Ecolab OMEGA 5E Installation & Operation Manual

Download

Page 1

INSTALLATION & OPERATION MANUAL

FOR ECOLAB MODEL:

OMEGA 5E

www.ecolab.com

CHEMICAL SANITIZING DISHMACHINE

October 4, 2007 P/N 7610-003-28-32 (Revision A)

Manufactured in the United States by:

Page 2

Page 3

REVISION/

PAGE

REVISION

DATE

MADEBYAPPLICABLE

ECN

DETAILS

A 04-02-2007 MAW N/A Release to production.

3 08-20-2007 MAW N/A Corrected dimension from 38” to 39”.

30, 35 08-27-2007 MAW N/A Added two Ecolab numbers.

2, 7 09-07-2007 MAW N/A

Removed total cycle time of 130. Corrected booster heater cover to say control box cover.

32 10-04-2007 MAW 7934 Changed cover on power junction box.

Page 4

NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL

OMEGA-5E

Omega 5E - Chemical sanitizing, electrically-heated dishmachine

Model:

Serial No.:

Installation Date:

Service Rep. Name:

Phone No.:

Page 5

SECTION

DESCRIPTION PAGE

I. SPECIFICATION INFORMATION

Specifications 2 Dimensions 3

II. INSTALLATION/OPERATION INSTRUCTIONS

Installation Instructions 5 Electrical Installation Instructions 6 Operation Instructions 7 Chemical Dispensing Equipment 9 Cam Timer Operation 10

III. PREVENTATIVE MAINTENANCE 13

IV. TROUBLESHOOTING SECTION

Common Problems 15

V. SERVICE PROCEDURES

Rinse Solenoid Valve Repair Parts 17

VI. PARTS SECTION

Standard Parts 22 Chemical Feeder Pump Assembly 25 Solenoid Valve Repair Parts 26 Vacuum Breaker Repair Parts 27 Control Box Assembly 28 Peripump Box Assembly 31 Electrical Connection Box Assembly 32 Frame Assembly 33 Hood Assembly 34 Switch Panel Assembly 35 Tub Assembly 36 Frame & Motor Assembly 38 Pump and Motor Assembly 40 Booster Tank Assembly 41 Incoming Plumbing Assembly 42 Door Components 43 Front Panel Assembly 44 Retrofit Kit, Switch Box Assembly 45

VII. ELECTRICAL DIAGRAMS

OMEGA 5E (115 Volt, 60 Hz, Single Phase) 47

TABLE OF CONTENTS

Page 6

SECTION 1:

SPECIFICATION INFORMATION

Page 7

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: 09-07-2007

SECTION 1: SPECIFICATION INFORMATION

SPECIFICATIONS OF THE OMEGA 5E

OPERATING CAPACITY ( NSF RATED):

RACKS PER HOUR 29 DISHES PER HOUR 725 GLASSES PER HOUR 725

OPERATING CYCLES (SECONDS):

NORMAL

CYCLE:

WASH TIME 45 RINSE TIME 25 TOTAL CYCLE TIME 90

WASH TANK CAPACITY (GALLONS): 1.2

WASH PUMP CAPACITY (GPM): 61

OPERATING TEMPERATURES:

WASH (MINIMUM) 120°F WASH (RECOMMENDED) 140°F RINSE (MINIMUM) 120°F RINSE (RECOMMENDED) 140°F

WATER REQUIREMENTS:

WATER LINE SIZE NPT 1/2” DRAIN LINE SIZE NPT 2” FLOW PRESSURE 20 ±5 PSI

MINIMUM CHLORINE REQUIRED (PPM): 50

ELECTRICAL REQUIREMENTS:

WASH PUMP MOTOR HP 3/4

RINSE TYPICAL HEATER TOTAL ELECTRICAL

VOL

TS PH HZ RATINGS AMPS CIRCUIT

115 1 60 2KW@110V *16 A 20 AMP

* This dishmachine is designed so that the wash motor is never running when the wash heater is on. Service load is based upon the higher of the two amperages.

NOTE: Typical Electrical Circuit is based upon (1) 125% of the full amperage load of the machine and (2) typical fixed-trip circuit breaker sizes as listed in the NEC 2002 Edition. Local codes may require more stringent protection than what is displayed here. Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes. These numbers are provided in this manual simply for reference and may change without notice at any given time.

FRAME DIMENSIONS:

WIDTH 24 1/2” DEPTH 25 1/4” DEPTH, WITH FRONT DOOR OPEN 36 3/4” HEIGHT 41 3/8” MAXIMUM WASH CHAMBER CLEARANCE 11 1/2”

NOTE: Always refer to the machine data plate for specific electrical and water requirements. The material provided on this page is for reference only and may be subject to change without notice.

Page 8

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: 08-20-2007

SECTION 1: SPECIFICATION INFORMATION

DIMENSIONS

21 1/4

(540 mm)

(432 mm)

(508 mm)

21 1/4

(540 mm)

7 3/4

(197 mm)

(991 mm)

6 3/4 (171 mm)

6 (152 mm)

12 1/4

(311 mm)

36 3/4

(933 mm)

24 1/2

(622 mm)

25 1/4

(642 mm)

3 (76 mm)

A - Incoming Water Connection B - Drain Connection - 2" IPS C - Electrical Connection P oi nt NOTE: All vertical dimens ions are

at lowest point due to adjustable bullet feet and may be raised an additional 2 3/4".

11 1/2

(292 mm)

DISH

CLEARANCE

Page 9

SECTION 2: INSTALLATION/OPERATION

INSTRUCTIONS

Page 10

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

VISUAL INSPECTION: Before installing the unit, check the container and the machine for any damage. Adamaged container could be an indication of damage to the unit. If there is damage to both the container and the unit, DO NOT throw away the container. The dishmachine has been inspected and packed at the factory with the expectation that it will arrive to you in new, undamaged condition. However, rough handling by carriers or others may damage the unit while in transit. If this situation does occur, do not return the unit to Ecolab; instead contact the carrier and ask them to inspect the damage to the unit and to complete an inspection report. You must contact the carrier within 48 hours of receiving the machine. Also, contact your Ecolab representative.

UNPACKING THE DISHMACHINE: Remove the machine from the container and inspect for any missing parts. If an item appears to be missing, contact your Ecolab representative immediately to report it.

LEVEL THE DISHMACHINE: The dishmachine(s) covered in this manual are designed to operate on a level surface. Ensure that the machine is level from side to side and from front to back; adjust the unit’s bullet feet as required. Failure to level the dishmachine may cause decreased washing performance.

