Mart Cyclone 30 Series User manual

MART Standard Turntable Power Washer
Installation, Operations, and Maintenance Manual
Version 4.0
JAN 2004
1st Printing
Copyright 1993,1994, 1995 1996, 1997,1998,1999,2000, 2002 and 2004
by The MART Corporation.
All rights reserved.
The MART Corporation
2450 Adie Road
Maryland Heights, MO 63043-9978 U.S.A.
Phone: [phone]-MART
Missouri Direct: [phone]
Fax: [phone]
e-mail: [e-mail]
Website: www.martwash.com
Power Blast Manifold (PBM), Auto Rinse Cycle, Rinse Bank, Single Ball Float Control,
Wet Grit Blasting feature, NPSH reduction system, Automatic Pressure Equalization
(APE), Fold-up Turntable and Clean Machine are protected by one or more of the
following U.S. Patents: 4,741,351; 4,143,669; 4,213,475, 5,529,080; 5,524.653;
5,427,128; 5,540,246.
This manual is an unpublished, copyrighted work by The MART Corporation.
The information and drawings in this manual are the property of The MART Corporation
and shall not be reproduced or copied or used in whole or in part in other media without
written permission.
MART has attempted to provide a Manual that is reliable and accurate. Note that the
information contained in this Manual is subject to change at any time without notification.
The information contained in this version of the Manual supersedes all previous versions,
while some information may not be accurate due to changes in the product or operating
system since this version of the Manual was completed. Please report any discrepancies
or omissions to MART. No liability is assumed with respect to the information contained
herein.

Table of Contents Contents - 1
Standard Turntable Power Washer v. 4.0 The MART Corporation
Table of Contents
Letter from MART's President
Title Page
Table of Contents.................................... Contents-1
List of Figures ............................................Figures-1
Welcome and Introduction .....................Welcome-1
Purpose of Manual ...................................................................Welcome-1
Audience ..................................................................................Welcome-2
How the Manual Is Organized ..................................................Welcome-2
How to Use This Manual ..........................................................Welcome-3
MART Technical Services ........................................................Welcome-3
Other Resources ......................................................................Welcome-4
Vendor-supplied Manuals .............................................Welcome-4
Startup..........................................................................Welcome-4
HELP ............................................................................Welcome-4
Other Product-Support Services ...................................Welcome-5
Important Safety Instructions and
Warnings.......................................................Safety-1

Contents - 2 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
1 Overview ........................................................... 1-1
Purpose..................................................................................... 1-1
Prerequisites ............................................................................. 1-1
What You Will Learn In This Chapter ........................................ 1-1
1. Your New MART Power Washer .....................................1-2
1.1. Getting Acquainted ........................................................................ 1-2
1.2. Major Components......................................................................... 1-2
2. Materials and Components .............................................1-5
2.1. Electrical Standards ....................................................................... 1-5
2.2. Cabinet Construction .....................................................................1-5
3. Theory Of Operation........................................................1-6
3.1. How The Power Washer Works.....................................................1-6
3.1.1. Power .............................................................................. 1-7
Pressure and Flow = Power ........................................ 1-7
Closed-Loop System And Grit-Blasting ....................... 1-7
3.1.2. Temperature.................................................................... 1-8
3.1.3. Chemical ......................................................................... 1-8
Removal of Soils ......................................................... 1-9
Applications................................................................. 1-9
Usage ....................................................................... 1-10
3.1.4. Time .............................................................................. 1-10
3.1.5. General Information and Conclusion ............................. 1-11
3.2. Operating Principles Of Key Features......................................... 1-12
3.2.1. Pumping System ........................................................... 1-12
3.2.2. Power Blast Manifold (PBM).......................................... 1-12
3.2.3. Door-Mounted Turntable ............................................... 1-13
3.2.4. Turntable Drive System ................................................. 1-14
3.2.5. Automatic Steam Exhaust (ASE)................................... 1-14
3.2.6. Automatic Rinse System (ARC)..................................... 1-14
3.2.7. Heating System .............................................................1-16
3.2.8. Water-Level Control System.......................................... 1-17
3.2.9. Power Washer Control System ..................................... 1-19
Operator Controls ..................................................... 1-20
Major Components.................................................... 1-21
Sequence of Washer Operation................................ 1-23
Interdependent System Features .............................. 1-23
Electrical Schematics ................................................ 1-23
4. Washer Inspection.........................................................1-24

