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IPC OPTIMA DS 145M Service Manual

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Service Manual
Rev.1.0 January 2014
OPTIMA DS
145M - 175T - 195T

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Summary of Contents for IPC OPTIMA DS 145M

  • Page 1 Service Manual Rev.1.0 January 2014 OPTIMA DS 145M - 175T - 195T...
  • Page 2 Service Manual Ip Cleaning S.p.A. Viale Treviso, 63 – 30026 Summaga di Portogruaro – VENICE – ITALY Tel. +39 0421 205511 (r.a.) – Fax +39 0421 204227 Internet address: www.ipcportotecnica.com e-mail address: infoipcportotecnica@ipcleaning.com INDEX 1. The machine doesn’t starts Pag. 1a No electrical connection 1b Electric motor’s overload relay tripping or burnt fuses 1c Low voltage transformer burnt...
  • Page 3 4. The boiler doesn’t ignite Pag. 4a Wrong blower’s motor rotation sense (only for Three-phase models) 4b Missing fuel 4c Suction pipe and/or, fuel filers clogged 4d Fuel pump out of order 4e Fuel solenoid not electrically supplied or defective or damaged 4f Fuel nozzle clogged or spraying irregularly 4g High voltage ignition transformer not functioning 4h Sparking plugs are dirt or worn...
  • Page 4 1. The machine doesn’t start 1) TROUBLE: Rotating the main switch “0 - I” (A) the high pressure cleaner doesn’t start or suddenly stops after a while. fig. 1 CAUSES: 1a No electrical connection 1b Electric motor’s overload relay tripping or burnt fuses 1c Low voltage transformer burnt 1d Contactor not working REMEDIES:...
  • Page 5 Remove the machine cover unscrew and dismount the tank inserts slide out the tank inserts unlink the hook that hold electric box panel unlink the side hinges and open the el. box ) check the main switch contacts continuity using a multimeter ) rotate the switch's knob to position “I”...
  • Page 6 For single-phase models, reset the overload switch pressing its button; for three-phase models, reset the thermal relay. - If the thermal overload protection intervenes very quickly just after switched on, the cause may be a short circuit problem, hence check connecting the electric components one by one following the electric diagram in order to identify which is defective, then replace it with a new component.
  • Page 7 Single phase version On which:  IG = Main switch  DA= Thermal overload switch  K = Contactor  C = Electric motor capacitor  M = Electric motor  F = Fuse  TR= Low voltage transformer  TA = High voltage ignition transformer ...
  • Page 8 Three phase version On which:  IG = Main switch  K = Contactor  RT= Thermal relay  M = Electric motor  F = Fuse  TR = Low voltage transformer  TA = High voltage ignition transformer ...
  • Page 9 ELECTRONIC BOARD (p.n.MECE48580) Functions description The electronic board operates machine total-stop; no water system; micro-leakages system; boiler start delay; antiscale pump.  Delayed Total stop 15” (P off between terminals n° 12-13) After 15 "from the end of the grip, the K contactor is de-energized. The machine is in stand-by mode, restarts by opening the grip.
  • Page 10 - In case the overload thermal switch intervenes after a while, is necessary to check the machine Amperage with the machine operating at full load by a Amp clamp meter and compare the measurement done with the characteristics indicated in the machine’s data plate. Adjust the thermal relay RT in relation at the machine Amperage measured.
  • Page 11 Check the continuity of fuses and if burnt, replace them with new fuses having equivalent characteristics. Check the continuity of fuses using a multimeter We recommend to check the proper functioning of safety electric components, at least once a year. - 1c Connect the machine to the power supply, pay the maximum attention: danger of electric shocks;...
  • Page 12 1. Starting phase MEPF45229 MEPF39902 The contact of pressure switch (P1) MEPF45229 is ON (closed); in this situation, when the main switch is turned to “I” position, the machine starts. 2. High pressure phase MEPF45229 MEPF399022 When pressure becomes over 25 bar, the pressure switch (P2) MEPF39902 switches from open (OFF) to closed (ON), this allow the machine functioning and in the meantime the pressure switch (P1) MEPF45229 switches from closed (ON) to open (OFF).
  • Page 13 MEPF45229 is open (OFF). The machine’s outlet hydraulic circuit, is kept under pressure by the spray gun and the check valve placed at the by-pass outlet. The machine is now in “stand-by”, until the spray gun’s trigger is reactivated in order to discharge the outlet pressure and restart from the phase “1”...
