Unitor HPC Extreme 330 User manual

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03/13
Instruction Manual
HPC Extreme
330 / 405 / 520

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Contents
1. Introduction Page 4
2. Safety Instructions Page 5 –6
3. Configuration/Operation/Illustrations Page 7 –10
4. Start-up/Operation/Shut-down Page 11 –16
5. Maintenance and Care Page 17 –18
6. Electric Wiring Diagram Page 19
7. Technical Data Page 20
8. Trouble Shooting Page 21
9. Declaration of Conformity Page 22
HPE-02/13-VS

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1. Introduction
Congratulations - you have purchased one of the most durable and reliable
high pressure cleaners available on the market. Its balanced ratio of water flow
and working pressure perfectly meets all cleaning requirements. The high
pressure cleaner conforms to all European safety regulations which is
guaranteed by the CE symbol.
This manual to be made available to the operating personnel and to be
read completely before start-up. We point out that we cannot be held
responsible for any damage or malfunctions as a result of ignoring this
manual.
The machine described in this manual to be inspected every year by
qualified personnel. Inspection results to be recorded and to be made
available to authorities on request. The manufacturer offers qualified
service personnel to carry out safety inspections at attractive prices.
The packing materials (plastic foil, wood, cardboard boxes, nails etc.)
are potentially dangerous, should be kept away from children and
disposed according to environmental requirements.
This symbol appears at all operating and safety instructions
dealing with risks for personal entirety and life.
This warning symbol appears in the operating manual at all
operating safety instructions dealing with risks due to electric
power.
This symbol appears at all operating and safety instructions
dealing with the fulfilment of rules, regulations and instructions for
the proper operation and destruction of the machine.
This manual is subject to technical alteration.
All rights reserved. Any use in other than legally authorised cases requires the
manufacturer’s written approval.

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2. Safety Instructions
The following instructions to be followed before, during and after work:
This instruction manual to be read completely before initial start-up. If strictly followed,
no danger should occur.
This machine must only be run by qualified adult persons who are fully familiar with
possible dangers. Relevant national safety rules to be followed.
The machine is not suitable for unattended operation and must be operated according
to specification. Protective clothing to be worn.
The water jet emerging from the spray pistol has a dangerous cutting effect. There-
fore the water jet must never be directed onto persons, animals or electrical installa-
tions. It must never be used for cleaning of clothes, footwear and the like. Be aware of
torque and recoil. Ensure stable foothold.
The max. allowed pressure which is stated on the type plate must not be exceeded.
The unloader valve opens, if the max. operating pressure is exceeded by more than
10 % and returns the water into the suction side of the high pressure pump. The
unloader valve is workshop-set and sealed. Adjustment must not be changed.
Unsuitable respectively defective high pressure hoses often cause severe accidents
during operation. Therefore high pressure hoses to be carefully inspected before
start-up and replaced by original equipment in case of damage. Use of other than
original equipment which has not expressively been approved by the manufacturer,
results in expiration of the CE Declaration of Conformity, as well as product liability
and warranty.
Used or damaged high pressure hoses must never be repaired and reused but to be
replaced by original hoses.
Spray pistols with delayed closing mechanism must not be used because of risk of
injuries.
Lever of pistol in open position must never be blocked or fixed in any way.
The use of spray wands shorter than 750 mm is prohibited.
The machine must not be run in areas jeopardized by fire or explosions. During
operation at filling stations “Technical Rules for flammable Liquids” (TfbF) to be
observed.
Consumables like detergents or lubricants to be handled thoroughly according to
technical rules and safety and environmental regulations to be observed.
Machine must not be started, if power cable, plug, switches, etc. are damaged or
defective.
Only extension cables designed according to IEC to be used. Extension cables on
reels to be completely reeled off during operation in order to avoid overheating of the
cable. Plug, couplings to be watertight. A faulty current protection switch to be
foreseen in electricity supply.