Table of Contents Contents - 3
Standard Turntable Power Washer v. 4.0 The MART Corporation
2 Installation .........................................................2-1
Purpose .................................................................................... 2-1
Prerequisites............................................................................. 2-1
Results of Correct Installation ................................................... 2-4
Safety/Precautions.................................................................... 2-4
What You Will Learn In This Chapter........................................ 2-5
1. Lifting and Moving...........................................................2-6
2. Placement ........................................................................2-8
3. Unpacking ........................................................................2-9
4. Leveling and Anchoring ................................................2-11
4.1. Leveling........................................................................................2-11
4.2. Anchoring .....................................................................................2-12
5. Services and Connections ............................................2-14
5.1. Introduction ..................................................................................2-14
5.2. Connection Procedures - Input.....................................................2-15
5.2.1. Heat Source...................................................................2-15
Gas & Oil Heat Source ..............................................2-15
Electric Heat Source..................................................2-20
Steam Heat Source ...................................................2-20
5.2.2. Water (Input)..................................................................2-21
5.2.3. Compressed Air (Input)..................................................2-22
5.2.4. Electricity (Input) ............................................................2-23
Earthgrounding to Prevent Corrosion ........................2-23
5.3. Connection Procedures - Output ..................................................2-25
5.3.1. Steam Exhaust (Output) ................................................2-25
Steam-Exhaust Pipe..................................................2-26
Steam-Exhaust Fan...................................................2-28
5.3.2. Flue Pipe (Output) .........................................................2-31
5.3.3. Drain (Output) ................................................................2-33
5.4. Installation of Options...................................................................2-33
5.5. Inspection and Verification ...........................................................2-34
6. Startup Procedure .........................................................2-35
6.1. Electrical Connections Inspection.................................................2-36
6.2. Lubrication Procedure ..................................................................2-36
6.3. Power-up Procedure.....................................................................2-37
6.4. Chemical-Charging Procedure .....................................................2-48
6.5. 7-Day Dual-Circuit Clock Initialization...........................................2-50
6.6. Rinse System (optional) ...............................................................2-50
6.7. Startup Problems..........................................................................2-51

Contents - 4 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
3 Basic Operations.............................................. 3-1
Purpose..................................................................................... 3-1
Prerequisites ............................................................................. 3-1
Safety/Precautions .................................................................... 3-1
What You Will Learn In This Chapter ........................................ 3-2
1. Control Panel ...................................................................3-3
2. Standard Cleaning Cycle.................................................3-5
2.1. Checking Water Temperature........................................................ 3-5
2.2. Using the Clock-Override Switch.................................................... 3-6
2.3. Opening the Door .......................................................................... 3-7
2.4. Loading and Securing Parts........................................................... 3-9
2.5. Closing and Locking the Door ...................................................... 3-10
2.6. Verifying Wash Temperature ....................................................... 3-10
2.7. Setting the Wash-Cycle Timer ..................................................... 3-11
2.8. Setting the Rinse Cycle (optional) ................................................ 3-11
2.9. Starting the Washer ..................................................................... 3-12
2.10. Verifying Proper Function........................................................... 3-12
2.11. Opening the Door after a Cycle.................................................. 3-13
2.12. Unloading Parts ......................................................................... 3-13
3. Continuous Operation...................................................3-14
4 Advanced Operations: Process-Control ........ 4-1
Purpose..................................................................................... 4-1
Prerequisites ............................................................................. 4-1
Safety/Precautions .................................................................... 4-2
What You Will Learn In This Chapter ........................................ 4-2
1. Chemical-Concentration Management...........................4-3
1.1. Chemical: General ......................................................................... 4-3
1.2. Selecting the Right Chemical .........................................................4-4
1.3. Selecting the Right Concentration................................................. 4-5
1.4. Maintaining the Proper Chemical Charge....................................... 4-6
1.5. Problems........................................................................................ 4-7
1.5.1. Foaming Related to Chemical Concentration .................. 4-7
1.5.2. Supersaturation of Solution ............................................. 4-8
1.6. Charging the Power Washer with Chemical................................... 4-8
1.7 Corrosion Protection……………………………………..…………...…4-8
2. Temperature Adjustment ..............................................4-11

