HPS0003 high-pressure System
200 bar - 50 l/min
Read and understand the manual
Wear safety glasses
Wear safety gloves
Wear safety boots
Wear hardhat
Warning - Risk of electrical shock
Warning - Risk of falling objects
Caution - Risk of frost damage
Warning - High-pressure jet
Caution - Read the explanatory text
Instruction steps
Number of crew members required
This is the manual for the High-pressure System. The manual contains instructions in safety, transportation, storage, preparation for use and maintenance.
The manual for the In-line Heater is a separate manual.
Read the safety instructions in this document carefully.
Read all documentation before first use.
property caused by non-compliance with instruction requirements and the contents of this manual.
• High-pressure water jet.
• Never aim the water jet at yourself, people, animals or the machine itself.
• Incorrect installation and use may result in serious damage or injury.
• Do not under any circumstances tamper with or adjust the safety valve.
• Any warranty of the system will be waived if the safety valve has been tampered with.
• Sub-zero temperatures can result in equipment rupture and will damage the High-pressure System.
• Never use the High-pressure System in sub-zero temperatures (i.e. below 0 °C (32 °F)).
• The High-pressure System should always be stored in a frost proof place, if this is not possible, the machine must be frost protected as described in this manual.
• Any damage caused by the use or storage of the In-Line Heater in sub-zero temperatures (i.e. below 0 °C (32 °F)) will not be covered by any warranty of the system.
• Keep away from children and animals.
• Do not spray on electrical wiring or installations.
• Avoid spraying on fragile surfaces and facilities.
• Never pull the High-pressure System power or communication cables as this may result in damage to the system and lead to potentially dangerous situations.
• Only use tap water as working medium.
• Do not add cleaning agents to the working medium.
• Never drink the water used in the High-pressure System even though tap water is used as medium.
• If necessary, use wheel chocks to keep the High-pressure System stationary.
• No modification must be made to the High-pressure System without the express written consent of CLIIN.
• Do not leave the High-pressure System unattended in operation.
• Any warranty of the system will be waived if proper maintenance is not performed as described in this manual at the given intervals.
• Always wear proper personal protective equipment (PPE).
• Only trained and qualified personnel must perform lifts.
• Plan the lift and lifting route before execution, to minimise the risk of accidents.
• Only use approved equipment for lifting.
• Never stand underneath objects being lifted.
M000494 2 m, lance for hatch coamings
M000217
Double-barreled highpressure lance with handle and flat jet nozzle
MA00049
High-pressure lance for removal of rust and loose paint
MA00050 Pistol for lances
Voltage (robot/pump)
Frequency
Current (robot/pump)
400 V connection
-240 V / 380-440 V
Hz
A / 32 A
poles + earth, 3H 110/230 V connection
Working pressure (non adjustable)
Flowrate @ 50 Hz
Flowrate @ 60 Hz
Working
poles + earth, 6H
bar (2,900 psi)
l/min (9 UK gal/min)
l/min (10.9 UK gal/min)
OD: 33 mm (1.3”)
ID: 25 mm (1”)
Coupling for the vessel freshwater installation must be fitted to freshwater hose before the hose can be used. The coupling is to fit the above measurements and withstand a pressure of min. 6 bar (87 psi) at 40 °C (104 °F).
Below installation must be performed by an authorised electrician.
400 V electric cable - 4 cores @ 6 mm2
Voltage rating: 380-440 V Current rating: 32 A
400 V power plug to fit the vessel electrical installation must be fitted to 400 V cable before the cable can be used. The plug must comply with applicable legislation and the specifications above.
230 V electric cable - 3 cores @ 1.5 mm2
Voltage rating: 100-240 V Current rating: 16 A
230 V power plug to fit the vessel electrical installation must be fitted to
230 V cable before the cable can be used. The plug must comply with applicable legislation and the specifications above.
Control panel
For control and surveillance of the High-pressure System.
Drains
For draining water from the system after usage. The left drain flushes the filter.
For securing communication cables.
Further information is found in the Cargo Hold Robot manual.
Signal cable connection
Hybrid cable connection
110/230 V power inlet connection
400 V power inlet connection
Emergency buttons
Press the emergency button in the case of an emergency or if an unexpected situation occurs. The button “EMG. STOP ACTIVATED/RESET” will illuminate to indicate emergency mode.