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Before opening the machine in case of malfunction or emergency, switch off by
means of the ON/OFF switch and disconnect it from electric power source.
Electric power can cause severe injuries or death. All symptoms of faulty electric
components to be taken seriously and possible causes for accidents to be eliminated
immediately. All repair work only to be carried out by qualified service personnel.
Make sure that the machine cannot move. The unit is equipped with a parking brake
which must be set during working.
During loading hoisting device to be fastened properly at jack rings. Ensure balanced
load.
Repair work in the high pressure section of the machine (pump, hoses, piping) only to
be carried out by qualified personnel.
After work the machine to be locked and secured against unauthorized/accidental
operation by means of the pistol lever safety lock.
Use of equipment and/or consumables which is/are not delivered or
expressively approved by the manufacturer results in expiration of the CE
Declaration of Conformity, as well as product liability and warranty.

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3. Configuration, Operation, Illustration
The cold water machines of this series mainly comprise of a low speed high
pressure inline plunger pump, which is directly flanged to and driven by a
100 % duty electric motor.
The supply water is directed with the required minimum pressure via a pre-
filter to the high pressure pump which –in connection with the required spray
nozzle –boosts it to the stated/adjusted working pressure. In order to protect
the pump against cavitation due to poor water flow, a low water cut-out is
arranged which stops the machine as soon as the flow pressure drops below
1 bar.
Downstreams of the high pressure pump a locked and sealed unloader valve
is installed which opens as soon as the operating pressure is exceeded by
more than 10 % and returns the water, which cannot be taken by the nozzle,
back into the suction line of the pump.
Model HPCExtreme 330 only: By opening of the rotary handle of the double
lance the working pressure can be adjusted as required.
The machine is equipped with a circulation shut-off system and additionally
with a thermo valve in order to protect the pump against overheating. After
closing the spray pistol the unloader valve opens, and returns the circulating
water back into the suction line. If during that procedure the water temperature
exceeds 60 °C, the thermo valve opens, releases a small amount of hot water,
and cold water can enter the pump. Re-starting and immediate generation of
required/adjusted working pressure is achieved by opening the spray pistol
again, allowing to continue the cleaning task without delay.
The range of applications can be extended by a variety of accessories
available. Contact your local UNITOR representative.

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4. Start-up / Shut-down
Before Start-up:
Read and observe operation manual.
In order to guarantee proper function and trouble-free operation, the
following checks to be carried out before start-up:
Check electricity supply with electric data on type shield.
If voltage deviates by more than 10 %, there is a risk of damage due to
overheating.
General condition of the unit (connections, gaskets, etc.).
Power cables/connections (see p. 11).
High pressure hoses, hose pipes, whether damaged.
Air supply, cooling air grill must not be covered.
Correct oil level of high pressure pump (oil window/dip stick).
High pressure pump: OSP special pump oil (see Technical Data).
Pump/pump connections whether leaking.
Machine only to be run with absolutely clean water. Before connecting
the water supply hose, rinse it thoroughly. Depending on feed water
quality, regularly check water filter in short intervals, replace if needed.
Machine only to be run horizontally (+/- 5°).
In order to guarantee proper function and trouble-free operation, the
following checks to be carried out during working:
Observe pressure variations on pressure gauge.
Observe leaks at high pressure pump, hose pipes, connections.
Observe abnormal noise.
In case of malfunctions immediately stop machine, eliminate cause according
to chapter „Trouble Shooting“, call qualified service.

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Connections
Water Supply
Connect water inlet (6) of the machine to water source with a clean hose
(diameter see table below). Before connecting water supply hose, rinse out
thoroughly. In case of connection to the potable water distribution, observe
DIN 1988 (for momentary connections use a backflow preventer with non-
return function and ventilation).
Flow pressure machine in operation
Water connection
minimum: 2 bar maximum: 8 bar
min. ¾" water supply hose
Insufficient water supply will cause heavy damage on high
pressure pump (cavitation).
Power Supply
Arrange correct electric connection with correct plug/socket (see electric wiring
diagram and type shield) which is protected by 3 x 32 A (slow). Only correctly
dimensioned cables to be used (see table). Extension cables on cable reels to
be reeled off completely, in order to avoid overheating of the reel. A faulty
current protection switch to be foreseen. National technical regulations to be
observed.
Lead length
Cross section
up to 20 m
4 mm²
20 m to 50 m
50 m to 80 m
6 mm²
10 mm²
High Pressure Connection
Connect high pressure hose to high pressure outlet (11) by means of the
union without using tools.

