
Ensure water supply is not restricted and hoses are in good repair and not kinked.
Check spray nozzle, repair or replace.
Check inlet filter, repair or replace.
Float valves can become stuck in the "UP" position. Manually dislodge and inspect for problems.
Remove and check for proper action, repair or replace.
Nozzle should be properly sized for the system. Low pressure indicates that the nozzle in use is
too large.
Replace nozzle when it shows signs of internal erosion.
Clean valves and check o-rings for pits and cracks.
Adjust pressure so the water flows through properly.
Adjust unloader to proper level.
Use a new pressure gauge on a quick connect at outlet to check system pressure and replace if
gauge is faulty.
If low pressure persists, pump packings may need replaced.
If unit has volume adjustment, it may need readjustment
Look for leaks on the discharge side of system.
Remove the injector and retest system. If the flow is restored, replace the injector.
If belts do not have proper deflection, replace them.
Check engine throttle and see that the motor is rated for the same speed as the pump.
Inspect coupling and repair or replace.
Check the start or throttle-back valve for proper operation.
Ensure that the motor or engine is working properly
Piston assembly may be stuck or fouled
Build up can restrict flow. If water is not flowing freely, flush with garden hose to isolate the clog
or restriction.
Distorted spray pattern can indicate a clogged nozzle.
Ensure nozzle is proper size for the system.
Correct any kinks or restrictions. Replace crushed hoses.
Debris can lodge in the discharge side of the system (valves, fittings, injectors, filters) Flushing
with water may correct it.
16 of 23
Rev. 4/8/2016
PROBLEM
Excessive pressure
POSSIBLE CAUSE
Small spray nozzle
Faulty pressure gauge
Pump chatters, caviataion,
vibration
Improperly adjusted unloader
Faulty unloader
Air in system
Chemical line not submerged
Inlet line restricted
Inadequate water supply
Float valve stuck (optional)
Inlet line vibrates
Outlet line vibrates
Inlet and outlet lines vibrate
Turbulence in float tank (optional)
Inlet or inlet strainer clogged
Water supply to hot
Air in system
Debris in inlet check valves
Air in system
Debris in inlet check valves
Pump packing bad
Inlet and outlet check valves
fouled
SOLUTION
Nozzle must be properly sized for the rated flow and pressure. Reset unloader or pressure relief
if nozzle size is changed.
Check the pressure gauge using a properly calibrated pressure gauge on quick connects at the
equipment outlet.
Adjust to the proper pressure using pressure gauge.
Check the unloader action. If it is not working properly, it may need repaired or replaced.
Inspect places where air can enter the system. i.e. fittings, hose, connections etc.
If the chemical valve is on, ensure that the chemical line is fully submerged in the chemical
All inlet connections should be snug and not kinked to reduce the chances of pump starvation.
Water supply to the system must meet or exceed the rated flow (GPM) on the serial number
plate. Faucet must be completely opened or water above the tank outlet in a gravity fed system.
If float valve is stuck in the up position, water can not enter the float tank. Unstick valve if
possible of replace if necessary.
Excessive turbulence allows the pump to draw air into the system. Correct excessive turbulence.
Regularly clean the inlet and inlet strainer to keep debris from entering the float tank
Inlet temperature should not exceed 140F - 160F range.
Inspect places where air can enter the system, i.e.; fittings, hose, connections etc.
If there is no float tank and the outlet line does no vibrate, the inlet check valve may be clogged.
Remove debris. Check o-rings under valves.
Inspect places where air can enter the system, i.e.; fittings, hose, connections etc.
If there is no float tank and the outlet line does no vibrate, the inlet check valve may be clogged.
Remove debris.
If they show signs of ware or damage, replace them.
Look for the source of debris in the inlet and discharge check valves and remove.
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FLUID SYSTEM DIAGNOSTICS - Unloader
PROBLEM
Very low or no flow
POSSIBLE CAUSE
Unloader stuck in bypass
Unloader will not unload
Debris in unloader
Sever leak on the outlet of unit
Improper flow
Unloader (flow) cycles with
system under pressure
Unloader (flow) cycles with
system in bypass
Unloader (pressure)
produces smooth flow & low
volume
Unloader (flow) produces
smooth flow & low volume
Nozzle to small
Nozzle clogged
Improper unloader orifice
Unloader orifice clogged
Injector orifice clogged
Other downstream restriction
Pump not delivering the rated
pressure
High water supply pressure
No restrictions on the unloader
SOLUTION
Isolate the flow problem. If it occurs before the unloader discharge point, check the piston
assembly to see if it is fouled or stuck in bypass mode.
