Den-Sin Merlion Plus E500 Guida

www.densin.com

USER GUIDE & SPARE PARTS MANUAL

Electrical Powered

Heavy Duty Cold Water High

HIGH PRESSURE CLEANER

Original Instruction

Merlion Plus

E500

INTRODUCTION

MERLION PLUS - E500 STD04

Page 1 of 50

Disclaimers

Den-Sin reserves the right to change specifications and to improve our products without notice or

obligation.

This document or part of it may not be photocopied, or in any other way reproduced, or translated to other

languages without the prior written consent of

DEN-SIN.

Warning

Read this user manual before you start up your Heavy Duty Pressure Washer for the first time.

This Heavy Duty Pressure Washer producing water jet under high-pressure, which is why severe injuries

can occur if the safety precautions are not observed.

Therefore a full understanding of the contents of this instruction manual is required, in order to prevent

injuries to you, objects and persons nearby.

Safety

The following symbols are used in this manual to indicate procedures that if not followed, may results in

personal injuries or damage to equipment.

WARNING

is used to alert the reader of procedures or practice which if not

followed correctly could result in personal injuries.

CAUTION

is used to alert the reader of procedures or practice which if not

followed correctly could result in damage to machine or other equipment.

NOTE

is used to highlight important information that may assist the reader

carrying out the procedure or understanding the text.

EAR PROTECTION

is used to caution of high noise machine level. User

must wear ear plug or ear muffler. High noise level will damage user hearing.

HOT SURFACE

is used to caution user of hot surface that may cause injuries.

Any maintenance work to be done after the surfaces had cool down.

WARNING

CAUTION

NOTE

INTRODUCTION

MERLION PLUS - E500 STD04

Page 2 of 50

INTRODUCTION............................................................................................................................1

1. Getting acquainted with your Heavy Duty Pressure Washer ................................................2

OPERATIONAL INFORMATION .................................................................................................3

MACHINE DIMENSION................................................................................................................5

High Pressure Machine Schematic Diagram....................................................................................6

Marking & Indication.......................................................................................................................7

Machine Highlights ..........................................................................................................................8

HIGH PRESSURE MACHINE LOCKOUT/TAGOUT PROCEDURE .........................................8

2. Safety and protection information..........................................................................................13

General safety.................................................................................................................................13

WARNING.....................................................................................................................................14

Safety devices.................................................................................................................................15

Transporting the machine...............................................................................................................15

Safety PPE......................................................................................................................................17

Operations ......................................................................................................................................18

Application Guidelines...................................................................................................................18

3. Maintenance and troubleshooting ..........................................................................................19

Maintenance Schedule....................................................................................................................19

Troubleshooting..............................................................................................................................21

Pump Service Instructions..............................................................................................................22

Torque Specification ......................................................................................................................24

4. Machine Spare Parts Lists.......................................................................................................25

Motor/Pump Assembly Spare-Parts List........................................................................................26

Water Tank Assembly Spare-Parts List .........................................................................................27

Filter Assembly Spare-Parts List....................................................................................................28

E500 Pump Assembly Spare-Parts List..........................................................................................29

E500 Trigger Gun / lance & hose assembly...................................................................................37

4. Electrical Assembly ..................................................................................................................39

Wiring diagram...............................................................................................................................39

Main Contactor Overload Setting...................................................................................................40

Motor Switch Timer Setting...........................................................................................................40

5.Optional Rotating Nozzle..........................................................................................................44

E500 Bar Rotating Nozzle – Type 3 ..............................................................................................45

Operation & Use of Rotating Nozzle –E500..................................................................................48

Optional sand & slurry blasting kit E500.......................................................................................49

6. Warranty...................................................................................................................................50

Revison History:-

1. Getting acquainted with your Heavy Duty Pressure Washer

Date Revision Rev. No.

03/08/2016 Added start-up issues and troubleshooting guide 01

19/04/2017 Updating 220V components 02

05/06/2017

Pump and Component Changeover and removal of CE declaration

25/09/2017

Manual Content U

pdating. Cable and Water Tank P/N update.

The information contained in this user guide is subject to change without notice.

Getting Acquainted with your Heavy Duty Pressure Washer

MERLION PLUS - E500 STD04

Page 3 of 50

The DEN-SIN Merlion Plus E500 facilitates cleaning in less time at high performance. The compact

design enables the machines to be agile within tight/ narrow places, and the high performance gives you the

opportunity to solve an array of cleaning tasks. With built in water tank, machine now works even more

efficient and reliable.