The emergency buttons does not shut down the In-line heater if such is used. Use the switches on the In-line Heater.
The In-line Heater burner will however pause when the water supply is stopped.
Control box emergency button
The control box emergency button is ONLY functional when all the following criteria are met:
• Control box connected to the High-pressure System.
• Cargo Hold Robot connected to the High-pressure System.
• 230/110 V power connected to the High-pressure System.
Before releasing the emergency button, investigate why the button was pressed and assess the situation. When the situation is safe the emergency button can be released.
1. Release the emergency button by twisting it clockwise.
stop button on the control box (5 seconds) to reset the emergency mode.
START
Press the “START” button to activate the pump.
A short delay must be expected before the pump is at full capacity.
Main switch
Switches the 400 V power ON/OFF.
The main switch does not effect the Cargo Hold Robot.
STOP
Press the “STOP” button to deactivate the pump.
The pump can be started/stopped remotely on the control box.
• Start: Press and hold the water button (2 seconds) to activate the pump.
• Stop: Press the water button to deactivate the pump.
The control box is only functional when all the following criteria are met:
• Control box connected to the High-pressure System.
• Cargo Hold Robot connected to the High-pressure System.
• 230/110 V power connected to the High-pressure System.
The “SYSTEM READY” indicator illuminates green when all the following criteria are met:
• Sufficient water in the tank.
• Emergency mode not triggered.
• No overload detected on the system.
The “POWER ON” indicator illuminates white when all the following criteria are met:
• 400 V power is connected to the High-pressure System.
• Main switch is in the ON position.
• DC circuit breaker not tripped.
LOW WATER / SERVICE (continuous / flashing)
• The “LOW WATER / SERVICE” indicator illuminates yellow when there is insufficient water in the tank.
• The “LOW WATER / SERVICE” indicator flashes yellow when service is needed. Service indication does not effect the function of the High-pressure System. Information regarding service is found in the maintenance chapter.
The “HP PUMP OVERLOAD” indicator illuminates yellow when one of the following failures are detected:
• Overload
• Overtemperature
• Phase loss
• Phase imbalance
• Only trained and qualified personnel must perform lifts.
• Always use proper PPE.
• Plan the lift and lifting route before execution, to minimise the risk of accidents. Only use approved equipment for lifting. Inspect the four lifting plates for any damage or extensive wear before attaching the lifting equipment. Chains/slings must have a minimum length of 2 meters from the system to the connection point. This is to avoid damage to the system.
Never stand underneath objects being lifted.
the system must be drained before lifting.
To drain the system open the two drain valves by placing both handles in the vertical position.
System weight: 285 kg (630 lb)
Min. Length: 2 m (6.5 feet)
1. Stop the system by pressing the stop button.
2. Turn the main switch to the OFF position.
3. Activate the gun, if such is installed, to release the pressure.
Stop the water supply going into the system. Close the high-pressure valve (vertical position).
Disconnect all hoses.
Take care not to damage threads and fittings.
Drain the system by opening the two drain valves (vertical position).
When the system is empty close the drain valves again (horizontal position).
Do not move the system when not empty. The total weight of the system with a full tank is approximately 685 kg (1500 lb).
protection plugs
Disconnect all cables. Do not pull the cables but grab the plug itself to avoid damage.
Place the protection plugs on the signal and hybrid connections. Remember lubrication.
Close and lock the caps on the electrical
Further information on protection the signal and hybrid cables is found in the Cargo Hold Robot manual.
Move the High-pressure System to the storage position.
When the system is in place lock the two back wheels. Preferably use wheel chocks to further secure the system during storage.
Take special care, when moving the system, if the vessel is in transit.
Do not store the system in sub-zero conditions without frost protection.
hose
The main hose can advantageously be disassembled half way for easier handling.
Take care not to damage threads/fittings.
• For easier handling, drain water from the hoses before storage. Can easily be done with an airgun.
• Anti-seize paste can be used on the stainless steel threads to ease the disassembly.
• General cleaning before storage will prolong the life time of the equipment.
• Use the High-pressure System Cover (M000475) for extra protection during storage.
Never store equipment in splash zones on vessels - e.g forecastle area.
- Avoid splash from waves and heavy weather.
• Sub-zero temperatures can result in equipment rupture and will damage the High-pressure System.