PLUMBING THE DISHMACHINE: All plumbing connections must comply with all applicable local, state and national plumbing codes. The plumber is responsible for flushing the incoming water line prior to connecting it to remove all foreign debris that may get trapped in the valves or cause an obstruction. Any valves that are fouled by matter left in the water line and the expenses resulting are not the responsibility of the manufacturer.

CONNECTING THE DRAIN LINE: The Omega 5 drain requires a minimum 2” NPT piping that is pitched at least 1/4” per foot. There must also be an air gap between the machine drain line and the floor sink or drain. If a grease trap is required by code, it should have a flow capacity of 5 gallons per minute.

WATER SUPPLY CONNECTION: Install the water supply line (1/2” NPT minimum) to the dishmachine line y-strainer using copper pipe. It is recommended that a water shut-off valve be installed between the main supply and the machine to allow for service. The water supply line must be capable of 20 ±5 PSI “flow” pressure at the recommended temperature as indicated on the data plate.

In areas where the water pressure fluctuates or is greater than the recommended pressure, it is suggested that a water pressure regulator be installed. The Omega 5 does not come with a water pressure regulator as standard equipment.

It is also recommended that a shock absorber (not supplied with the Omega 5) be installed in the incoming water line. This prevents line hammer (hydraulic shock), induced by the solenoid valve, which can cause damage to the equipment.

PLUMBING CHECK: Slowly turn on the water supply to the machine after connecting the incoming fill line and drain line. Check for leaks and repair as required. Leaks must be repaired prior to placing the machine in operation.

Frame with Adjustable Foot

Drain Connection

Y-Strainer

Raise

Lower

Page 11

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

ELECTRICAL INSTALLATION INSTRUCTIONS

ELECTRICAL POWER CONNECTION: Electrical and grounding connections must comply with all applicable portions of the National Electric Code (ANSI/NFPA 70) and/or other electrical codes that may apply.

Disconnect the electrical power supply and lockout the disconnect switch to indicate that you are working on the circuit. The dishmachine data plate is located on the left front corner of the machine. Refer to this data plate for information concern-

ing the unit’s specific electrical requirements. To install the incoming power lines, open the connection box by removing the con-

nection box lid. Install 1/2” conduit into the pre-punched holes in the back of the connection box. Route the power wires and connect to the power block and grounding lug. Install the service wires (L1 and N) to the appropriate terminals as they are marked on the terminal block. Install the grounding wire into the lug provided. Wires should be firmly secured in place.

It is recommended that “De-Ox” or another similar anti-oxidation agent be used on all voltage connections.

VOLTAGE CHECK: Ensure that the machine is off and apply power to the machine. Check the incoming power at the terminal block and ensure it corresponds to the voltage on the machine data plate. Do not run the dishmachine if the voltage is too high or too low. Shut off the service breaker and mark it as being for the dishmachine. Advise all personnel of the location of the service breaker. Replace all covers and tighten the screws.

NOTE: Always refer to the machine data plate for specific electrical and water requirements. The material provided on this page is for reference only and may be subject to change without notice.

Ground Lug

Power Block

Page 12

OPERATIONAL START-UP AND CHECK: Before proceeding with the start-up, verify the following:

1. Open the door and verify that the sump strainer is correctly installed in the sump.

2. Verify that the drain stopper is in position.

3. Check that the plugs are securely screwed into the ends of the wash arm.

4. Check that the wash arm is securely screwed into the stationary base and that it rotates freely.

5. Check the levels in all chemical containers and replace if necessary.

INSTALLATION/INITIAL START-UP PROCEDURE:

1. Turn on dishmachine a) Turn on the incoming power to the machine at the circuit disconnect box. b) Turn on the dishmachine by pressing the ON/OFF button. The red light will come on. c) Check voltage at incoming terminals L1& L2. The voltage measured at these points should match data plate voltage. d) If voltages are in required range, close the control box cover.

2. Fill Rinse Booster Heater with Water

a) Before the heater element can be energized, the rinse booster heater must be initially filled with water. Damage to the heater

element will occur if the element is not submerged in water. To initially fill the booster heater with water:

i) Press and hold the FILL button to turn on the incoming water solenoid valve. Continue holding the button until you hear water

entering the wash chamber through the airgap, then release the button. The rinse booster heater is now filled with water.

ii) Turn off the unit by pressing the on/off switch.

3. Enable Heater Element

a) For the initial start-up only, the heater element must be enabled. The machine is shipped from the factory with the heater element disabled. This is done to ensure that the heater element is not damaged by energizing the element without the element being submerged in water. To enable the heater element:

i) Remove the control box cover panel. ii) Connect the tagged white/blue wires. iii) Replace control box cover. iv) Press the on/off switch, heaters will energize to maintain booster heater temperature.

Note: Water must be in the sump while the machine is running to avoid running the pump dry and causing damage to the pump seal.

4. Adjust dishmachine fill level. If the water level is not between the linses on the drain standpipe, it will require adjustment. Check to ensure that the recommended

water pressure is being supplied to the machine (20 ±5 PSI is required). If the water pressure is correct then the fill valve cam will need adjustment. Use the following steps to adjust the cam.

A. Turn power off at the machine circuit breaker. B. Open control box cover

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: 09-07-2007

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

OPERATION INSTRUCTIONS

Page 13

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

OPERATION INSTRUCTIONS (CONTINUED)

C. Locate the timer fill valve cam (Cam 4 from the timer motor) D. Locate the spanner wrench taped to the electrical panel. The spanner wrench is used to adjust the cam. E. To increase the water level, open the notch of the adjustable cam. To decrease the water level, close the notch. Care must be

taken that the set point does not extend into the home position of the timer. Do not move the side of the cam that starts the fill; this will change the sequence of cycle operation.

F. With the door closed turn the power circuit breaker on. Open and close the door to run a cycle, then check the water level. Adjust as necessary then close the control box cover.

Refer to pages entitled “Cam Timer Operation”. NOTE: The machine must run a complete cycle to drain and fill. If the machine is not allowed to drain, the water will build up inside

the tub. After the initial fill, the rinse water for the current cycle will become the wash water for the next cycle. The dishmachine is now ready to proceed with the washing of dishes. WARNING: Certain materials, including silver, silver plate, aluminum and pewter, are attacked by sodium hypochlorite sanitizers

(bleach). PREPARING DISHES: Preparation of the ware will help ensure good results and less re-washes. If not done properly the dishes will

not be clean and will reduce the efficiency of the dishmachine. The following steps should be followed to ensure good results: A. Remove all scraps and gross soil into a garbage can.