Take bottom nut off unloader, identify ball, spring and seat. Clean out any debris and
Check for leaks and repair.
Any variation in flow form what the orifice is sized can cause cycling. System must produce the
rated flow constantly.
A nozzle that is too small can cause the flow to be reduced.
A distorted spray pattern indicates a clogged nozzle.
The systems rated output should indicate the proper sized orifice for your system.
Check the orifice for clogs and clear out any debris.
If the system has a Venturi injector downstream of the unloader, check the orifice for clogs.
Scale buildup can restrict flow. Check; controls, valves, switches, trigger gun, and lance.
Descale as necessary and begin preventive maintenance program for scale prevention.
See low pressure or low flow diagnostics.
Check inlet water supply for excessive pressure.
Check unloader bypass port to see if a flow restrictor is properly installed. Install one if none is
present.
Downstream leakage (excessive)
Accumulator downstream (option)
Unloader adjusted too low
Causes the unloader to since a continuing flow and divert it to the closed gun. Repair or replace.
Remove the accumulator from the system.
Adjust the unloader using the pressure gauge for the correct pressure.
Spray nozzle clogged
Spray nozzle too small
Injector orifice blocked
System not delivering rated flow
Unloader adjusted too low
A distorted spray pattern indicates a clogged nozzle.
A small nozzle causes a reduced flow and cycling may result.
If the system has a Venturi injector downstream of the unloader, check the orifice for clogs.
See flow diagnostics.
Adjust unloader and regulator until proper pressure is achieved.
Unloader valve stuck in bypass
Restriction in system
If unloader is sticking, repair or replace as necessary.
Downstream restrictions can cause a reduction in flow. Check; controls, valves, switches, trigger
gun, and lance. Descale as necessary and begin preventive maintenance program for scale
prevention.
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Unloader (pressure)
produces low flow and
normal pressure
Unloader (flow) produces
low flow & normal pressure
Unloader (pressure) leaks
from main spring or
adjusting bolt
Unloader (flow) pressure
increases when trigger
released
Unloader (flow) leaks water
around adjusting bolt
Unloader adjusted too low
If the unloader is diverting flow to bypass it may be adjusted too low, readjust as necessary.
Spray nozzle to large
Internal nozzle erosion
Insufficient pump pressure
Unloader adjusted too low
Ensure the proper nozzle is installed on system.
The number of hours of usage can give you a clue to the extent of the ware. If in doubt, change
Check pump seals and packings and tighten drive belts.
If unloader is diverting flow to bypass, readjust using the pressure gauge.
Nozzle too large
Shaft O-ring in valve body warn
Ensure the proper sized nozzle is being used.
Check O-rings for ware or damage and replace as necessary.
Unloader piston stuck or frozen
Check unloader shaft for proper action. Unstick piston and shaft or replace unloader.
Bypass port clogged or restricted
Excessive tension on main spring
Sleeve O-ring worn
Ensure that unloader bypass port is not clogged
If tension is incorrect, adjust or replace as necessary.
Check O-rings for ware or damage and replace as necessary.
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FLUID SYSTEM DIAGNOSTICS - Leaking
ANY LEAKS SHOULD BE REPAIRED ASAP TO PREVENT DAMAGE TO THE SYSTEM.
PROBLEM
From inlet
From low pressure (inlet)
line fittings
From float tank(option)
POSSIBLE CAUSE
Garden hose washer
Loose clamps or connections
SOLUTION
Ensure the washer is present and in good condition.
Low pressure line should be properly sealed on barb and tightly clamped.
Float tank full of water or stuck
From pressure fittings
Fittings not tightened or taped, or
cracked
Bad o-rings
Bad packing
If float is not floating above water, check the float to see if it has filled up with water. If
necessary, drain and seal.
Usually metal to metal fittings should be taped with Teflon tape or lock tight to provide a tight
seal. (unless
If quick connect o-ring shows wear or damage, replace it.
If the seal leak is detected under the pump manifold, packing may be worn and in need of
replacement.
If o-rings show wear or damage, they may need replaced.
Physical damage may not be apparent, but unseen warping from freezing or extreme pressure
can still cause leakage.