  • Page 14  2. No water jet at the lance nozzle TROUBLE: No water jet sprayed from the lance nozzle. CAUSES: 2a Bad or missing water feeding connection 2b Inlet water filter clogged 2c Air intake from the water feeding circuit 2d Pump head’s valves stuck 2e Air intake from the detergent circuit 2f High pressure nozzle clogged REMEDIES:...
  • Page 15 2c Check the water circuit that connects the water tank to the high pressure pump inlet, particularly check that fittings are properly tightened and are not leaking water. Be sure that the detergent tap is closed, if detergent tank is empty. In order to put in evidence any area not sealed, that intakes air, we suggest to feed directly with pressurized water the pump inlet fitting.
  • Page 16 Unscrew the inlet valve caps Unscrew the outlet valve caps Strip out the valves Clean and unstuck the valves We recommend the replacement of inlet and outlet valves every 500 hours or one a year. Pag. 16...
  • Page 17 2e Check the detergent knob adjust (pic.1 C); it must be placed in position “closed”. Close position Open position Check the o-ring wear that is placed inside of the detergent tap, remove the detergent tap from the control panel as following: Unscrew the two screws that hold the tap Detergent tap with its spring and washer Check the...
  • Page 18 Disassembling of VNR Check the o-ring wear Check the o-ring wear and clean the VNR internal body 2f Clean the high pressure nozzle and if necessary, replace it with a new genuine part. Check the spare part manual that is downloadable from the web from “Business area” of www.ipcleaning.com ;...
  • Page 19 3. No pressure to the lance 3) TROUBLE: The high pressure pump rotates, but doesn’t achieve the rated pressure or the pressure is not stable and fluctuates. CAUSES: 3a Defective water feeding connection 3b Inlet water filter clogged 3c Air intake from the water feeding circuit 3d Pump head’s valves stuck or worn 3e Air intake from the detergent circuit 3f High pressure nozzle worn or deformed...
  • Page 20 Check the o-ring wear We recommend the replacement of inlet and outlet valves every 500 hours or one a year. 3e Check the detergent knob adjust (pic.1 C); it must be placed in position “closed”. Make checks as described in the paragraph 2e 3f Replace the high pressure nozzle with a new genuine part.
  • Page 21 3g Check if the pressure adjusting knob is set to maximum position. The position maximum is when the knob it fully rotated clockwise. 3h Repair the pressure adjusting valve (by pass valve) by replacing its cartridge that is part of the dedicated repairing kit.
  • Page 22 Unlock the valve kit Use two screwdrivers as shown in the picture Remove the valve kit Remove the by-pass seat, use a M6 screw Pag. 22...
  • Page 23 After replaced the valve kit, will be necessary to readjust the machine working pressure. The pressure adjustment can be done trough the adjusting screw as indicated in the following picture: Press Press Nut to lock the maximum pressure setting Nut to lock the minimum pressure setting (steam phase) In order to readjust the machine pressure setting, the lance high pressure nozzle must be brand...
  • Page 24 Replace the high pressure pump’s gaskets kit and ensure that the ceramic pistons are not damaged. If ceramic piston are cracked, replace them following the instruction as described in the paragraph 8c. Remove the pressure switches Disconnect all the hoses fitted to the pump head Disconnect the pump inlet fitting Unscrew the 8 screws that hold the pump head Remove the pump head...
  • Page 25 Head p/n PVVR31383 for gaskets with diameter 18 Strip out the pump gasket packages using the extractor tool p/n PVVR31382 Pag. 25...
  • Page 26 Gaskets that can wear out Pag. 26...
  • Page 27 4. The boiler doesn’t ignite 4) TROUBLE: Switching on the burner by setting the thermostat at the desired temperature, but the burner doesn’t ignite. 4a Wrong blower’s motor rotation sense (only for Triphase models) CAUSES: 4b Missing fuel 4c Suction pipe and/or fuel filters clogged 4d Fuel pump out of order 4e Fuel solenoid not electrically supplied or defective or damaged 4f Fuel nozzle clogged or spraying irregularly...
  • Page 28 Check and clean the fuel filter inside of the fuel pump. If necessary replace it. Clean the filter We recommend to check the fuel filter every 100 ore 4d Check with a pressure gauge (p/n AZMC27323) the fuel pump's setting pressure that should be in the interval 12,5 - 13bar.