• The High-pressure System should always be stored in a frost-free place, if this is not possible, the system must be frost protected.
• Any damage caused by the use or storage of the In-Line Heater in sub-zero temperatures (i.e. below 0 °C (32 °F)) will not be covered by any warranty of the system.
Dismount all hoses from the High-pressure System.
Drain the water from all hoses. pressure valve (horizontal position).
Drain the system by opening the two drain valves
When the System is empty close both drains again
Remove the lid from the tank.
Fill 10 l (2.2 UK gal) of glycol (40/60) into the tank.
9. Force-start the system by pressing and holding the start button for 20 seconds. The force-start have a 10 seconds delay. The system will then run for 10 seconds if the start button is not released before.
10. Repeat step 9 until glycol is beginning to exit the high-pressure outlet.
11. Stop the system by releasing the start button.
12. Close the high-pressure valve (vertical position).
13. Force-start the system again to mix the glycol with the last remaining water in the system. Let the system run till it stops by it self (10 seconds).
With correct frost protection the High-pressure System can be stored in temperatures down to -10 °C (14 °F).
Close both drains to avoid wasting water.
The system will not function correctly with the drains open.
If positioned on an inclined or moving surface (e.g. vessel during transit) use wheel chocks for securing the High-pressure System. x2 1 - 2 1 2
Before connecting any equipment to the High-pressure System, find a suitable place for it and lock the wheels.
Visually check the High-pressure System for any damage inflicted during storage or transport. Focus on the highlighted areas.
Freshwater hose x2 4 4 - 5 5
• Inspect the entire length of both hoses for damage before use.
• Check and clean threads and seals for dirt.
• Anti-seize paste can be used on the stainless steel thread to ease the disassembly.
Assemble the main hose if disassembled. Must be tightened thoroughly before use.
400 V electric cable
230 V electric cable
• Go through the entire length of both the electric cables for damage before use. If the insulation is breached the cables must be changed.
• Visually check the plugs in both ends for damage.
• Check and clean the plugs for dirt.
Visually check the pistol and lances for damage.
Voltage rating: 100 8 - 9 8 9
Connect the 400 V cable to the vessel power supply and the control panel left side. Secure the plug with the collar.
Information on connecting the Cargo Hold Robot and control box is found in the designated manual.
Current rating: 32 A
Voltage rating: 380 - 440 V
Connect the 110/230 V cable to the vessel power supply and the control panel left side. Secure the plug with the collar.
Current rating: 16 A
• Cleaning without the Cargo Hold Robot, only requires 400 V power supply.
• The High-pressure System cannot be controlled by the control box without 110/230 V power supply and Cargo Hold Robot connected.
The emergency button on the control box will be disabled.
• Performing inspections with the Cargo Hold Robot without the need for water, only requires 110/230 V power supply.
• When 400 V power supply is not connected, an ”Error – No Power" message is shown on the control box display. The message can in this case be safely ignored.
The emergency button on the High-pressure System does not effect the Cargo Hold Robot.
Before connecting the freshwater hose to the vessel freshwater supply, open the supply to let any debris out.
This is to protect the High-pressure System against clogging and consequently pressure loss, cavitation and internal damage.
• Water supply must be clean freshwater (i.e. debris larger than 500 µm is not recommended). The use of other fluids as working medium may damage the system.
• Water supply pressure must not exceed 6 bar (85 psi).
• Water supply temperature must not exceed 40 °C (104 °F).
11 - 13 11-13
• Connect the freshwater hose to the vessel freshwater supply and the inlet connection on the back side of the High-pressure System.
• Make sure there are no twists and sharp bends on the hose.
• Open the water supply to fill the tank.
Connect the high-pressure hose to the system output connection. Tighten thoroughly before use.
• Further information on connecting the Cargo Hold Robot is found in the designated manual.
• Information regarding cleaning at elevated temperatures and connecting the In-line Heater is found in the In-line Heater manual.
The first 12.5 meters (41 feet) of the high pressure hose is strengthened by a plastic hose
Make sure to place the strengthened part pressure hose where sharp edges are found (e.g. hatch coamings).
This can prevent damage to the high Hose protection
16 - 18
16-17
• Connect the high-pressure hose to the pistol.
Always lock the highwards the hose and turn it either way to secure it.
Connect the pistol to the desired lance.
16
Connect high-pressure hose to the highpressure tool on the Cargo Hold Robot.