B. Separate and pre-soak silverware. C. Separate and pre-soak the egg and casserole dishes. D. Scrape all ware with a brush or spatula. E. Flush cups, bowls and glasses with running water. F. Prewash dishware by soaking or spraying with a pre-rinse hose. G. Place dishes and cups in dish rack. Cups should be upside down (so they don’t hold water). H. Place glasses and flatware in their respective racks. Scatter flatware loosely in rack. Glasses should be placed upside down in a properly sized rack. For optimal results, flatware should be washed twice, the first being horizontal, the second in a special rack to hold flatware vertical.

DAILY MACHINE PREPARATION: Before proceeding with start-up, verify the following: A. Open door and verify that the sump strainer is in place in the sump.

B. Verify that the drain stopper is in position. C. Check that the plugs are securely screwed into the ends of all wash arms. D. Check that the wash arms are securely screwed into the stationary bases and rotate freely. E. Check levels in all chemical containers and replace if empty. F. For initial fill, close doors then depress the “FILL” switch to the “FILL” position.

WASHING A RACK OF WARE:

A. Open doors, place a full rack into the machine, and close doors. Push the start switch and hold until unit starts (about 2 seconds). B. After cycle is completed open doors and remove rack. C. Repeat steps Aand B.

SHUT DOWN AND CLEANING:

A. At the end of mealtime, move the “ON/OFF” switch to the “OFF” position. B. Open doors and manually remove drain stopper to drain the unit. C. Remove and clean upper and lower wash arms. D. Remove and clean the sump strainer.

Page 14

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

TO PREPARE PUMPS FOR OPERATION

The OMEGA 5E dishmachines are supplied with detergent, rinse additive and sanitizer dispensing chemical feeder pumps. Locate the open ends of the chemical tubes with the tube stiffeners and place each one in the appropriate container.

A. Red Tubing = Detergent B. Blue Tubing = Rinse Aid C. White Tubing = Sanitizer

PRIMING PERISTALTIC PUMPS

Peristaltic pumps need priming when the machine is first installed or if for some reason the chemical lines have been removed and air has been allowed to enter.

CAUTION: Water must be in the sump and wash tank prior to the dispensing of chemicals. Sanitizer in concentration is detrimental to the metal of the dishmachine and may cause damage without dilution.

1. Verify that the proper chemical tube stiffener inlet is in the proper container.

2. Use the toggle switches on the left side of control box to prime each pump. One will prime the sanitizer pump only, and the second will prime either the detergent or rinse aid pump, depending upon which way it is depressed.

3. To prime the pumps, hold the switch in the momentary position until chemical can be observed entering the sump.

4. Detergent is dispensed as required during the wash cycle by the cam timer. The amount of detergent may need to be increased or decreased depending on water quality and type of detergent. It is adjusted by changing Cam 6 on the cam timer.

5. Rinse additive is dispensed as required into the final rinse. The amount of rinse aid may need to be adjusted depending on water hardness and results. It can be changed by changing Cam 7 on the cam timer.

6. Sanitizer, either chlorine or iodine, is dispensed into the final rinse. The amount of sanitizer may need to be adjusted depending on the concentration and type of sanitizer used. It is adjusted by changing Cam 5 on the cam timer.

WARNING: Some of the chemicals used in dishwashing may cause chemical burns if they come on contact with your skin. Wear appropriate protective gear when handling these chemicals. If you do come in contact with these chemicals flush the area with fresh water.

CHEMICAL DISPENSING EQUIPMENT

Page 15

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

The cam timer is a 1 minute, 30 second, 8-cam timer that controls the operation of the dishmachine. The following is a description of the set points for each cam and the function of each switch.

CAM 1: Cam 1 is a cut cam with a single notch and serves as the cycle/reset control. FUNCTION: When the machine is in the operation mode the notch is the home position. The machine will remain idle until the door

is opened, then cam 1 moves to the start position and holds until the door is closed. The closing of the door will start the next cycle. The cam will rotate a complete cycle, and return to the home position and hold.

CAM 2: Cam 2 is a cut cam and provides the wash cycle timing. FUNCTION: The wash cam works off the normally open contacts of Cam 2. This requires the switch be held closed by the cam.

It will close and energize the wash pump 2 seconds after the cycle switch is activated. The pump will operate through the wash cycle (40 seconds) then shut down for the dwell period (20 seconds). As the cam rotates it energizes the pump for the rinse cycle (25 seconds). When cam 1 reaches it’s home position it will de-energize cam 2, shutting down the wash pump.

NOTE: The last 6 cams are adjustable. The following instructions will require that the timer position have the cams to the front and the motor to the left.

CAM 3: Cam 3 is an adjustable cam and controls the drain solenoid. FUNCTION: The drain solenoid works off the normally closed contacts of cam 3. When the cycle is initiated, the micro switch will

be held open until it is allowed to drop into the notch of the cam. This energizes the drain solenoid which drains the machine. Af ter a 12 second delay the cam reverses the micro switch, de-energizing the drain solenoid. This cam may require adjusting due to varying water pressure. The drain solenoid must remain open long enough to remove whatever water the fill valve solenoid allows in the machine.

SETTINGS: The right side of cam 3 must be set to pick up the switch arm just before the wash/rinse cycle cam switch drops. It will hold the drain solenoid open to drain all the water in the tank from the unit during the dwell period. Any adjustment made to the drain should be made to the left side of cam 3. The cam must be moved back into the wash time until all of the water is drained from the machine.

CAM 4: Cam 4 is an adjustable cam and controls the fill valve and therefore the rinse cycle. FUNCTION: The fill valve cam works off the normally closed contacts of cam 4. This requires the switch to be held open by the

cam and allowed to drop into the notch to operate the fill valve. This energizes the fill solenoid which opens to fill the machine with fresh water. After a 10 second delay, the cam reverses the micro switch, de-energizing the fill solenoid. The fill cam may require adjustment due to varying water pressure. The fill solenoid must remain open a sufficient length of time to fill the machine to the correct level.

SETTINGS: The right side of cam 4 must be set to allow the switch arm to drop 2 seconds before the drain solenoid is de-energized which flushes the detergent residue from the unit. It will hold the fill solenoid open until the cam switch arm is raised. At that time the fill solenoid is de-energized, shutting off the incoming water. The tub will be filled to the correct level to rinse the rack. Any adjustment made to the timing of the fill solenoid should be made with the left side of cam 4. To increase the water level, open the notch of the cam and for decreasing the level of the notch should be closed.

