PEM SprayWand P-500 User manual

PEM P-500
SprayWand™ Pretreatment Application System
Installation • Operation • Maintenance • Troubleshooting
Revision 07.02.17

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Table of Contents
Introduction ..................................................................................................3
General specifications........................................................................................ 3
Limited warranty................................................................................................ 4
Safety ................................................................................................................. 6
Safety Rules.................................................................................................... 6
Installation ..................................................................................................10
Machine delivery and inspection.....................................................................10
Machine identification.....................................................................................10
Machine location .............................................................................................10
Machine setup .................................................................................................11
Electrical service ..........................................................................................11
Mechanical (gas) service..............................................................................12
Burner fuel pressure ................................................................................12
Guide to gas line pipe size .......................................................................13
Venting the machine to the outside ........................................................ 14
Water supply................................................................................................15
Float tank .....................................................................................................15
Wand and Hose............................................................................................ 16
Initial start-up..............................................................................................17
Control panel ...................................................................................................17
Switches.......................................................................................................17
Pump switch.............................................................................................17
Burner switch...........................................................................................17
Indicator lights .............................................................................................17
Pump motor overload indicator light ......................................................17
Flow indictor light ....................................................................................17
Temp indicator light................................................................................. 17
Fuel indicator light ...................................................................................17
Temperature control ...................................................................................18
Initial startup procedure..............................................................................19
Adjusting chemical concentration ...............................................................20
Daily Operation............................................................................................22
Starting the machine........................................................................................22
Shutting down the machine............................................................................. 22

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Winterizing the machine..................................................................................23
Preventative maintenance ...........................................................................24
Pressure hose...................................................................................................24
Water inlet tank filter screen...........................................................................25
Pump ................................................................................................................25
Pump lubrication..........................................................................................25
Pump belt.....................................................................................................27
High-pressure filter ..........................................................................................28
Heating coil descaling ......................................................................................29
Machine exterior..............................................................................................30
Repair..........................................................................................................31
Pump ................................................................................................................31
Servicing the pumping section.....................................................................31
Servicing the ceramic plungers and V-packings...........................................32
Removing the pump manifold head ........................................................32
Replacing plungers...................................................................................33
Replacing V-packings ...............................................................................34
Reinstalling the manifold head ................................................................34
Pump parts list (5CP310, 5CP3120G1, 5CP3130G1) ....................................36
Intermittent ignition device .............................................................................40
Wiring...........................................................................................................40
Engineering data ..........................................................................................41
Gas Valve..........................................................................................................42
Adjusting the pilot light ...............................................................................43
Troubleshooting ..........................................................................................44
Gas burner malfunction ...................................................................................45
Intermittent ignition device problems.............................................................46
Pump malfunction and pressure delivery problems........................................46
General malfunctions.......................................................................................48
Chemical system malfunction..........................................................................48
Electrical malfunction ......................................................................................49
Service record..............................................................................................51

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Introduction
The PEM P-500 Spraywand™ Pretreatment Application System is designed to
meet the demands of high production environments. The heavy-duty system
and precision fixed-ration chemical injectors ensure consistent outputs and
results.
The PEM system features an optional air-activated gel pump. This allows the
operator to apply gel products to metal surfaces that standard cleaners cannot
handle.
Another option delivers sealer right from the drum through a low-volume, low-
pressure pump.
Warning: To prevent injury and equipment damage, thoroughly read
and understand the contents of this manual before operating the P-500.
General specifications
Model: P-500
HP: 7.5
Electrical: 230 V, 3 phase –20 A
460 V, 3 phase –10 A
Connection: 4 wire through junction box
GPM: 5
Pressure 1500 PSI
Burner input: 415,000 BTUH
Gas connection: 1’” NPT
Fuel requirements:
- Natural gas: 7”-9” W.C.
- L.P.: 11” W.C.
Stack size: 10”
Water connection: Standard garden hose, female swivel
Dimensions (L,W,H): 42” x 29” x 48”
Weight:
- Dry: 500 lbs.
- Shipping: 650 lbs.
Nozzles: 1-15085 x ¼ NPT

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Note: The manufacturer reserves the right to make improvements in design
and/or changes in specifications at any time without incurring any obligation to
install them on units previously sold. Some photos and/or illustrations may not
be exact representations of your particular machine; however, the technical
information will apply.
Limited warranty
PEM Corporation warrants each machine sold by us to be free from
manufacturing defects in normal service for 90 days commencing with the
delivery of the machine to the original owner.
If the machine is used with approved products, the warranty is extended to two
full years or 2000 hours, whichever occurs first.
Three (3) Years Parts
• Pump drive assembly
• Frame
• Coil wrapper
Heating coils
• Float tank
Two (2) Years Parts
Plumbing
One (1) Year Parts
• Control switches
•Electric motors
•Float valves
•Safety switches
•Pulleys
•Thermostat
• Ground fault circuit
interrupter
Ninety (90) Days Parts
• Lights
• Trigger gun
• Unloaders
• Wand
• Ignition module
• Coil wrapper
Our obligation under this warranty is expressly limited at our option to the
replacement or repair by our company approval, or a service facility designated
by us¸ of such part or parts as inspection shall disclose have been defective. This
warranty does not apply to defects caused by damage or unreasonable use
(including failure to provide reasonable and necessary maintenance) while in
the possession of the consumer.
This warranty does not apply to nozzles, V-belts, hoses, pump wear parts, filters
or 0-rings or damage to the wand or gun due to mishandling.