Always lock the high-pressure coupling.
Press the collar towards the hose and turn it either way to secure it.
Further information on connecting the Cargo Hold Robot, cleaning tool etc. is found in the designated manual.
Cargo Hold Robot with high-pressure tool installed.
-
16-17
• Go through the preparation steps before continuing with operation.
• Make sure the output end of the high-pressure hose is under control before starting the High-pressure System to avoid injury and damage to personnel and equipment.
• Remove any equipment that cannot withstand cleaning by high-pressure water.
• Never aim the water jet at yourself, people, animals or the machine itself.
• Do not spray on electrical wiring or installations.
• Avoid spraying on fragile surfaces and facilities.
• Do not leave the High-pressure System unattended in operation. Turn OFF the main switch before leaving.
Start the system by pressing the start button.
Wait 5 - 10 seconds then press the stop button. 7
8
• When water is flowing consistently normal operation can begin.
• If water was not running consistently wait 10 seconds before repeating step 6 and 7 again. If inconsistent water flow continues make sure the high-pressure valve and/or gun are open. Otherwise, refer to the trouble shooting scheme, “No water is coming from the output - Air in the system”.
• When the start-up procedure is completed, normal operation can begin.
• The High-pressure System can be started and stopped as needed.
• If the pistol and lance are installed, the system will automatically stop 30 seconds after gun deactivation. The system will automatically start up again when the gun is activated (restart is not necessary). This is a precaution to avoid overheating of the pump.
• If the water level in the tank becomes critical the system will automatically stop. A restart is needed when the water level is back at normal.
Activate the gun, if such is installed, to release pressure.
2
3 1 - 3
Refer to the “preparation - storage” chapter for the further process of preparing the High-pressure System for storage.
Always store the High-pressure System in a frost-free place. If not possible refer to the “preparation - storage in cold conditions” chapter.
• Only trained personnel and authorised electricians are allowed to operate within the control panel.
• No modification must be made to the High-pressure System without the express written consent from CLIIN.
• Under no circumstances tamper with or adjust the safety valve.
• Any warranty of the system will be waived if the mentioned restrictions are not met.
“HP PUMP OVERLOAD” status indicator is illuminated
Possible cause: Solution:
Circuit breaker (-Q02) in OFF position. 1. Disconnect power.
2. Within the control panel check position of the circuit breaker (-Q02).
3. If the knob is in the “OFF” position, turn the knob to the “ON” position.
Circuit breaker (-Q02) tripped. 1. Disconnect power.
2. Within the control panel check position of the circuit breaker (-Q02).
3. If the knob is in the “TRIPPED” position. Contact CLIIN for instructions.
4. To reset, turn the knob to the “OFF” position then to the “ON” position.
Soft Starter (-U01) fault/ overload.
1. Within the control panel locate the soft starter (-U01).
2. The fault will be display by the number of flashes from the small red light on the soft starter.
3. Contact
4. To reset, hold the reset button until the small red light stops flashing or turn the main switch OFF then
LOW WATER/SERVICE status indicator is illuminated (continuously)
Possible cause: Solution:
Water level in the tank is low. Fill the tank with water.
LOW WATER/SERVICE status indicator is illuminated (continuously) with a full tank
Possible cause: Solution:
2
Defect water level detection. Contact CLIIN for troubleshooting and/or water level switch replacement.
3
LOW WATER/SERVICE indicator is flashing
Possible cause: Solution:
Service is required. The “LOW WATER/SERVICE” indicator will start flashing when service is needed. The PLC within the control panel will inform of the specific service needed.
Further information is found in the “Service” section of this chapter.
4
Possible cause: Solution:
Pressure regulator switch incorrectly adjusted (“HP PUMP OVERLOAD” indicator not illuminated).
• Short term - Bypass the switch (can damage the pump due to overheating).
1. Locate the PLC within the control panel.
2. On the PLC, While pressing and holding the first and third button from the left, press the fourth button three times.
3. The switch has now been bypassed until the main switch is turned OFF or the 400 V power is disconnected. To protect the pump, avoid closing gun when using gun/lance and in bypass mode.
• Long term - Adjust the switch.
1. Follow the steps 135 to 147 in the “1000 hours service” section in this chapter.
Possible cause: Solution:
High-pressure valve closed or partly opened.
Air in the system.