CAM 5: Cam 5 is an adjustable cam and controls the sanitizer pump. FUNCTION: The sanitizer pump cam works off the normally closed contacts of cam 5. This requires the switch arm to be held

open by the cam and allowed to drop into the notch to operate the pump. The time that the sanitizer pump will remain energized must be determined in the field to suit the chemical used and water conditions.

SETTINGS: The left side of cam 5 must be set to allow the switch arm to drop in past the starting point of the fill cam and after the drain solenoid has closed. The adjustment for sanitizer volume must be made with the right side of the cam. To increase the volume the notch should be increased or to decrease the amount of sanitizer the notch should be closed slightly in increments until the correct level is reached.

CAM TIMER OPERATION

Page 16

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS

CAM 6: Cam 6 is an adjustable can and controls the detergent pump. FUNCTION: The detergent pump cam works off the normally closed contacts of cam 6. This requires the switch arm to be held

open by the cam and allowed to drop into the notch to operate the pump. The time that the detergent pump will remain energized must be determined in the field to suit the chemical used and water conditions.

SETTINGS: The left side of cam 6 must be set to drop in past the starting point of the wash pump cam. The adjustment for dete rgent volume must be made with the right side of the cam. To increase the volume, the notch should be increased or to decrease the amount of detergent the notch should be closed slightly in increments until the correct level is reached.

CAM 7: Cam 7 is an adjustable cam and controls the rinse aid pump. FUNCTION: The rinse aid pump cam works off the normally closed contacts of cam 7. This requires the switch arm to be held

open by the cam and allowed to drop into the notch to operate the pump. The time that the rinse aid pump will remain energized must be determined in the field to suit the chemical used and water conditions.

SETTINGS: The left side of cam 7 must be set to drop in past the starting point of the fill cam and after the drain solenoid has closed. The adjustment for rinse aid volume must be made with the right side of the cam. To increase the volume the notch should be increased or to decrease the amount of detergent the notch should be closed slightly in increments until the correct level is reached.

CAM 8: Cam 8 is an adjustable cam and is not used.

CAM TIMER OPERATION (CONTINUED)

Page 17

SECTION 3:

PREVENTATIVE MAINTENANCE

Page 18

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 3: PREVENTATIVE MAINTENANCE

PREVENTATIVE MAINTENANCE

The dishmachines covered in this manual are designed to operate with a minimum of interaction with the operator. However, this does not mean that some items will not wear out in time.

There are many things that operators can do to prevent catastrophic damage to the dishmachine. One of the major causes of component failure has to do with prescrapping procedures. Adishmachine is not a garbage disposal; any large pieces of material that are put into the machine shall remain in the machine until they are either broken up (after spreading out on your ware!) or physically removed. Strainers are installed to help catch debris, but they do no good if they are clogged. Have operators regularly inspect the pan strainers to ensure (1) that they are free of soil and debris and (2) they are laying flat in the tub.

When cleaning out strainers, do NOT beat them on waste cans. The strainers are made of metal and can be forgiving; but once severe damage is done, it is next to impossible for the strainer to work in the way it was designed to. Wipe out strainers with a rag and rinse under a faucet if necessary. For stubborn debris, a toothpick should be able to dislodge any obstructions from the perforations. Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub.

You may wish to contact your Ecolab representative in order to learn more about how your water hardness will effect the performance of your machine. Hard water makes dishmachines work harder and decreases efficiency.

Again, it is important to remind operators that trying to perform corrective maintenance on the dishmachine could lead to larger problems or even cause harm to the operator. If a problem is discovered; secure the dishmachine using proper shut down procedures as listed in this manual and contact your Ecolab representative.

Some problems, however, may having nothing to do with the machine itself and no amount of preventative maintanence is going to help. Acommon problem has to do with temperatures being too low. Verify that the water temperatures coming to your dishmachine match the requirements listed on the machine data plate. There can be a variety of reasons why your water temperature could be too low and you should discuss it with your Ecolab representative to determine what can be done.

By following the operating and cleaning instructions in this manual, you should get the most efficient results from your machine. As a reminder, here are some steps to take to ensure that you are using the dishmachine the way it was designed to work:

1. Ensure that the water temperatures match those listed on the machine data plate.

2. Ensure that all strainers are in place before operating the machine.

3. Ensure that all wash and/or rinse arms are secure in the machine before operating.

4. Ensure that drains are closed/sealed before operating.

5. Remove as much soil from dishes by hand as possible before loading into racks.

6. Do not overfill racks.

7. Ensure that glasses are placed upside down in the rack.

8. Ensure that all chemicals being injected to machine have been verified as being at the correct concentrations.

9. Clean out the machine at the end of every workday as per the instructions in the manual.

10. Always contact your Ecolab representative whenever a serious problem arises. 1 1. Follow all safety procedures, whether listed in this manual or put forth by local, st ate or national codes/regulations.

Page 19

SECTION 4:

TROUBLESHOOTING

Page 20

WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power, att ach test equipment and reapply power to test. When replacing electrical parts, disconnect power at source circuit breaker.

Problem: Machine will not run; no power to the unit.

1. Verify that the service disconnect or service breaker are not off.

2. Verify that electrical service has been hooked to the machine.

3. Verify that the correct voltage, phase and frequency have been hooked to the machine.

4. Verify wiring of power switch to the schematic. Check continuity of switch. If switch is wired correctly, switch may need replaced.

Problem: Machine has power, but will not cycle.

1. Verify that the correct voltage, phase and frequency have been hooked to the machine.

2. Check that the switch button hasn’t seperated.

3. Check cycle switch for continuity.

Problem: Machine runs, but there is no water.

1. Verify that there is water connected to the machine and that it is turned on.

2. If a strainer is placed in line with the machine, ensure that it is not clogged.

3. Verify that there is 20 ±5 PSI of water flow pressure to the machine.

4. Water fill valve may be faulty and may need to be replaced.

Problem: Machine runs and there is water, but dishes are dirty.

1. Ensure that good prescrapping occurs be removing as much heavy soil from the ware as possible before starting the cycle.