If a weep gun has been installed, check the gun valve seat to ensure it is functioning properly.
Inspect trigger gun valve assembly for damage or ware to ball or seat. Lodged debris can stop
valve from closing. Repair with kit or replace.
If quick connect o-ring shows wear, damage or improper seating.
Inspect o-rings for ware or damage and replace as necessary.
From quick connects
From pump
From trigger gun
Bad rod o-ring
Stripped connectors
From nozzle
Weep gun (optional)
Damage gun valve ball or seat
From unloader
From variable pressure
Lance(option)
Unloader will not unload
Bad o-rings or seals
Bad o-rings at adjusting knob
From pressure relief valve
Debris in unloader
Sever leak on the outlet of unit
System over pressure
Clogged nozzle
Trigger gun valve not working
Excessive pressure spike
Wear or damage to ball or seal
Improper relief valve adjustment
Take bottom nut off unloader, identify ball, spring and seat. Clean out any debris and
reassemble.
Check for leaks and repair.
See pressure and flow diagnostics to find the cause of the excessive pressure and correct it.
Spray pattern will be distorted if nozzle is clogged, clean out.
If trigger gun valve action is not correct, repair or replace.
If water spurts from valve when trigger is released, check unloader adjustment. Pressure spike
should be below the level where pressure relief valve is activated.
Inspect ball and seal for damage and adjust as necessary.
Adjust valve properly.
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PROBLEM
No nozzle flow from nozzle
when trigger depressed.
Excess pressure when
trigger gun is released
Flow not stopping when
trigger gun released
Trigger action sticks
Trigger gun leaks
No chemical
FLUID SYSTEM DIAGNOSTICS - Trigger Gun/Spray Nozzle
POSSIBLE CAUSE
Broken piston rod in trigger gun
SOLUTION
If water flows through discharge hose without gun, check trigger gun valve piston rod and
replace if necessary.
Missing metal insert in trigger gun
(European style gun)
Blockage in system past gun
Excessive pressure spikes
Inspect to assure insert is in place.
Debris in gun valve
Keeper plug too tight
Worn or bad o-ring
Stripped or loose connections
Debris in gun valve can stop piston return. Clear debris.
It may be possible to loosen plug slightly without leakage but it will likely need replaced.
Check trigger gun o-rings for ware or damage and replace.
Physical damage may not be apparent but unseen warping from freezing or sever overpressure
may still cause leaking.
Open chemical valve. If It chatters with no chemical delivery, air is being drawn from the
upstream side of the pump. Check fittings, connections and ensure the inlet line is fully
submerged into the chemical jug.
inspect and clean as necessary.
May be a strainer or check valve. Ensure that the ball is not stuck or clogged.
Chemical line kinking or binding prevents chemical delivery.
An overly long chemical line can prevent the pump from drawing chemical into the system. Try
installing a shorter line.
Verify chemical strength.
Downstream injectors only - Low pressure is required for most injectors to draw chemical. If no
adjuster exists it may need low pressure spray nozzle installed on the lance.
If not properly sized for the systems rated output, chemical delivery problems will result. Check
serial plate for specs.
To properly adjust, a chemical flow meter may be used to precisely measure chemical flow.
Check nozzle or spray accessory for blockage and clear it.
After unloader increases pressure to a maximum, further adjustment will only increase the
pressure spikes. Re-adjust.
Broken return spring on trigger gun If trigger action is too loose, return spring may need replaced.
Chemical valve closed
Black nozzle
Chemical dried up in the injector
Chemical foot strainer clogged
Chemical line kinked
Chemical line too long
Chemical too dilute
No adjustment for low pressure
Incorrect injector orifice
Excessive chemical
Spray pattern irregular
Volume proper, pressure
low
Pressure proper, volume
low
Valve improperly adjusted, check
knob on injector
Chemical dilution to strong
Clogged nozzle
Nozzle to large
Internal nozzle wear
Clogged nozzle
Verify chemical strength.
Spray pattern will be distorted if nozzle is clogged.
Ensure that the nozzle is sized properly sized for the system
A loss of pressure may result form gradual nozzle wear. Replace a nozzle of correct size.
Spray pattern will be distorted if nozzle is clogged. Check nozzle for clogging if the unit has a
pressure unloader.