Make sure the high-pressure valve is completely open (horizontal) to allow water free passage from the pump.
1. Stop the pump.
2. Make sure there is water in tank.
3. Make sure the high-pressure valve is open.
4. Disconnect the main hose from the high-pressure output.
5. Start the pump station and let it run for 5-10 seconds and stop it again.
6. If water is not running consistently wait for 10 seconds and repeat step 5.
7. When water is running regularly, reattach the main hose again and continue work.
Possible cause: Solution:
Drain valve(s) open. Close both drain valves.
Air in the system See troubleshooting no. 6 under “Air in the system”
Level switch defect. Low/no water.
Clogged filter.
If the pump keeps running with no water in the tank. Stop the pump immediately to avoid damage to the pump.
The system can continue operation when the tank is filled. However, personnel MUST manually monitor the water level to stop the system before it runs dry and damage the pump.
Contact CLIIN for troubleshooting and/or level switch replacement.
Clean the filter. Further information is found in the “Service” section of this Chapter.
Leaky low-pressure system. Stop the pump and make sure there is water in the tank.
Check for water leaks around the filter, drains and the hoses connecting. Contact CLIIN for further troubleshooting.
System does not provide necessary pressure
Possible cause: Solution:
High –pressure valve closed or partly opened.
Make sure the high-pressure valve is completely open (horizontal) to allow water free passage from the pump.
Loose/leaky connection. Tighten leaky connections.
Leaky hoses.
Check hoses, fittings and high-pressure tools for leaks.
Contact CLIIN if replacement is necessary.
Hose is pinched or twisted. Straighten the hoses and make sure no equipment is placed on top of the hoses.
Running 50 Hz with too large nozzles.
Change the high-pressure tool to fit the flow from the pump.
Worn nozzles. Contact CLIIN for replacement.
Worn/incorrectly adjusted pressure regulator. Contact CLIIN for instructions.
Pressure regulator valve clogged. Contact CLIIN for instructions.
Pump valves dirty or worn (pulsating).
Level switch defect. Low/no water.
1000 hours service needed. Further information is found in the ”Service” section of this chapter.
See troubleshooting no. 7 under “Level switch defect”.
System does not provide necessary pressure
Possible cause: Solution:
High-pressure system frost damaged/leaky.
Look for dripping/running water under the High-pressure System. Contact CLIIN for instructions.
Pump cavitation. See troubleshooting no. 7.
System does not start/power up
Possible cause: Solution:
Missing power.
Dirty power plug.
Connect the power cables. Turn the main switch ON.
Clean the power plugs.
Emergency button triggered. The control button “EMG. STOP ACTIVATED/RESET” will illuminate.
1. Investigate why the emergency button was activated.
2. Assess the situation.
3. When the situation is safe, deactivate the emergency button and reset.
8
Fuse (-F01) tripped.
On the control panel, turn the main switch ON. If the status indicator “POWER ON” does not illuminate, check the fuse (-F01) within the control panel.
Motor protection tripped. The status indicator “HP PUMP OVERLOAD” will illuminate. See troubleshooting no. 1.
9
System does not start/power up
Possible cause: Solution:
Low water.
The status indicator “LOW WATER/SERVICE” will illuminate (continuously). Fill the tank with water.
Level switch stuck/defect. The status indicator “LOW WATER/SERVICE” will illuminate (continuously) even though the tank is filled with water. Contact CLIIN for instructions.
“SYSTEM READY” status indicator does not activate
Possible cause:
Emergency button activated.
Solution:
1. Investigate why the emergency button is activated.
2. Assess the situation.
3. When the situation is safe, deactivate the emergency button and reset.
Low water. The status indicator “LOW WATER/SERVICE” will illuminate continuously. Fill the tank with water.
HP Pump overload. See troubleshooting no. 1.
Possible cause: Solution:
Too high inlet pressure. Max of 6 bar (85 psi) inlet pressure. The float valve cannot adequately close the water flow at higher pressure.
Float valve stuck in open position. Open the tank lid to check if the lever arm of the float valve is not raised against the tank top. If so, gently jerk the lever arm up and down to loosen the arm.
Float valve incorrectly set. Open the tank lid. Use the wing nut on the float valve to adjust the lever arm correctly.
Contact CLIIN for instructions.