2. Verify that chemical concentrations for detergent are correct for the given water conditions.

3. Verify that none of the wash or rinse arms have clogged nozzles.

4. Ensure that the unit is filling to the correct water level.

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 4: TROUBLESHOOTING

COMMON PROBLEMS

Page 21

SECTION 5:

SERVICE PROCEDURES

Page 22

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 5: SERVICE PROCEDURES

RINSE SOLENOID VALVE REPAIR PARTS KIT

These dishmachines are equipped with electrical solenoid valves to allow for automatic fill and rinse. These valves are designed to specific tolerances and design aspects that must be met in order to function properly.

Ecolab offers repair kits for replacing some of the wear items associated with solenoid valves which will allow you to save money in that replacement of these parts can take place without removing the solenoid valve from the plumbing assembly.

The instructions provided here are for maintenance personnel only. Unauthorized persons should not attempt any of the steps contained in these instructions.

Warning: many of the instructions and steps within this document require the use of tools. Only authorized personnel should ever perform any maintenance procedure on the dishmachine!

PREPARATION

1. Power must be secured to the unit at the service breaker. Tag or lock out the service breaker to prevent accidental or unauthorized energizing of the machine.

2. Ensure that incoming water to the machine is secured either by use of a shut-off valve or disconnecting the incoming water line.

TOOLS REQUIRED

The following tools will be needed to perform this

maintenance evolution:

1. Small flathead screwdriver

2. Medium flathead screwdriver

2. Needle nose pliers

3. 5/16” nutdriver

4. Channel locks

5. 12” pipe wrench

TIME REQUIRED

It is estimated that it will take (1) person twenty minutes to perform this task, not including all of the items indicated in the section entitled “PREPARATION”.

IMPORT

ANT NOTES

1. Read these instructions thoroughly before attempting this maintenance evolution. Become familiar with the parts and what actions need to be taken. This will save time in the long run!

2. The procedures demonstrated in this manual are shown being performed on an ES-4400 rack conveyor dishmachine. The actual maintenance steps, however, apply to any Parker style solenoid valve found on a Ecolab dishmachine.

STEPS

1. Remove the top screw with the 5/16” nutdriver. Remove the screw and the data plate and set to the side.

2. With the top screw and data plate removed, grasp the solenoid coil and gently pull up. The coil should slide up, allowing you to remove it from the valve bonnet. If you are wanting to replace the coil, continue on with Step 3. If you are wanting to replace some of the internal components of the valve, proceed to step 12.

3. NOTE: Replacing the solenoid coil requires working with the wiring of your machine. It is important that all wiring maintenance be performed by qualified personnel. Always verify the wiring steps presented in this instruction with the schematic that shipped with the unit. A current schematic can also be found in the unit’s installation manual. Before beginning any step that involves working with wiring, ensure that the steps located in the section entitled “Preparation” have been performed. Power must be secured to the machine at the service breaker. Failure to do so could result in severe injury to maintenance personnel.

Removing the top screw

Removing the coil

Page 23

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 5: SERVICE PROCEDURES

RINSE SOLENOID VALVE REPAIR PARTS KIT (CONTINUED)

4. When replacing the coil, ensure that when removing the coil wire cover that care is taken not to damage the wires inside. Using the medium flathead screwdriver, gently use it to open the cover enough to where it could be pulled off.

5. Once the coil wire cover has been removed and set to the side, take the internal wires and pull them out straight.

6. Remove the wire nuts from the wires and separate them.

7. Using a pair of channel locks, gently loosen the conduit retaining ring for the conduit nut. Once it is loosened, use your fingers to unscrew and remove it.

8. Pull the conduit away and discard the bad coil. Take the new coil and attach the conduit, reinstall & tighten the conduit nut, and pull the wires through so that you will be able to wire the valve back up.

9. Reconnect the wires from the conduit to the wires from the solenoid as they had been connected previously. Ensure that the wire nuts are on tight.

10. Slide the coil wire cover back on, taking care not to damage the wires.

1 1. If you are done performing maintenance on the valve, continue on to step 23. Otherwise, please go on to step 12.L

12. To remove the valve bonnet, grasp it with the jaws of the pipe wrench and turn to the left. Note: on some models you may have to remove the valve in order to perform this and any further steps. Be careful not to damage the plumbing assembly. Only use the pipe wrench enough to where you can spin the valve bonnet off with your hand.

Prying open the coil wire cover

Straightening the wires

Loosening the conduit nut

Removing the wire nuts

Loosening the valve bonnet

Page 24

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 5: SERVICE PROCEDURES

RINSE SOLENOID VALVE REPAIR PARTS KIT (CONTINUED)

13. Slowly remove the valve bonnet. Note: The spring for the plunger is located directly under the bonnet and may come free if you are not careful. Remove the plunger, spring and valve bonnet and place to the side.

14. Remove the O-ring and inspect it. If it has any tears or cuts or excessive flat spaces, it should be replaced.

15. Examine the threads for the valve bonnet. Check them for scoring or signs of damage. Take a cloth and clean them out to remove any foreign particles that might get lodged in the threads and cause a leak. Severely damage threads should not be repaired; instead it is recommended that the entire valve should be replaced. These instructions do not provide information on replacing the solenoid valve.

16. Note: Even though an O-ring may not appear damaged, it is a good idea to go ahead and replace it if you have a new one. This will help ensure that your valve remains leak-free in the future!

17. Remove the diaphragm retainer and then the diaphragm itself. Many problems associated with a solenoid valve can be traced to a clogged pilot port in the diaphragm.

18. As indicated in the photo above, the extension hole can become clogged. If it is difficult to clean out, you can use a heated straight pin to push through the hole. The center hole, the pilot port, must also be clear. If the diaphragm is torn or bent in any way, it must be replaced.

Removing the valve bonnet

Removing the O-ring

Removing the diaphragm

Pointing out the extension hole

Diaphragm showing (1) pilot port and (2) extension hole

Page 25

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 5: SERVICE PROCEDURES

RINSE SOLENOID VALVE REPAIR PARTS KIT (CONTINUED)

19. Using the small flathead screwdriver, lift out the screen retainer. Verify that the holes in it are free of clogs and debris.

20. Again using the small flathead screwdriver, carefully remove the mesh screen from inside the valve body. The screen should be taken and rinsed out to remove any debris fouling it.

21. With the mesh screen removed, look down into the valve and verify it is not clogged. Remove any foreign objects from the valve body that would obstruct flow.

22. Reassemble the valve, reversing the steps needed to take it apart. Replace defective replacement parts with new parts from ordered kits. Ensure that components are sufficiently tightened to prevent leakage.