All pump parts, fittings and pipes in contact with water are made of non-corrosive materials. Together with

the ceramic pistons, long life seals and stainless steel valves, it ensures long life and high durability.

Applications

These Heavy Duty Pressure Washers are capable of removing any kind of dirt:

•Algae off concrete constructions

•Paint and graffiti off walls

•Dust, dirt, soil & mud off floors

•Oil & grease off engines and other mechanical parts

•Rust, dirt, salt, scale and paint off ship decks

The Heavy Duty Pressure Washer can also be used for tasks such as:

•Surface preparation

•Concrete removal

And with the option of using different accessories, many more jobs can be dealt with:

•Sandblasting

•Drain-cleaning

•Extra-long / short lances for hard to reach places

•Rotating nozzle

This machine is only to be used for the purposes it is designed for. Any other use shall

be considered improper and therefore potentially dangerous. The manufacturer is NOT

to be held responsible for any damages caused by improper use.

Unpacking

Remove the Heavy Duty Pressure Washer and its accessories from the packing material. For transport and

packing reasons some accessories are supplied disassembled. Make sure all components are present:

Standard items:

CAUTION

Trigger Gun

Machine Manual

Nozzle

Machine

High Pressure Hose

Getting Acquainted with your Heavy Duty Pressure Washer

MERLION PLUS - E500 STD04

Page 4 of 50

1.1 OPERATIONAL INFORMATION

High Pressure Machine has IP55 rating. Parking the machine outdoor will not pose any damage to

the machine. Ensure that the ventilation to the motor must not be blocked. During operation, the

machine must not park at an incline angle of 10deg. The machine will become unstable and may

endanger user. When hose is pull up to a high, pressure will drop due to gravity.

This machine is designed to deliver clean water or non-aggressive water. Using any other water

source or sea water will damage the pump unless authorized in writing by Den-Sin.

Prior to beginning work, all equipment must be inspected to ensure that it is in safe working

condition. Inspection shall include verifying the integrity of hoses and connections, tips, lances.

Personal protective equipment must be worn.

Prior to commencing any water blasting work, the area must be barricaded to restrict unauthorized

access.

We recommend to practice to employ 2 operators* blasting method. The role of the 2

operator is

to attend the pump unit keep close watch on the 1

operator for tiredness. Therefore, the operators

can take turns to operate the machine.

∗Operators must be trained on how to operate the machine (DENSIN) and the basic blasting

protocol before allow to use the machine.

How to prepare machine for usage

Correct way of holding the trigger gun for blasting due to the recoil force from the

trigger gun.

Understand how to operate the machine correctly.

Basic Maintenance and Troubleshooting.

** Den-Sin Training program is available upon request. Please contact us for more details **

IMPORTANT

that user read the manual guide to understand the operation of the

machine before usage.

NOTE

Getting Acquainted with your Heavy Duty Pressure Washer

MERLION PLUS - E500 STD04

Page 5 of 50

1.2 MACHINE DIMENSION

MACHINE SPECIFICATION

Model Merlion Plus Model Type

Type

E500

E500 E500

M/C no.

700995876 700995877 700995878

Pump Specification

Power Phase

Power Supply

380~415V

440~4

60V

220V~230V

Freq. 50Hz 60Hz 60Hz

Motor Type 25HP 25HP 25HP

Motor Class

Motor Speed

1450rpm

1750rpm

0rpm

Power Req. 32A 32A

56A

Pump Specification

Working Pressure

500

Bar/

7250

psi

0Bar/

7250

psi

500

Bar/

7250

psi

Flow

Rate

l/min / 4.3gpm

16 l/min / 4.3g

16 l/min / 4.3gpm

Nozzle size 0003 0003 0003

Machine Dimensions

Machine Mass 220kg 220kg 220kg

Dimension LxWxH 1060x490x938 1060x490x938 1060x490x938

* Water inlet should not more than 40DegC

Getting Acquainted with your Heavy Duty Pressure Washer

MERLION PLUS - E500 STD04

Page 6 of 50

1.3 High Pressure Machine Schematic Diagram

Symbol Description Symbol Description

F1 Filter 1-Incomming MP Main Pump

FV Float Valve UV Unloader

LS Level Sensor PG2 Pressure Gauge High Pressure

Safety Valve

Trigger Gun (Dry Shut Type)

Remarks:

•SV : - SV(Safety Valve) is set at factory about 20~30Bar more than PG 2(Pressure Gauge)

•TG: - TG(Trigger Gun –Dry) is normally close, pressurize when trigger is pressed.