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PROBLEM
Steady fuel flow at bleed
valve but none in
combustion chamber
Boiler controls activating
Solenoid valve energizing
Air and fuel flow proper
POSSIBLE CAUSE
SOLUTION
Solenoid valve not energizing
Remove the solenoid cover and place blade of an insulated screwdriver in the coil with the
system operating in hot water mode. A good working solenoid will hold the screwdriver in the
solenoid. If not it may need replaced.
Oil pump may have debris, replace as necessary.
Solenoid valve coil not energizing If boiler controls work properly, the pressure or vacuum on the fuel pump may be misadjusted.
Check solenoid coil again.
Debris in internal fuel pump valve Check for clogging in the solenoid valve inside fuel pump.
Fuel nozzle clogged
Check fuel nozzle for clogging and clear if necessary.
Restriction in fuel outlet line
Check fuel line from pump to burner for any restriction.
Fuel pump piston frozen closed
Check piston in fuel pump to see if it will travel. Free piston or replace fuel pump.
No power reaching transformer
Ensure the proper voltage is reaching the ignition transformer with a volt meter.
Ignition transformer bad
Using a volt meter, ensure that the transformer is supplying the proper voltage.
Electrode gap improperly set
Check the gap and readjust if necessary, taking care that the proper distance is maintained from
the fuel nozzle.
Electrode caps cracked
Down fired, multi-pass boiler systems have a cap on the top of each electrode. Examine caps
for cracks or carbon build-up and replace if there problems are evident.
Electrode wires loose or damaged Applies to down fired, multi-pass boiler systems - Check the wire to each electrode to ensure
there is a good connection.
Electrodes arcing to fuel lines
Electrodes should not be arcing to fuel lines or nozzle. Check electrode for cracking or carbon
build-up.
Transformer bus bars not lining up Applies to gun type burners - Bus bars on the transformer should line up and connect properly
with the electrode terminals
Improper air delivery
Check air delivery to combustion chamber. Down fired; check air damper and air bag. Gun type;
Check air bands.
Burner or electrode
assembly fires when
removed from housing
Ignites with air bands closed Excessive electrode gap
down
Choked down
Ignites with air bands
opened up
Ensure electrode gap is properly set.
Open air bands to proper setting.
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PROBLEM
Switch activated manually
Switch shows continuity
when activated
Switch does not shows
continuity when activated
BOILER SYSTEM DIAGNOSTICS - Vacuum Switch - Optional
POSSIBLE CAUSE
Improper diaphragm movement
Low water flow
Air leak in or punctured diaphragm
Problem elsewhere in system
SOLUTION
Replace switch if improper diaphragm movement is detected.
Correct problems related to inadequate water flow.
Replace vacuum switch if diaphragm shows an air leak or hole.
If vacuum switch works properly, continue with other boiler control diagnostics.
Switch contact bad
Replace switch with another one.
BOILER SYSTEM DIAGNOSTICS - Flow Switch - Optional
PROBLEM
POSSIBLE CAUSE
Reed switch activates when Magnet fouled and will not move
tested with external magnet
Reed switch does not
activate when tested with
external magnet
SOLUTION
If magnet does not move freely within its housing, remove debris to unstick it.
Reed switch misadjusted
Magnet is bad
Reed switch is bad
To adjust it for the flow the system is producing, loosen the reed switch and move it in its
If reed switch activated the boiler when tested with a hand held magnet, the internal magnet may
If reed switch does not activated the boiler when tested with a hand held magnet, the reed
switch may need replacement.
Problem else where in system
See diagnostics listed above.
BOILER SYSTEM DIAGNOSTICS - Thermostat
PROBLEM
POSSIBLE CAUSE
Thermostat set improperly Thermostat set too low
Boiler fires when thermostat Thermostat bad
jumped, but will not fire with
thermostat in circuit
Boiler will not fire when
thermostat jumped
Problem else where in system
SOLUTION
Set thermostat properly and ensure connections are not loose or corroded.
Replace Thermostat.
Continue with boiler control diagnostics. If boiler still does not fire, the thermostat may need
replaced.
BOILER SYSTEM DIAGNOSTICS - High Temperature Limit
PROBLEM
POSSIBLE CAUSE
Electrical continuity through Connections loose or corroded
switch
Problem else where in system
No continuity through switch Switch bad
SOLUTION
Check connections to high temperature limit switch to ensure that they are not loose or
corroded.
If there is continuity through the switch but the boiler still does not fire, there is a problem
elsewhere in the system. Continue with boiler control diagnostics.
Replace switch.
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