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Operation HPC Extreme 330
This machine is equipped with an EMERGENCY STOP switch. In case of
emergency push EMERGENCY STOP (2a).
Before starting the machine EMERGENCY STOP switch (2a) to be unlocked by
slightly turning it clockwise.
Fully open water source.
Unlock/release spray pistol, bleed unit.
Unlock EMERGENCY STOP (2a) by slightly turning it clockwise.
Push switch ON (2).
Be aware of torque and recoil.
Carry out cleaning task.
Pressure Regulation
Pressure can continuously be adjusted as required by opening the turning handle of
the double lance.
Counter-clockwise: pressure reduction
Clockwise: pressure increase
When pistol is closed, machine is running in circulation mode. If in this
working condition the water temperature exceeds 60 °C a thermo valve
opens, releases small amounts of hot water and same amount of cold
water enters.
After Work
Push EMERGENCY STOP (2a), machine stops.
De-pressurize spray pistol by shortly
opening and closing.
Lock spray pistol.
Disconnect machine from water and power source.
If the machine has been run with sea water,
thoroughly flush with sweet water after use, in order to avoid corrosion.
The unit must never be stored with sea water residues inside.
Thoroughly clean high pressure hose. In case of
damage (cuts, abrasions, kinks, etc.) replace high pressure hose for
safety reasons.
Only original high pressure hoses to be used. Otherwise CE
Declaration of Conformity and warranty will expire.
Reel up high pressure hose properly without any loops.
Store machine and accessories in a dry, frost-protected area.

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Particularly note:
In case of malfunctions, eliminate cause according to chapter „Trouble Shooting“, call
qualified service.
In case frost is likely, frost protection to be carried out (see chapter „Maintenance and
Care“), otherwise severe damage will result.

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Operation HPC Extreme 405 / 520
These machines are equipped with an EMERGENCY STOP switch. In case of
emergency push EMERGENCY STOP (2a).
Before starting the machine EMERGENCY STOP switch (2a) to be unlocked by
slightly turning it clockwise.
Fully open water source.
Unlock/release spray pistol, bleed unit.
Unlock EMERGENCY STOP (2a) by slightly turning it clockwise.
Push switch ON (2).
Be aware of torque and recoil.
Carry out cleaning task.
When pistol is closed, machine is running in circulation mode. If in this
working condition the water temperature exceeds 60 °C a thermo valve
opens, releases small amounts of hot water and same amount of cold
water enters.
After Work
Push EMERGENCY STOP (2a), machine stops.
De-pressurize spray pistol by shortly
opening and closing.
Lock spray pistol.
Disconnect machine from water and power source.
Thoroughly clean high pressure hose. In case of
damage (cuts, abrasions, kinks, etc.) replace high pressure hose for
safety reasons.
Only original high pressure hoses to be used. Otherwise CE
Declaration of Conformity and warranty will expire.
Reel up high pressure hose properly without any loops.
Store machine and accessories in a dry, frost-protected area.

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Particularly note:
In case of malfunctions, eliminate cause according to chapter „Trouble Shooting“, call
qualified service.
In case frost is likely, frost protection to be carried out (see chapter „Maintenance and
Care“), otherwise severe damage will result.

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5. Maintenance and Care
Every machine is only as reliable as maintenance is carried out.
The manufacturer offers maintenance agreements for every machine
comprising the yearly safety inspection. Contact your local distributor for
more information.
The machine to be inspected every year by qualified personnel, in order
to guarantee trouble-free and safe operation. Inspection results to be
recorded and to be made available to authorities on request. The
manufacturer offers qualified service personnel to carry out safety
inspections at attractive prices.
In order to guarantee reliability and trouble free operation of the
machine, it is of vital interest to follow the instructions below:
If the required maintenance intervals are disregarded, warranty will
expire.
High Pressure Pump
First oil change after 50 operating hours, further oil changes after every 500 operating
hours, minimum once per year. In case the oil becomes milky due to condensate
formation, stop the machine immediately and carry out oil change. If this happens
repeatedly, arrange replacement of all pump seals by qualified personnel.
For the high pressure pump only special pump oil OSP to be used, as
otherwise guarantee expires.