Table of Contents Contents - 5
Standard Turntable Power Washer v. 4.0 The MART Corporation
3. Rinse-System Control (optional ARC)..........................4-13
3.1. Setting the Rinse Timer................................................................4-13
3.2. Rinse Injector Pump .....................................................................4-14
3.3. Rinse Water-Flow Adjustment ......................................................4-18
4. Setting the 7-Day Dual-Circuit Clock............................4-19
4.1. 7-Day Dual-Circuit Clock and Optional Devices............................4-20
5. Steam-Exhaust Timer ....................................................4-21
5.1. Setting the ASE Timer..................................................................4-21
6. Monitoring......................................................................4-22
6.1. Monitoring Lubrication ..................................................................4-22
6.2. Other Monitoring...........................................................................4-23
5 Maintenance ......................................................5-1
Purpose .................................................................................... 5-1
Prerequisites............................................................................. 5-1
Safety/Precautions.................................................................... 5-1
What You Will Learn In This Chapter........................................ 5-2
1. Service Schedule.............................................................5-3
2. Performing Maintenance and Common
Washer Adjustments ......................................................5-4
2.1. Pumps and Power Blast Manifold (PBM) Assembly....................... 5-4
2.1.1. Wash Pump Intake Filter (Inspect/Clean) ....................... 5-4
2.1.2. PBM Swivel Joint (Grease) ............................................. 5-5
2.1.3. PBM Nozzles (Inspect/Monitor)....................................... 5-6
2.1.4. PBM Swivel (Inspect/Adjust) ........................................... 5-8
2.1.5. Amperage Draw at Wash Pump(s) (Measure) ................ 5-9
2.1.6. Upper Manifold Bearing (Grease) ................................... 5-9
2.1.7. Wash Pump and Pump Motor (Grease).........................5-10
2.1.8. Wash Pump Couplings (Inspect) ...................................5-12
2.2. Heating System............................................................................5-13
2.2.1. Air Intake - Burner Blower Motor (Clean) .......................5-13
2.2.2. Burner Blower Motor (Oil) ..............................................5-13
2.3. Water-Level Control System.........................................................5-14
2.3.1. Float Assembly (Inspect/Clean) .....................................5-14
2.3.2. Water Solenoid Valves (Clean or Replace)....................5-16
2.4. Turntable and Drive Assembly......................................................5-17
2.4.1. Turntable Bearings (Grease) .........................................5-17
2.4.2. Turntable Drive Bearings (Grease) ................................5-17
2.4.3. Slip Clutch/Torque Limiter (Inspect)...............................5-17
2.4.4. Door Bearings (Grease).................................................5-20

Contents - 6 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
2.5. Auto Steam Exhaust (ASE) Assembly.......................................... 5-20
2.5.1. ASE Blower Motor (Oil) ................................................. 5-20
2.6. Chemical Concentration............................................................... 5-20
2.7. Voltage ........................................................................................ 5-21
2.7.1. Voltage at Power Distribution Block (Measure).............. 5-21
3. Sludge Monitoring and Clean-Out ................................5-22
3.1. Sludge Monitoring ........................................................................ 5-24
3.2. Sludge Clean-Out and Heat Exchanger/Suction Tube (Clean)..... 5-24
3.3. Heating Elements (Clean - electric only) ...................................... 5-24
4. Maintenance of Options ................................................5-25
6 Troubleshooting .............................................. 6-1
Purpose..................................................................................... 6-1
Prerequisites ............................................................................. 6-1
Safety/Precautions .................................................................... 6-2
What You Will Learn In This Chapter ........................................ 6-2
1. Startup..............................................................................6-3
2. Ineffective Cleaning.........................................................6-4
3. Wash Pump System.........................................................6-5
4. Heating System................................................................6-8
5. Turntable Drive ..............................................................6-10
6. Nozzles ...........................................................................6-11
7. Foaming..........................................................................6-12
8. Power Blast Manifold (PBM) .........................................6-13
9. Solution-Level Control System.....................................6-14
10. Door Limit Switch ........................................................6-15
11. Rinse System ...............................................................6-16
12. Automatic Steam Exhaust (ASE) ................................6-17
13. Electrical Control System ...........................................6-18

Table of Contents Contents - 7
Standard Turntable Power Washer v. 4.0 The MART Corporation
7 Options...............................................................7-1
Purpose .................................................................................... 7-1
Prerequisites............................................................................. 7-1
Safety/Precautions.................................................................... 7-1
What You Will Learn In This Chapter........................................ 7-2
1. Automatic Turntable/Swivel Bearings Lubrication .......7-3
1.1. Theory of Operation ...................................................................... 7-3
1.2. Installation ..................................................................................... 7-4
1.3. Operations..................................................................................... 7-5
1.4. Maintenance.................................................................................. 7-7
1.5. Troubleshooting............................................................................. 7-8
2. Clean Machine .................................................................7-9
2.1 Theory of Operation ....................................................................... 7-9
2.2 Installation .....................................................................................7-10
2.3 Operations.....................................................................................7-13
2.3.1 Clean-Machine Operation: Frequency............................7-14
2.3.2 Clean Machine: Chemical Management.........................7-14
2.4 Maintenance..................................................................................7-15
2.5 Troubleshooting.............................................................................7-16
3. Center Manifold .............................................................7-18
3.1. Theory of Operation .....................................................................7-18
3.2. Installation ....................................................................................7-19
3.3. Operations....................................................................................7-21
3.4. Maintenance.................................................................................7-22
Every 40 Hours of Operation .....................................7-22
Every 250 Hours of Operation ...................................7-22
3.5. Troubleshooting............................................................................7-23
4. Chemical Concentration Controller..............................7-25
4.1. Theory of Operation .....................................................................7-25
4.2. Installation ....................................................................................7-28
4.3. Operations....................................................................................7-29
4.4. Maintenance.................................................................................7-30
4.5. Troubleshooting............................................................................7-31
5. False Floor .....................................................................7-32
5.1. Theory of Operation .....................................................................7-32
5.2. Installation ....................................................................................7-32
5.3. Operations....................................................................................7-32
5.4. Maintenance.................................................................................7-33
5.5. Troubleshooting............................................................................7-33