AFTER MAINTENANCE

ACTIONS

Reconnect the incoming water (if disconnected) and turn on. Then restore power to the unit. Run the unit for at least 10 minutes to ensure there are no leaks. If any problems arise please contact your Ecolab representative.

SPECIAL

PARTS

Repair kit includes: Plunger, Spring, O-ring, and

Diaphragm.

1/2” Repair Kit

Ecolab No.: 85283489

Mfg. No.: N/A

3/4” Repair Kit

Ecolab No.: 85283406

Mfg. No.: N/A

110/240 Volt Coil & Housing Only

Ecolab No.: 85289411

Mfg. No.: N/A

1/2” 110/240 Volt Solenoid Valve

Complete Assembly

Ecolab No.: 96580683

Mfg. No.: N/A

3/4” 110/240 Volt Solenoid Valve

Complete Assembly

Ecolab No.: 85260511

Mfg. No.: N/A

Removing the screen retainer

Removing the mesh strainer screen

View inside the solenoid valve body

Page 26

SECTION 6:

PARTS SECTION

Page 27

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

STANDARD PARTS

HARDWARE- Stainless Steel

Ecolab No. Description Jackson No.

96023832 SCREW 4-40X1/4" 05305-002-32-38 96584354 SCREW 4-40X3/8" N/A 88120365 SCREW 4-40X1/2" N/A 96570478 SCREW 4-40X3/4" N/A 96028436 SCREW 4-40 X 1" N/A

88125554 SCREW 6-32X3/8" N/A 88120068 SCREW 6-32X1/2" N/A 96025010 SCREW 6-32X3/4" 05305-011-37-05 96032883 SCREW 6-32X1-1/2" N/A

88120639 SCREW 8-32X3/8" 05305-172-02-00 88123740 SCREW 8-32X1/2" 05305-172-07-00 88120175 SCREW 8-32X5/8" N/A 88122254 SCREW 8-32X3/4" 05305-172-06-00

88120878 SCREW 10-32X3/8" 05305-173-12-00 88120142 SCREW 10-32X1/2" N/A 88120217 SCREW 10-32X3/4" 05305-011-62-17 88120282 SCREW 10-32X1" N/A 88120936 SCREW 10-32X1-1/2" N/A

88120753 SCREW 10-24X3/8" 05305-173-03-00 88120746 SCREW 10-24X1/2" N/A 88120191 SCREW 10-24X3/4" N/A 88120019 SCREW 10-24X1" N/A 88120000 SCREW 10-24X6" N/A

88220007 SCREW SOCKET 1/4-20X3/8" N/A 88020433 SCREW 1/4-20X1/2" 05305-274-02-00 88000013 SCREW 1/4-20X5/8" 05305-274-24-00 88020458 SCREW 1/4-20X3/4" 05305-274-04-00 88030069 SCREW 1/4-20X1-1/2" 05305-274-23-00 88000104 SCREW 1/4-20X2-1/2" 05305-274-13-00

88021027 SCREW 3/8-16X3/4" 05306-011-71-60 88021050 SCREW 3/8-16X1-1/4" 05305-276-10-00 88926002 SCREW SOCKET 3/8-16X1-1/2" N/A 88021076 SCREW 3/8-16X1-3/4" 05306-011-36-94

88420047 NUT HEX 4-40 N/A 88420062 NUT HEX 6-32 N/A 88420070 NUT HEX 8-32 N/A 88420088 NUT HEX 10-32 N/A 88420120 NUT HEX 10-24 N/A 88420104 NUT HEX 1/4-20 05310-274-01-00 88422043 NUT HEX 5/16-18 05310-275-01-00 88422068 NUT HEX 3/8-16 05310-276-01-00

88429121 NUT LOCK 4-40 N/A 88460050 NUT LOCK 6-32 05310-373-03-00 88429105 NUT LOCK 8-32 05310-272-02-00 88460068 NUT LOCK 10-32 05310-373-02-00 88429063 NUT LOCK 10-24 05310-373-01-00

Page 28

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

STANDARD PARTS (CONTINUED)

88429113 NUT LOCK 1/4-20 05310-374-01-00 88419056 NUT LOCK 5/16-18 N/A 88419007 NUT LOCK 3/8-16 05310-011-72-55

88520000 WASHER FLAT 1/4 05311-002-78-93 880530597 WASHER FLAT 5/16 05311-175-01-00 880530605 WASHER FLAT 3/8 05311-176-01-00

88521059 WASHER LOCK #8 05311-272-01-00 88521075 WASHER LOCK #10 N/A 88521083 WASHER LOCK 1/4 05311-274-01-00 88521117 WASHER LOCK 5/16 05311-275-01-00 88521109 WASHER LOCK 3/8 05311-276-01-00 88520069 WASHER LOCK 1/2 05311-011-71-93 88500000 WASHER BEV 3/8 SQUARE 05311-011-35-36

88900733 PIN COTTER 1/16X1/2" 05315-011-68-56 96027495 PIN COTTER 3/32X3/4" 05315-207-01-00 88900501 PIN COTTER 1/8X3/4" 05315-011-60-09 88930581 PIN COTTER 1/8X1-1/2" 05315-002-05-86 88920087 PIN COTTER 3/16X1-3/4" N/A

HARDWARE MISC.

83109041 CABLE TIE 7" 05975-602-05-16 83109199 CABLE TIE 15" 100PK N/A 83109025 CABLE TIE W/SCREW HOLE N/A

89990121 GREASE SILICONE 3OZ TUBE N/A 89992176 SILICONE CAULK WHITE3OZ TUBE N/A 89991996 TEFLON TAPE ROLL N/A 83109125 ELECTRICAL TAPE N/A

96022447 ENDCAP, DOOR HANDLE 05340-011-35-00 96552336 DOOR GUIDE, PLASTIC, 23 1/2” Long 05700-111-33-59

ELECTRICAL

83300541 CONDUIT 1/2" 05975-111-46-57 83312017 NUT, CONDUIT 1/2" N/A 83311506 CONNECTOR, CONDUIT 1/2" 05975-011-45-13 83311753 ELBOW, 90DEG, CONDUIT 1/2" 05975-111-01-00 83311852 ELBOW 45DEG, CONDUIT 1/2" 05975-011-45-23 83115003 PLUG, PLASTIC 1/2" N/A 96540067 PLUG, METAL 1/2" N/A 83199570 PLUG, RUBBER 1/2" N/A 83116814 PLUG, METAL 1-1/2" N/A 87301412 HANGER, CONDUIT METAL N/A