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Cartridge Filter (micro filter 25/50 µm)
Upstreams of the high pressure pump there is a cartridge filter (5)
installed. The filter cartridge to be replaced whenever required.
Frost Protection
Frost protection of the entire water system during storage and transport
is a must, as otherwise heavy damage on the system and severe
dangers during operation may occur.
The best frost protection is to store the machine and accessories in a frost-
protected room.
If frost is likely during storage and/or transportation the machine to be
protected as described below:
Mix 2 Liters of a 1 : 1 water/anti-freeze liquid (e.g. Glysantin) in a clean
vessel, dip water connecting hose into anti-freeze liquid and start pump
by pressing motor protection switch and red frost protection switch on
the right side of electric box simultaneously.
Open spray pistol and return drawn-off anti-freeze liquid into the vessel,
so allowing the liquid to circulate through the system. The frost
protection switch (15) to be kept pressed during the procedure.
Spray pistol to be opened and closed several times in order to fill
unloader valve and pressure gauge with anti-freeze liquid.
Stop pump, release frost protection switch and disconnect all hoses.
Machine is now protected against frost to –30 °C.
Disregarding frost protection instructions will result in heavy
damage of the water carrying components.
Never simply dump anti-freeze liquid but collect it for re-use or
dispose according to environmental regulations.

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6. Electric Wiring Diagrams
Model HPCExtreme 330 / 405 / 520
400 Volt / 3~50 Hz
440 Volt / 3~60 Hz

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7. Technical Data
* according to DIN EN ISO 3744
** Specification: Hypoid Oil SAE 85/90, 78 cSt./10,3 ° E/50 °C
with EP high pressure additives,
e.g. TEXACO Geartex EP-B-85W/90
Standard Scope of Supply:
Low water cut-out, frost protection switch, water connecting coupling/hose fitting
GEKA ¾", 5 m power cable 4 x 4 mm², double spray wand with pressure regulation
(HPCExtreme 330 only); HPCExtreme 405 and 520 with single spray wand. Spare
cartridge 5", 50 µm for water filter. Mounting tool for filter housing. Copy of electric
wiring diagram in switchbox cover.
Technical Data
HPCExtreme 330
HPCExtreme 405
HPCExtreme 520
Water flow
1320 l/h
1320 l/h
1020 l/h
Unloading pressure
330 bar
405 bar
550 bar
Working pressure
adjustable max. 310 bar
385 bar
150 –500 bar
Power supply
400 V / 3 ~ 50 Hz
400 V / 3 ~ 50 Hz
400 V / 3 ~ 50 Hz
Electric motor power
11 kW
15 kW
15 kW
Pump speed
1420 1/min
1420 1/min
1420 1/min
Amperage
25 A
30 A
30 A
Noise level Lp/Lw *
61/74 dB(A)
62/71 dB(A)
69/81 dB(A)
Recoil force
94 N
106 N
99 N
Dimensions (L x W x H mm)
740 x 610 x 740 mm
800 x 600 x 750 mm
800 x 600 x 810 mm
Weight
115 kg
159 kg
166 kg
Water inlet temperature max.
60 °C
60 °C
60 °C
Spray nozzle
2038 HIP
2338 HIP
3538 HIP
Pump Oil ** 1,04 l
IP Code
OSP special pump oil
55
OSP special pump oil
55
OSP special pump oil
55
Technical Data
HPCExtreme 330
HPCExtreme 405
HPCExtreme 520
Water flow
1320 l/h
1320 l/h
1020 l/h
Unloading pressure
330 bar
405 bar
550 bar
Working pressure
adjustable max. 310 bar
385 bar
150 –500 bar
Power supply
440 V / 3 ~ 60 Hz
440 V / 3 ~ 60 Hz
440 V / 3 ~ 60 Hz
Electric motor power
13 kW
18 kW
18 kW
Pump speed
1720 1/min
1720 1/min
1720 1/min
Amperage
23 A
27 A
27 A
Noise level Lp/Lw *
61/74 dB(A)
62/71 dB(A)
69/81 dB(A)
Recoil force
94 N
106 N
99 N
Dimensions (L x W x H mm)
740 x 610 x 740 mm
800 x 600 x 750 mm
800 x 600 x 810 mm
Weight
115 kg
159 kg
166 kg
Water inlet temperature max.
60 °C
60 °C
60 °C
Spray nozzle
2038 HIP
2338 HIP
3538 HIP
Pump Oil ** 1,04 l
IP Code
OSP special pump oil
55
OSP special pump oil
55
OSP special pump oil
55