IPC OPTIMA DS 145M User manual

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

Pag. 2
Service Manual
INDEX
1. The machine doesn’t starts Pag.
1a No electrical connection 4
1b Electric motor’s overload relay tripping or burnt fuses 4
1c Low voltage transformer burnt 11
1d Contactor not working 11
2. No water jet at the lance nozzle Pag.
2a Bad or missing water feeding connection 14
2b Inlet water filter clogged 14
2c Air intake from the water feeding circuit 15
2d Pump head’s valves stuck 15
2e Air intake from the detergent circuit 17
2f High pressure nozzle clogged 18
3. No pressure to the lance Pag.
3a Defective water feeding connection 19
3b Inlet water filter clogged 19
3c Air intake from the water feeding circuit 19
3d Pump head’s valves stuck or worn 19
3e Air intake from the detergent circuit 20
3f High pressure nozzle worn or deformed 20
3g Pressure adjusting valve setting at minimum position 21
3h Seat of pressure adjusting valve damaged 21
3i Pump gaskets worn or water leaks from the pump’s head 24
Ip Cleaning S.p.A.
Viale Treviso, 63 –30026 Summaga di Portogruaro –VENICE –ITALY
Tel. [phone] (r.a.) –Fax [phone]
Internet address: www.ipcportotecnica.com
e-mail address: [e-mail]

Pag. 3
4. The boiler doesn’t ignite Pag.
4a Wrong blower’s motor rotation sense (only for Three-phase models) 27
4b Missing fuel 27
4c Suction pipe and/or, fuel filers clogged 27
4d Fuel pump out of order 28
4e Fuel solenoid not electrically supplied or defective or damaged 30
4f Fuel nozzle clogged or spraying irregularly 30
4g High voltage ignition transformer not functioning 31
4h Sparking plugs are dirt or worn 31
5. Bad fuel combustion Pag.
5a Fuel tank almost empty 32
5b Suction pipe and/or, fuel filers clogged 32
5c Fuel pump pressure setting not properly adjusted 32
5d Fuel with impurities, dirt or water 32
5e Combustion adjustment incorrect 32
5f Burner’s coil clogged by dirt or soot 34
5g Fuel nozzle partially clogged 35
6. Poor hot water temperature at the machine outlet Pag.
6a Thermostat adjusted at minimum or not working 36
6b Fuel filters clogged or dirty 36
6c Fuel pump pressure setting not properly adjusted 36
6d Fuel with impurities, dirt or water 36
6e Fuel nozzle partially clogged 36
6f Burner’s coil pipe internally clogged by limestone 36
7. Poor detergent delivery Pag.
7a Detergent’s tap closed or clogged 37
7b Empty detergent tank 37
7c The check valve of the detergent circuit is stuck or clogged 37
7d Burner’s coil or high pressure outlet pipes clogged 37
8. Oil and water emulsion phenomena to the high pressure pump oil Pag.
8a Extremely high environment humidity percentage 38
8b High pressure pump gaskets worn 38
8c High pressure pump pistons damaged 39

Pag. 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:
1a Check the power supply voltage using a “multimeter”. This machine’s power supply
characteristics are indicated on the machine data plate placed on the side of its chassis.
For single-phase models, the allowed voltage tolerance is +/- 5% of nominal voltage shown in the
machine’s data plate; for three-phase models the allowed voltage tolerance is +/- 10%.
If the voltage is over or lower than above mentioned tolerance, the machine’s electric
components may become damaged.
Pay maximum attention while checking electric component: danger of electric shocks.
1b Pay maximum attention: danger of electric shocks.
Disconnect the machine from the power supply before open the electric box, hence:
- check using a multimeter, the conductivity of the main switch contacts, rotate the switch's knob
to position “I” and in case of problems, replace the switch with a new component.
To open the electric box, proceed as following described:

Pag. 5
1) Remove the machine cover 2) unscrew and dismount the tank inserts
3) slide out the tank inserts 4) unlink the hook that hold electric box panel
5) unlink the side hinges and open the el. box 6) check the main switch contacts continuity using a
multimeter
7) rotate the switch's knob to position “I” for check

Pag. 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.

Pag. 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
TH = Water temperature adjustable thermostat
P1 = Pressure-switch N on
P2 = Pressure-switch N off
EC = PCboard
EV = Solenoid of fuel pump
PA= Antiscale pump

Pag. 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
TH = Water temperature adjustable thermostat
P1 = Pressure-switch N on
P2 = Pressure-switch N off
EC = PCboard
EV = Solenoid of fuel pump
PA= Antiscale pump

Pag. 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” (P1 off ;P2 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.
Machine without water or water leak from the high pressure circuit (P1on ; P2off)
In this condition activates the count of 3 min and after this the machine stop.
To restart the machine you must reset the circuit board by opening and closing the main
switch IG.
Micro-leakages (P1 ;P2 on-off impulse <1,5”) or lance nozze partially clogged
After 10 impulses P1, P2 <1.5 " the contactor K is de-energized. The count is reset with
impulse P2> 3 ".
To restart the machine you must reset the circuit board by opening and closing the main
switch IG.
Delay fuel pump EV
The solenoid valve EV is powered with main switch IG in position II (hot water), P2 on> 3
" and thermostat TH on. The ignition is delayed of 3 "on each impulse of P2 (OFF - ON).
Setting antiscale pump flow
Min position (-) 4 impulses/min → pump flow 70 ml/h
Max position (+) 16 impulses/min → pump flow 300 ml/h
With machine in t-stop mode the antiscale pump is off.