96203153 TERMINAL FEMALE 1/4" W/PIGGY BACK N/A 83100002 TERMINAL FEMALE 1/4" 14-8GA N/A 83102269 TERMINAL FEMALE 1/4" 16-14GA N/A 83102244 TERMINAL FEMALE 1/4" 22-18GA N/A 83101022 CONNECTOR BUTT SPLICE 16-14GA N/A 83101014 CONNECTOR BUTT SPLICE 22-18GA N/A 83102152 TERMINAL SPADE #8HOLE 16-14GA N/A 83102129 TERMINAL SPADE #8HOLE 22-16GA N/A 96570221 TERMINAL SPADE #10HOLE 14-16GA N/A

Page 29

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

STANDARD PARTS (CONTINUED)

96032271 TERMINAL SPADE .25HOLE 12-10GA N/A 96032701 TERMINAL SPADE .25HOLE 16-14GA N/A 83100073 TERMINAL EYELET #8HOLE 16-14GA N/A 83100339 TERMINAL EYELET #10HOLE 16-14GA N/A

83101113 WIRE NUT 18-12GA N/A 83101089 WIRE NUT 14-10GA CRIMP N/A

PLUMBING

89009138 THERMOMETER, SCREW-IN, ES2000/4000 06685-111-35-30 96021316 THERMOMETER, 96"LEAD, CONVEYOR 06685-111-68-49

85390193 GAUGE PRESSURE 0-30PSI, BOTTOM MOUNT 06685-011-64-29 96582086 GAUGE PRESSURE 0-100PSI, BOTTOM MOUNT 06685-111-88-34 85390417 GAUGE PRESSURE 0-100PSI, BACK MOUNT 06685-011-48-32 96022421 WASH ARM PRESSURE TEST KIT N/A 85230191 NEEDLE VALVE, 1/4" PIPE N/A

85250587 VALVE BALL1/2"PIPE N/A 85200269 VALVE GLOBE 1/2"PIPE 04820-100-15-00 85250595 VALVE BALL3/4"PIPE N/A

85221018 REGULATOR WATER 1/4"PIPE, 180F 04820-011-69-05 85220077 REGULATOR WATER 1/2"PIPE, 140F 04820-100-04-07 85220010 REGULATOR WATER 3/4"PIPE, 180F 04820-100-01-06 85284214 REPAIR KIT 3/4" WATER REGULATOR N/A

96027024 STRAINER Y 1/2" PIPE 04730-217-01-10 85300325 STRAINER Y 3/4" PIPE 04730-717-02-06 85300301 SCREEN, COARSE 3/4” N/A 85300333 SCREEN, FINE 3/4” N/A

TUBING

85015105 TUBING 1/4" CLEAR 05700-011-37-12 85015097 TUBING 1/4" RED 05700-011-37-14 85015089 TUBING 1/4" BLUE 05700-011-37-16 92661024 COPPER TUBE 1/4" 50 FT N/A 92661016 COPPER TUBE 3/8" 25 FT N/A 92661032 COPPER TUBE 1/2" 50 FT N/A

TUBING MISC.

92630000 WASH TANK CONNECTOR, 45DEG 1/2" HOSE 04730-002-69-80 92002008 WASH TANK CONNECTOR, 18DEG 5/8" HOSE 04820-111-51-14 92002019 WASH TANK CONNECTOR, 45DEG 5/8" HOSE 04730-011-45-21 96581475 CHECK VALVE, ELBOW, RINSE LINE N/A 92171271 RINSE INJECTOR CHECK VALVE KIT N/A 96572573 PICK-UP TUBE STIFFENER 05700-002-66-49

87301149 CLAMP, HOSE 7/32-5/8" 05700-000-35-06 87301131 CLAMP, HOSE 5/16-7/8" 04730-011-36-05 96020078 CLAMP, HOSE 11/16-1.5" N/A 87301362 CLAMP, HOSE 7/8-2.75" 04730-719-01-37 87301503 CLAMP, HOSE 4.75-6.5" 04730-011-34-90

Page 30

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

CHEMICAL FEEDER PUMP ASSEMBLY

Roller, Red (Detergent/Sanitizer)

Ecolab No.: 96037924

Mfg. No.: 04320-111-36-70

Roller, White (Rinse Aid)

Ecolab No.: 84800041

Mfg. No.: 04320-002-82-28

Roller, Black

Ecolab No.: 96029533

Mfg. No.: 04320-111-65-27

Housing Kit (Red roller)

Ecolab No.: 96562871

Mfg. No.: 04320-121-37-10

1/4” Sight Tube Ecolab No.: 92001017 Mfg. No.: N/A 3/8” Sight Tube Ecolab No.: 96569496 Mfg. No.: 05700-111-35-33

Squeeze Tube Lubricant

Ecolab No.: 89990121

Squeeze Tube, Detergent/Sanitizer

(Use with the red roller.)

Ecolab No.: 96562673

Mfg. No.: 05700-111-35-29

Clear Squeeze Tube, Rinse Aid

(Use with the white roller.)

Ecolab No.: 85017119

Mfg. No.: 05700-011-76-41

Tube, Small 7/32”

(Use with the black roller.)

Ecolab No.: 85016079

Mfg. No.: 05700-011-65-21

Motor, 36 RPM 115V

Detergent/Sanitizer Feeder Pump

Ecolab No.: 83740209

Mfg. No.: 04320-111-35-14

Motor, 14 RPM 115V

Rinse Aid Feeder Pump

Ecolab No.: 83740282

Mfg. No.: 04320-111-35-13

Motor, 36 RPM 240V

Detergent/Sanitizer Feeder Pump

Ecolab No.: 96029293

Mfg. No.: 04320-111-47-47

Motor, 14 RPM 240V

Rinse Aid Feeder Pump

Ecolab No.: 96029897

Mfg. No.: 04320-111-47-46

Motor, 14 RPM 24V

Rinse Aid Feeder Pump

Ecolab No.: 96030317

Mfg. No.: 04320-011-63-33

Page 31

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

SOLENOID VALVE REPAIR PARTS KITS

Screw

Data Plate

110/240 Volt Coil & Housing Only Ecolab No.: 85289411 Mfg. No.: N/A

Valve Bonnet

Diaphragm Retainer

Diaphragm

O-Ring

Plunger

Spring

Screen Retainer

Mesh Screen

Valve Body

1/2” 110/240 Volt Solenoid Valve

Complete Assembly

Ecolab No.: 96580683

Mfg. No.: 04810-100-12-18

3/4” 110/240 Volt Solenoid Valve

Complete Assembly

Ecolab No.: 85260511

Mfg. No.: 04810-100-53-00

TO DISASSEMBLE - These valves may be taken apart by unscrewing the bonnet and the enclosing tube assembly from the valve body assembly. After unscrewing, carefully lift off the bonnet and enclosing tube assembly. Don’t drop the plunger. The o-ring seal and diaphragm cartridge can now be lifted out. Be careful not to damage the machined faces while the valve is apart.