Float valve lever arm loose. Open the tank lid. Use the wing nut on the float valve to adjust the lever arm correctly.
Contact CLIIN for instructions.
Possible cause: Solution:
No water supply. Check that the water supply is open and hoses connected correctly.
Inlet hose is pinched or twisted. Straighten the hoses and make sure no equipment is placed on top of the hoses.
Float valve stuck in closed position. Open the tank lid to check if the lever arm of the float valve is raised against the tank top. If so, gently jerk the lever arm up and down to loosen the arm.
Float valve is clogged. Open the tank lid. Gently jerk the lever arm up and down to loosen any debris within the valve.
Contact CLIIN for further troubleshooting.
The “LOW WATER/SERVICE” status indicator starts flashing when service is required. Service is required at the following intervals:
• After the first 50 motor hours.
• Every 500 motor hours.
• Every 1000 motor hours.
Open the control panel and locate the PLC which will inform of the required service needed.
Needed kits and special tools can be ordered at CLIIN before commencing the service. Consult the maintenance chart or contact CLIIN for correct order.
The 50 hour and 500 hour service are the same.
1 - 2
2
Open the tank lid and wash down any dirt and debris on inside of the tank.
Take care not to damage the float valve.
Do not use high-pressure.
Dismount the right side panel.
4.Remount the drain plug (40 Nm). Remove the oil dipstick 4 5 4 - 5
1.Place a container under the pump to collect the oil.
2.remove the drain plug.
3.wait for the oil to drain.
Remount the oil dip stick by hand.
Fill in oil (CHEM011) to the middle of the oil gauge window (≈ 1 litre).
The oil is slow flowing, give it a minute to settle before reading the gauge window.
Pump oil - SAE 15W/40
10
9 - 11
Clean the filter and strainer body with a brush and hot water.
Assemble the strainer again. After assembly the fittings below the strainer must point slightly towards the back, to avoid twists and bends on the drain hose. 11
Do not detach or disassemble the fittings below the strainer body. 9
Disassemble the strainer body and filter from the strainer top.
Mount the right side panel.
Press and hold the start and stop button simultaneously for 10 seconds to reset the service alarm.
This concludes the 50/500 hours service.
During the first start-up after service, be aware of the following:
• Leaks on the low-pressure system.
• Abnormal noises from the pump.
1 - 2
2
Open the tank lid and wash down any dirt and debris on inside of the tank.
Take care not to damage the float valve.
Do not use high-pressure.
Dismount both side panels.
4.Remount the drain plug (40 Nm). Remove the oil dipstick 4 5 By hand remount the oil dip stick 6 4 - 6
1.Place a container under the pump to collect the oil.
2.remove the drain plug.
3.wait for the oil to drain.
Detach the strainer from the tank 8
Loosen the hose clamp 9
Do not detach or disassemble the fittings attached to the strainer top and body. 10 9 - 10
Detach the whole strainer assembly.
11
Disassemble the strainer body and filter from the strainer top.
Do not detach or disassemble the fittings attached to the strainer top and body.
12
Clean the filter and strainer body with a brush and hot water.
13 11 - 13
Assemble the strainer. Do not mount it back onto the rest of the system.
Open the control panel door. 15 14 - 15
Make sure there is NO power attached to the High-pressure System. 14
Inside view of the control panel.
By the use of a small screw driver detach the two wires for the water level switch and the two wires for the pressure regulator switch.
Loosen the cable glands for the three cables and remove them from the control panel.
By the use of a small screw driver detach the four wires for the motor.
and remove the water level switch.
At the collar dismount the inlet hose from the tank.
At the collar dismount the return hose from the tank. 22
Dismount the two bolts to loosen the back of the tank.
Dismount the two bolts holding the front of the tank to the frame.
Remove the tank assembly.
- 1000 hours
Unscrew the two M5 screws and remove the support bar.
At the collar detach
At the collar detach the hose from the manometer assembly.
At the collar detach the hose from the valve assembly.
Loosen and remove the nut locking the valve assembly to the frame.
The safety valve can now be replaced by a new or a serviced valve. Consult the maintenance chart and contact CLIIN for ordering.
-
• Service of the safety valve must be performed by CLIIN.
• Under no circumstances tamper with or adjust the safety valve.
• Any warranty of the system will be waived if the safety valve has been tampered with.
Remove the two fittings from the safety valve. 34
Loosen the three set screws by the use of a 2.5 mm Allen key.