•

UV:- UV(Unloader) is normally open, pressurize when trigger is pressed.

SV- Safety Valve Operation

Safety valve is a system to protect the machine from over pressure. Over pressure occurs when

nozzle size is wrong or the nozzle is chocked. Another possible cause is the unloader setting is

wrongly set. When machine is over pressurized, the safety valve will start to open and excess

water is dumped. The setting of the safety valve system is factory set. Do not try to reset them.

UV-Unloader Valve Operation

Unloader valve system is a system to regulate the pressure for the machine. The setting of the

unloader valve system is factory set. Do not try to reset the setting. There should not be any water

dump back from to the water tank if the nozzle is use correctly.

Water

80L

Water Tank

F 1

Signal Out

Dump Back

PG 2

TG 1

CAUTION

Machine is manufactured with factory preset settings for its Unloader and

Safety valves. Please do not try to change these setting. Adjusting the

setting will affect the machine performance or machine become unstable.

A trained personal is required to change the settings if necessary.

Getting Acquainted with your Heavy Duty Pressure Washer

MERLION PLUS - E500 STD04

Page 7 of 50

1.4 Marking & Indication

Hose Type:

Machine ID Plate

Manufacturing Date:

Quarter;

Year

WP:

500 Bar

Hose Size:

½”

or DN 12

Hose Fitting:

½”

Do not bend the hose or squeeze between doors. Replace the hose if

the hose wire is exposed. Read the WP allow on the hose before using

the machine. Always switch off and de-pressurize the machine before

attach or dettached the hose to the machine.

CAUTION

Getting Acquainted with your Heavy Duty Pressure Washer

MERLION PLUS - E500 STD04

Page 8 of 50

1.5 Machine Highlights

Solid

Wheels

Unloader Valve

Pressure Gauge

Powder

Coated Frame

Stainless Steel

Cover

Filter

Crawl

Coupling

Galvanizing

Electrical Box

Castor Wheels

Safety Valve

Getting Acquainted with your Heavy Duty Pressure Washer

MERLION PLUS - E500 STD04

Page 9 of 50

1.6 HIGH PRESSURE MACHINE LOCKOUT/TAGOUT PROCEDURE

This procedure establishes lockout on the high pressure machine that could cause injury to personnel. All

operators shall comply with the procedure. Equipment shall be locked out to protect against accidental or

inadvertent operation when such operation could cause injury to personnel. Do not attempt to operate any

switch, valve, or other main switch bearing a lock.

Responsibility

The responsibility for seeing that this procedure is followed is binding upon all operators. All operators

shall be instructed in the safety significance of the lockout procedure by (designated individual). Each new

or transferred affected operator shall be instructed by (designated individuals) in the purpose and use of the

lockout procedure.

Sequence of Lockout Procedure

1. Notify all affected operators that a lockout is required and the reason therefor.

2. If high pressure machine is operating, shut it down by the pressing the stop button. Only turn off the

booster pump switch when the motor has come to a stop.

3. Turn the main isolator to the off position.

4. Release residue pressure in the trigger gun.

5. Lockout the main isolator with a lock assigned individual lock. This is to disable the operation of

the machine.

6. Lock the electrical box and the keys are kept with an assigned individual lock to prevent any

unauthorized modification to the machine control settings.

7. Lockout the trigger with a lock that is assigned individual lock. This is to prevent accidentally activate

the trigger or sabotage. Possible way to lock the trigger gun as shown below.

After ensuring that no personnel are exposed and as a check on having disconnected the power sources,

operate the start push button and main switch to ensure the high pressure machine will not operate.



CAUTION: Return operating controls to neutral position after the test.

8. The equipment is now locked out

Restoring Equipment to Service

1. When the high pressure machine is to operate at is normal service, check the area around the machine

that no one is exposed. Barricade the area of working zone to prevent people entering the working zone.

2. When equipment is clear, remove all locks. Turn on the main switch, unlock the trigger gun lock and start

the normal operating procedure to start using the high pressure machine.

Lock

Indice

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