Contents - 8 Installation, Operations, and Maintenance Manual
The MART Corporation Standard Turntable Power Washer v. 4.0
6. 50 Hertz Electrical Power..............................................7-34
6.1. Theory of Operation ..................................................................... 7-34
6.2. Installation.................................................................................... 7-34
6.3. Operations ................................................................................... 7-34
6.4. Maintenance ................................................................................ 7-34
6.5. Troubleshooting ........................................................................... 7-36
7. Filters..............................................................................7-38
7.1. Theory of Operation ..................................................................... 7-38
7.2. Installation.................................................................................... 7-39
7.3. Operations ................................................................................... 7-40
7.4. Maintenance ................................................................................ 7-41
7.5. Troubleshooting ........................................................................... 7-41
8. Frequency Drive.............................................................7-42
8.1. Theory of Operation ..................................................................... 7-42
8.2. Installation.................................................................................... 7-42
8.3. Operations ................................................................................... 7-43
8.4. Maintenance ................................................................................ 7-43
8.5. Troubleshooting ........................................................................... 7-44
9. Hot-Air Blow-Off (HABO)...............................................7-45
9.1. Theory of Operation ..................................................................... 7-45
Steam-Exhaust Fan .................................................. 7-45
Controlling HABO Heat ............................................. 7-46
9.2. Installation.................................................................................... 7-46
9.3. Operations ................................................................................... 7-51
9.4. Maintenance ................................................................................ 7-52
9.5. Troubleshooting ........................................................................... 7-53
10. Jib Crane ......................................................................7-54
10.1. Theory of Operation ................................................................... 7-54
10.2. Installation.................................................................................. 7-54
10.3. Operations ................................................................................. 7-57
10.4. Maintenance .............................................................................. 7-59
10.5. Troubleshooting ......................................................................... 7-59
11. Oil Skimmer..................................................................7-60
11.1. Theory of Operation ................................................................... 7-60
11.2. Installation.................................................................................. 7-61
11.3. Operations ................................................................................. 7-61
11.4. Maintenance .............................................................................. 7-62
11.5. Troubleshooting ......................................................................... 7-62

Table of Contents Contents - 9
Standard Turntable Power Washer v. 4.0 The MART Corporation
12. Power-Assisted Door ..................................................7-63
12.1. Theory of Operation ...................................................................7-63
12.2. Installation ..................................................................................7-63
12.3. Operations..................................................................................7-63
12.4. Maintenance...............................................................................7-65
12.5. Troubleshooting..........................................................................7-65
13. Pump Pressure Control Valve and Gauge .................7-66
13.1. Theory of Operation ...................................................................7-66
13.2. Installation ..................................................................................7-66
13.3. Operations..................................................................................7-66
13.4. Maintenance...............................................................................7-67
13.5. Troubleshooting..........................................................................7-67
14. Pump Pressure Gauge ................................................7-68
14.1. Theory of Operation ...................................................................7-68
14.2. Installation ..................................................................................7-68
14.3. Operations..................................................................................7-68
14.4. Maintenance...............................................................................7-68
14.5. Troubleshooting..........................................................................7-69
15. Rack and Fixture Set, or Small-Parts Basket ............7-70
15.1. Theory of Operation ...................................................................7-70
15.2. Installation ..................................................................................7-70
15.3. Operations..................................................................................7-72
15.4. Maintenance...............................................................................7-73
15.5. Troubleshooting..........................................................................7-73
16. Remote Grease Fittings ..............................................7-74
16.1. Theory of Operation ...................................................................7-74
16.2. Installation ..................................................................................7-74
16.3. Operations..................................................................................7-74
16.4. Maintenance...............................................................................7-74
16.5. Troubleshooting..........................................................................7-74
17. Rinse Wand ..................................................................7-75
17.1. Theory of Operation ...................................................................7-75
17.2. Installation ..................................................................................7-75
17.3. Operations..................................................................................7-75
17.4. Maintenance...............................................................................7-76
17.5. Troubleshooting..........................................................................7-77
18. Sludge Scraper ............................................................7-78
18.1. Theory of Operation ...................................................................7-78
18.2. Installation ..................................................................................7-79
18.3. Operations..................................................................................7-80
18.4. Maintenance...............................................................................7-81
18.5. Troubleshooting..........................................................................7-83