42 40 - 42
40
41
Before disassembly, mark which hose is pointing up and which is pointing down for easier assembly.
Remove the nipples, Tpiece and hoses.
The pressure regulator can now be serviced or replaced. Consult the maintenance chart and contact CLIIN for ordering service kits.
Mount the discharge hose assembly. Make sure alignment is as noted when disassembled. Apply hemp and jointing compound on the thread.
44 - 46
45
Mount the bonded seal and nipple union.
44
Mount the bulkhead penetration and bonded seal.
46
Mount the T-piece and hose.
Apply anti seize paste on the thread.
Mount the nipple onto the bottom of the safety valve. Apply hemp and jointing compound.
Mount the bonded seal and nipple.
- 50
Mount the safety valve onto the rest of the valve assembly. Apply anti seize paste on the thread. 49
Mount the discharge hose onto the bottom of the safety valve. 50
Loosely mount the pressure regulator switch on top of the pressure regulator.
The valve assembly is ready and can be stored for reassembly at a later stage of the service.
On the front of the motor dismount the two nuts mounting the motor to the dampers.
On the back of the motor dismount the two nuts mounting the motor to the dampers.
Service - 1000 hours
weight: 120 kg (270 lb)
• Lift up the motor/pump assembly.
• Take special care to manometer and fittings when lifting.
Dismount the four bolts and lock washers.
-
Detach the motor flange and pump.
Watch for the loose nuts on the two sides and the bottom.
On the back of the pump coupling, loosen the set screw with a 4 mm Allen key.
Remove the pump coupling.
- 1000 hours
63 - 64
Dismount the four bolts and lock washers. 63
Detach the motor flange from the pump.
Two options are available at this step in the service procedure.
1. Performing the pump service.
2. Ordering a new or a serviced pump from CLIIN.
1. Pump service
The following are required for a pump service:
• Change of seals and valves.
• Change of piston guide oil seals (only if the pump looses oil).
• Special extraction and insertion tools are required not to damage seals and sealing surfaces.
Consult the maintenance chart and contact CLIIN for ordering service kits and special tools.
Instruction videos and further information can be found on www.interpump.it. Pump type no. W2141.
After completed pump service continue to next service step.
2. Pump change
Contact CLIIN for ordering a new or serviced pump.
Make sure the pump oil is drained completely before shipment as the oil dip stick is not leak free.
Continue to next service step.
- 1000 hours
Mount the four bolts and lock washers.
Mount the motor flange onto the pump.
- 1000 hours
Apply grease to the pump shaft to ease assembly/disassembly.
Mount the pump coupling.
On the back of the pump coupling, tighten the set screw with a 4 mm Allen key.
Post assembly distance.
Coupling → pump shaft.
5 mm
Mount the four bolts and lock washers.
73
Make sure all six coupling elements are in place. Align couplings for easier assembly.
Mount the motor flange and pump.
On the two sides and the bottom the screws to be fastened with nuts on the back.
-
Mount the fittings onto the pump.
The T-way must point slightly downwards from horizontal to enable a proper drainage route. 74
Use hemp and jointing compound on the thread going into the pump.
Mount the inlet hose.
Mount the manometer assembly.
Use anti seize paste on the thread.
The manometer view glass must point towards the back of the motor (opposite the pump).
- 1000 hours
weight: 120 kg (270 lb)
• Mount the motor/pump assembly.
• Take special care to manometer and fittings when lifting and mounting.
Place the studs from the dampers center in the motor slots. x4
On the back of the motor mount the two nuts and washers securing the motor to the dampers.
On the front of the motor
mount the two nuts and washers securing the motor to the dampers.
Mount the valve assembly.
Secure the valve assembly by tightening the flat nut on the bulkhead penetration. Apply anti seize paste.
Mount the hose onto the valve assembly.
Apply anti seize paste.
- 1000 hours
Mount the valve assembly hose to the manometer assembly.
Apply anti seize paste.
-
Mount the drain hose to the inlet
- 1000 hours
Mount the support with the two M5x10 screws.
Apply anti seize paste on the screws.
- 1000 hours
Lift the tank onto the frame.
Take care not to damage the fittings on to the tank.
Loosely mount the two bolts and washers to the back of the tank. Do not tighten.