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PEM Corporation shall not be liable for consequential damage of anything,
including but not limited to the consequential labor costs or transportation
charges in connection with the replacement or repair of the defective parts.
PEM Corporation makes no warranty with the respect to trade accessories. They
are subject to the warranties of their manufacturers.
Any implied or statutory warranties, including any warranty of merchantability
or fitness for a particular purpose are expressly limited to the duration of this
written warranty. We make no other express warranty, nor is anyone
authorized to make any on our behalf of PEM Corporation.

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Safety
This safety alert symbol indicts important messages in this manual. When you
see this symbol, carefully read the message that follows, and be alert to the
possibility of personal injury or death if you do not adhere to the requirements
of the safety message. Also be review and follow the safety decals on the
machine.
Note: PEM Corporation encourages the use of environmentally friendly
chemicals and waste storage and disposal practices. Always store and/or
dispose of chemicals in a manner that complies with local, state and federal
regulations. Furthermore, always read and follow the directions printed on
product labels when using chemicals.
Safety Rules
PEM Corporation cannot anticipate every possible circumstance that might
involve a potential hazard. The warnings and cautions in this manual are
therefore not all inclusive. If you use an operating procedure, installation or
work method not specifically recommended, you must satisfy yourself that it is
safe for you and for other persons. You must also ensure that the product will
not be damaged or made unsafe by the procedure that you use.
Warning: Fluids under pressure spray can be nearly invisible and can
penetrate the skin and cause extremely serious injury. Avoid contact with high
pressure spray. Specifically:
Never point the spray gun at any part of your body or at any other
persons.
Never put your hands or fingers over the spray tip while the machine is
in operation.
Never use your hands to stop or detect leaks.
Always shut of the machine and trigger the pressure gun to relieve
system pressure before removing the spray tip or servicing the machine.
Always wear full eye protection (preferably a face shield), protective
clothing and rubber boots when operating the machine to protect you
from burns caused by hot spray, fluid injection or debris dislodged by
high-pressure spray.
If any fluid appears to have penetrated the skin, get emergency medical
care at once. Do not treat as a simple cut. Tell the doctor exactly what
was injected. For treatment instructions, have your doctor call the
National Poison Control Network at 412-681-6669.

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Warning: Operate and maintain the machine in a manner that prevents
injury to you and others and damage to equipment. Specifically:
Never alter or modify the equipment.
Never exceed the factory pressure or temperature rating of the system.
Be sure all accessory equipment and system components used will
withstand the pressure developed.
Never let the pump or burner run without water supply flowing through
the unit.
Never attempt to run or relight the burner if ignition does not take place
the first time. Unburned gas, which may cause a fire or explosion, may
have accumulated.
Never allow children or any unauthorized or untrained persons to
operate, adjust or repair this machine.
Always keep other persons at a safe distance when using this machine.
Never attempt to clean or wash down the machine using its own spray
gun. Cleaning the machine in this manner will increase the hazard of
electrical shock and/or damage to the machine. The machine is water
resistant but not water proof.
Never leave an operating machine unattended. Always shut off the
machine and relieve pressure before leaving the machine.
Never spray inflammable or toxic liquids or chemicals such as
insecticides or weed killer.
Never operate the machine when combustible fumes or dust may be
present.
Never use detergents that are not compatible with the discharge hose.
Read and follow instructions provided by the detergent manufacturer.
Also follow directions on the container regarding contact with the eyes,
nose or skin.
Always provide approved vent stacks if the machine is to be used in an
enclosed area. Exhaust fumes contain odorless, invisible gasses that can
kill without warning. Comply with all federal, state and local codes for
locating, venting and using the machine in an enclosed area.
Always connect the machine to the correct electrical supply outlet.
Comply with all federal, state and local codes and ordinances regarding
electrical requirements.
Never allow electrical extension cord connections to fall or lay in water.
Use only extension cords rated for use with this machine.
Always respect and be alert for the potential hazards of electrical
equipment, hot burners, moving parts, high-pressure spray and steam.

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Always be certain that the machine safety decals are kept clean and
legible. Replace any decals that become damaged, lost or painted over.
Always disconnect the electrical plug before performing any repairs or
service on machine.
Never attempt repairs or modifications that you do not understand.
Contact your service dealer or contractor.
Always keep protective guards covers and shields in place. Replace any
that were removed for service or that were damaged before operating
the machine.
Always use a gas regulator of the specified type on LP tanks for butane
or propane-fired machines.
Never exceed the 210° F temperature setting for hot water, high-
pressure cleaning. Be sure the correct nozzle is used.
Danger: Chemicals used for cleaning are dangerous. Keep all chemicals
out of reach of children and untrained adults. Take proper safety precautions
before handing any chemicals. Read and follow all directions and instructions on
the product label as well as the safety data sheets before using the chemical.
Wear eye protection and rubber gloves when handling or using chemicals.
Always have a clean supply of water available to wash off any contact with the
skin or eyes. Should any chemical contact the eyes, immediately flood the eyes
with clean water and seek medical attention at once. If skin contact occurs,
flood the affected area with plenty of water for 15 minutes. If irritation persists,
seek medical attention. If chemicals are swallowed, follow the product label
directions and get immediate medical attention.
Warning: Do not start the machine unless you have the trigger gun or
wand assembly completely under your control. Left loose, the gun or wand
could recoil and damage property or cause injury.
Warning: The discharge hose supplied with the machine is designed for
use on steam and high-pressure cleaners. Special care, handling, and
maintenance are required to provide proper and safe operation. Follow the
guidelines to ensure safe operation and maximum hose service life:
Never exceed rated machine pressure or temperature.
Do not route the hose in a manner that will cause sharp bending,
kinking, cutting, abrasion or exterior damage.
Do not pull on the hose to move the machine, untangle knots or pull
excessively or cause stress on the hose.