Pag. 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.
The above instruction is valid for three-phase models.
Check the Amperage with a Amp clamp meter
- On single-phase models, reset the overload thermal switch or replace it if defective
Reset overload thermal switch O.T.S. internal control box position
We suggest to do not use extensions to feed the h.p. cleaner.
In case it is absolutely necessary, make sure that the power plug and socket of the extension
cord are the kind watertight; however the connections must be lifted from the ground in order to
prevent contact with water.
Thermal relay setting

Pag. 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; hence rotate the main switch to position “I” and check the voltage to the inlet and also to
the outlet of the low voltage transformer. In case there is no voltage at the transformer outlet,
replace it with a new transformer.
- 1d Check the voltage to the contactor’s coil and the continuity to the contactor’s contacts.
If there is no voltage to the contactor’s coil, also when the main switch is at position “I”, neither
pressure to the machine’s outlet circuit, check also the pressure-switches and particularly P2
should be N.O. (normally open) and P1 should be N.C. (normally closed).
Here following the functioning diagram for this machine model:

Pag. 12
1. Starting phase
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
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).
3. Stopping phase
When the spray gun’s trigger is released, the water flow is by-passed with no pressure, into the
high pressure pump by the by-pass valve; hence the pressure-switch (P2) MEPF39902 switches
from closed (ON) to open (OFF); the machine stops, because also the pressure-switch (P1)
MEPF39902
MEPF45229
MEPF399022
MEPF45229
MEPF39902
MEPF45229

Pag. 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” (starting phase).
In case that all the above mentioned check doesn’t evidences any functioning mistake, the failure is
probably caused by the electronic control board “EC”. Check and if necessary replace it with a new
electronic board.

Pag. 14
2. No water jet at the lance nozzle
2) 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:
2a Check the feeding water flow (l/min), in order to ensure that feeding water available is
sufficiently high compared with the machine characteristics.
The feeding water flow (l/min) must exceed at least 10%, than the water flow characteristics
declared in the machine data plate.
Check the fittings to the water inlet circuit and particularly ensure they are not damaged or not
properly sealed, causing flow obstruction or air intakes.
2b Check and clean the water inlet filters and if necessary, replace them.
NOTE Do not use tools for remove the h.p. pump inlet filter
Check the filter at the inlet fitting Check the filter at the h.p. pump inlet
Check the filter cartridge
We recommend to check the water filters every 50 hours (or every week)

Pag. 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.
The pressure of the feeding water, will put in evidence any area not properly sealed by leaking
water; in the case proceed with their repair.
2d Check the inlet and outlet valves placed into the pump head; if the valves are stuck, unstuck
the valve from its seat manually pressing gently the valve disk until released.
If the valves are dirty, disassemble them and clean.
In order to check and repair the high pressure pump, is necessary to dismount the machine
handle as following describe:
Unscrew the tank lock nut Remove the screws cover
Remove the lock screws

Pag. 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. 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
O-ring of detergent tap in detail
Check the whole detergent circuit in order to ensure that there are no holes or cuts to the rubber
pipes; check the proper tightening of the metal bands.
Finally check the detergent check valve (VNR) that is placed after the water inlet filter (to be
checked the wear of o-ring, spring and ball of VNR).
Check the
o-ring wear

Pag. 18
Disassembling of VNR
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 ; to access this area, customers registration is required.
Clean or replace the h.p. nozzle
We recommend the high pressure nozzle replacement every 200 hours or any time the machine
working pressure become 20% lower than rated pressure.
Check the
o-ring wear

Pag. 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
3g Pressure adjusting valve setting at minimum position
3h Seat of pressure adjusting valve damaged
3i Pump gaskets worn or water leaks from the pump’s head
REMEDIES:
3a Check the feeding water flow (l/min), in order to ensure that feeding water available is
sufficiently high compared with the machine characteristics.
The feeding water flow (l/min) must exceed at least 10%, than the water flow characteristics
declared in the machine data plate.
Check the fittings to the water inlet circuit and particularly ensure they are not damaged or not
properly sealed, causing flow obstruction or air intakes.
3b Check and clean the water inlet filters and if necessary, replace them. See 2b
We recommend to check the water filter every 50 hours (or every week)
3c 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.
The pressure of the feeding water, will put in evidence any area not properly sealed by leaking
water; in the case proceed with their repair.
3d Check the inlet and outlet valves placed into the pump head; if the valves are stuck, unstuck
the valve from its seat manually pressing gently the valve disk until released (see 2d).
If the valves are dirty, disassemble them and clean.
If the valves are worn or deformed, replace them and also replace the o-ring placed under the
valves.

Pag. 20
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.
Check the spare part manual that is downloadable from the web from “Business area” of
www.ipcleaning.com ; to access this area, customers registration is required.
We recommend the high pressure nozzle replacement every 200 hours or any time the machine
working pressure become 20% lower than rated pressure.
Check the
o-ring wear
Spraying
angle
Nozzle
size