- 1000 hours
Loosely mount the two bolts and washers to the front of the tank. Do not tighten.
- 1000 hours
Mount the inlet hose onto the tank.
Do not twist the hose.
Feed the inlet hose through the hole between the tank and frame.
-
Mount the return hose on the tank.
Do not twist the hose.
The small tap on the water level switch MUST face straight downwards.
Fasten the hose clamp thoroughly.
Mount the strainer assembly onto the inlet hose.
Service 1000 hours
Attach the strainer to the tank. Tighten the collar thoroughly.
Remove the oil dipstick.
Remount the oil dip stick by hand.
Fill in oil (CHEM011) to the middle of the oil gauge window (≈1 litre).
The oil is slow flowing, give it a minute to settle before reading the gauge window.
Pump oil - SAE 15W/40
Feed the cable from the water return switch through the middle cable gland and tighten.
Feed the cable from the motor through the bottom cable gland and tighten.
Feed the cable from the water level switch through the top cable gland and tighten.
Secure the loose cables with cable ties.
Inside view of the control panel.
Terminate the wires from the water return switch in the terminal block -X03, no. 3 and 4. 109 108 - 110
Terminate the wires from the water level switch in the terminal block -X03, no. 1 and 2. 108 Terminate the motor wires in the terminal block -X01. From the top:
- 1000 hours
Wait 10 seconds and ensure that the “LOW WATER/SERVICE” status indicator is still illuminated (continuously).
If not, ensure the water level switch orientation (service step 95) and termination (service step 108).
The tank must be empty at this stage. 115
Turn ON the main switch. Reset the emergency stop.
Connect water inlet and fill the tank. 117
Before connecting the freshwater hose to the vessel freshwater supply, open the supply to let any debris out.
This is to protect the High-pressure System against clogging and consequently pressure loss, cavitation and internal damage.
118
119
Reset the service signal by holding the start and stop button simultaneously for 10 seconds.
As the water level raises the “LOW WATER/SERVICE” status indicator must shift from continuous lit to flashing.
120
The “LOW WATER/SERVICE” status indicator will turn OFF. The tank must contain water at this stage.
Watch for leaks on the lowpressure system. I.e. strainer, inlet hoses, drains, fittings and sensors mounted on the tank.
Connect the highpressure hose to the system output connection. Open the high-pressure valve (horizontal position). 123
Start the system by pressing the start button.
Wait 5 - 10 seconds then press the stop button.
• When water is flowing consistently continue to next step.
• If water was not running consistently wait 10 seconds before repeating service step 124 and 125 again.
No high-pressure equipment must be attached to the end of the main hose.
• Connect the high-pressure hose to the pistol.
• Lock the high-pressure coupling. Press the black collar towards the hose and turn it either way to secure it.
Connect the doublebarreled lance to the pistol.
128
Turn the handle clockwise to utilize the small nozzle. This is important when adjusting the pressure.
Loosen the three set screws on the water return switch with a size 2.5 Allen key.
Lift off the water return switch.
Keep the gun activated.
Start the system.
Adjust the pressure to 190-195 bar by turning the nut on the pressure regulator valve.
• Clockwise to increase pressure.
• Anticlockwise to decrease pressure.
Monitor the pressure on the manometer.
132 - 134
Do NOT adjust the pressure higher than stated. This can cause damage to the High-pressure System and electrical installations.
electricians are allowed to operate within the control panel.
Press the first button from left on the PLC to enter the setup screen. The default screen will return automatically after 5 minutes.
PLC setup screen.
Place the water return switch on top of the regulator valve.
While monitoring the PLC input no. 4, gently push the water return switch downwards.
Once input 4 activates (small click can be heard from the relays) move the water return switch ≈1 mm further downwards. 141
142 x3
While holding the water return switch in place, tighten the three set screws.
143
Start the system.
145
Wait 30 seconds for the system to stop automatically.
Deactivate the gun. 144
143 -
147
Activate the gun to automatically start the system again.
146
The system must stop after service step 145 and start again after service step 146.
• If so, continue to next service step.
• If that is not the case, the water return switch has not been correctly adjusted. repeat service step 135 through 147 again.
Mount both side panels.
This concludes the 1000 hour service.
During the first start-up after service, be aware of the following:
• Leaks on the system.
• Abnormal noises from the pump.
• The system stops automatically when the water level in the tank gets low.