  • Page 29 If fuel pump doesn’t develops any pressure, check the plastic joint placed between the pump and the motor shaft that transmits the rotation to the pump, probably is damaged. Fuel pump coupling joint If the plastic joint is worn or damaged, replace it; check the free rotation of the fuel pump shaft by rotating it manually, finally check and eliminate any air intake problem from whole the fuel circuit.
  • Page 30 4e Check the voltage to the fuel solenoid using a multimeter, the voltage to EV, should be (230V+/- 5%), then check: Check the proper functioning of the pressure-switch P1 placed to the high pressure pump head. Check if the pressure-switch piston slides regularly (switch should be ON when under pressure and OFF during by-pass phase), then check if the switch inside of the pressure-switch functions correctly.
  • Page 31 Note : While replacing the burner nozzle, do not touch the nozzle orifice with fingers to avoid its oxidation hence modify its characteristics. We recommend to replace the burner nozzle every 200 hours. 4g Check the power supply voltage to the high voltage ignition transformer: it should be 230V (+/- 5%) on single-phase models and 400V (+/- 10%) on three-phase models.
  • Page 32 5. Bad fuel combustion 5) TROUBLE: Excessive smoke from the chimney CAUSES: 5a Fuel tank almost empty 5b Suction pipe and/or, fuel filers clogged 5c Fuel pump pressure setting not properly adjusted 5d Fuel with impurities, dirt or water 5e Combustion adjustment incorrect 5f Burner’s coil clogged by dirt or soot 5g Fuel nozzle partially clogged REMEDIES:...
  • Page 33 AZMC20915 Bacharach Shell tester kit In order to check the combustion accordingly to Bacharach Shell method, proceed as following described: - Switch on the machine and also the machine’s boiler, fit to the tester the paper filter (C) and use the smoke pump (A) in order to make 10 pump actions, hence obtain a gray colored spot, to the filter paper.
  • Page 34 - If the spot looks a little yellow colored, the air flow at the boiler is too much and should be reduced. Reduce the air flow at the boiler from the blower and repeat the smoke test as before explained. In order to achieve the best combustion and proper adjustment, we recommend to use clean and good quality fuel (Cetane, should be not less than 52) Air flow...
  • Page 35 Unscrew the nuts that fix the tanks and remove the tanks, disconnect the inlet and outlet fittings from the boiler. Strip out completely the boiler from the machine (to slide and rotate the boiler in order to disconnect it from the blower), then proceed with the cleaning of the coil that can be done with the help of a metal brush and a vacuum cleaner to remove the soot.
  • Page 36 6e Check and clean as described in the chapter 5g 6f Clean internally the coil’s pipe, in order to remove the limestone, using the chemical product M402 (see the IPC Portotecnica catalogue). Warning: M402 is an acid chemical, wear the individual protection devices to prevent accidents and injuries.
  • Page 37 See instructions at chapter 2e. 7b Refill with detergent the chemical tank if it is empty; we recommend to use only the detergents listed in the IPC Portotecnica catalogue. 7c Dismount and clean the detergent check valve as described in the chapter 2e.
  • Page 38 8. Oil and water emulsion phenomena to the high pressure pump oil 8) TROUBLE: The oil inside the high pressure pump looks white color (oil and water emulsion phenomena) CAUSES: 8a Extremely high environment humidity percentage 8b High pressure pump gaskets worn 8c High pressure pump pistons damaged REMEDIES: 8a Replace the pump’s oil using oil quality SAE 15 /W40:...
  • Page 39 8c Replacement of the pump’s pistons: Check if pistons are cracked Unscrew the piston lock nut Slide out the piston bush Slide out the damaged piston Check the o-ring wear Assemble the new piston and secure the nut with “Loctite” glue. Pag.
  • Page 40 Max torque 15 Nm Tighten the nut at max torque 15 Nm. Pag. 40...

  • Page 41: Periodic Maintenance

    Periodic maintenance Every Every Every Every Every Every Every 100h 200h 300h 500h year Check the power cord and the high pressure quick couplings. F i r s t p u m p o i l r e p l a c e m e n t P u m p o i l r e p l a c e m e n t...

This manual is also suitable for:

Optima ds 175tOptima ds 195t