TO REASSEMBLE - Place the diaphragm cartridge in the body with the pilot port extension UP. Hold the plunger with the synthetic seat against the pilot port. Make sure the o-ring is in place, then lower the bonnet and enclosing tube assembly over the plunger. Screw the bonnet assembly snugly down on the body assembly.

Pilot port extension #1 clogged. Clean hole.

Possible Problems:

Hole #2 Clogged. Pass heated straight pin through hole.

Repair kit includes: Plunger, Spring, Oring, and Diaphragm.

1/2” Repair Kit Ecolab No.: 85283489 Mfg. No.: N/A

3/4” Repair Kit Ecolab No.: 85283406 Mfg. No.: N/A

Page 32

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

VACUUM BREAKER REPAIR PARTS KITS

1/2” Complete Vacuum Breaker Assembly

Ecolab No.: 85242543

Mfg. No.: 04820-003-06-13

3/4” Complete Vacuum Breaker Assembly

Ecolab No.: 85242626

Mfg. No.: 04820-002-53-77

1/4” Complete Vacuum Breaker Assembly

Ecolab No.: 85242501

Mfg. No.: 04810-011-51-62

1/4” Complete Vacuum Breaker Assembly

Bottom Inlet & Outlet

Ecolab No.: 85242000

Mfg. No.: N/A

3/8” Complete Vacuum Breaker Assembly

Ecolab No.: 85242527

Mfg. No.: 04820-002-75-73

Components of 1/2” Repair Kit Ecolab No.: 85284156 Mfg. No.: 06401-003-06-23

Components of 3/4” Repair Kit Ecolab No.: 85284164 Mfg. No.: 06401-003-06-24

Data Plate (3/4”)

Ecolab No.: 96850342

Mfg. No.: N/A

3/4” Cap with Screws Ecolab No.: 96560230 Mfg. No.: N/A

O-Ring

Plunger

Body

1/2” Brass Bonnet

Ecolab No.: 85284073

Mfg. No.: N/A

3/4” Brass Bonnet

Ecolab No.: 85280063

Mfg. No.: N/A

3/4” Plastic Bonnet

Ecolab No.: 96560222

Mfg. No.: N/A

Page 33

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

CONTROL BOX ASSEMBLY

9, 10

11, 27

12, 13, 28

Normal/Delime

Rinse Aid/Detergent

Sanitizer

Page 34

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

CONTROL BOX ASSEMBLY

18, 27

17, 28

16, 27

24, 27

25, 26, 27

22, 23

Page 35

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: 08-27-2007

SECTION 6: PARTS SECTION

CONTROL BOX ASSEMBLY (CONTINUED)

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Control Box Weldment 96630942 05700-003-09-42 2 1 Control Box Cover 96633054 05700-003-30-54 3 1 Decal, Warning - Disconnect Power 96039821 09905-100-75-93 4 4 Screw, 10-32 x 1/2’’Long, Phillips Tusshead 96022140 05305-011-39-36 5 1 Decal, Peri-pump Prime 96633256 09905-003-32-56 6 1 Switch, Delime/Normal 83020149 05930-301-21-18 7 1 Detergent/Rinse Aid Pump Prime Switch 83020271 05930-011-35-27 8 1 Sanitizer Pump Prime Switch 83020164 05930-111-38-21 9 1 Locknut, 1/4”-20 S/S Hex with Nylon Insert 88429113 05310-374-01-00 10 1 Washer, 1/4”-20 S/S 88520000 05311-174-01-00 11 2 Contactor 83008250 05945-109-05-69 12 1 Timer, 8 Cam 83010785 05945-111-35-32 13 1 Decal, Cam Timer 96584594 09905-011-37-21 14 4 Fitting, Conduit, Heyco 1/2’’ 83311217 05975-011-49-03 15 1 Fitting, 1/2’’ Straight Snap In 96633327 05975-003-33-27 16 5 Clamp, 5/8” Nylon 87301024 04730-011-39-01 17 2 Relay, 2 Pole 96582895 05945-111-35-19 18 1 Terminal Board 96584693 05940-021-94-85 19 1 Harness, Switch Panel 96633537 05700-003-35-37 20 1 Fitting, 1/2’’ 90 Deg. Snap In 96633328 05975-003-33-28 21 1 Conduit, 1/2” x 40” 96633336 05700-003-35-48 22 1 Cycle Counter, 115V 83650044 05990-111-35-38 23 2 Screw, 4-40 x 1/4” Phillips Pan Head 96023832 05305-002-32-38 24 1 Terminal Board 96021134 05940-002-78-97 25 1 Terminal Board 96030424 05940-001-97-91 26 1 Decal, Terminal Board 8 Position N/A 09905-003-09-30 27 16 Locknut, 10-24 S/S Hex with Nylon Insert 88429063 05310-373-01-00 28 6 Locknut, 6-32 S/S Hex with Nylon Insert 88460050 05310-373-03-00 29 1 Harness, Wash Pump 96633534 05700-003-35-34 30 1 Harness, Drain Solenoid 96633536 05700-003-35-36 31 1 Harness, Peri-pump 96633535 05700-003-35-35 32 1 Conduit, 1/2” x 17” 96633336 05700-003-35-49

Page 36

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

PERI-PUMP BOX ASSEMBLY

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 2 Peri-pump Assembly, 36 RPM See Page 25 05700-002-96-08 2 1 Peri-pump Assembly, 14 RPM See Page 25 05700-002-96-09 3 1 Drip Channel 96633289 05700-003-32-89 4 1 Weldment, Peri-pump Box 96633200 05700-003-32-00 5 1 Weldment, Peri-pump Box Cover 96633380 05700-003-33-80 6 1 Fitting, Conduit, Heyco 1/2’’ 83311217 05975-011-49-03 7 1 Clamp, 5/8” Nylon (Located inside of box) 87301024 04730-011-39-01 8 1 Clamp, 1” Nylon N/A 04730-002-41-88 9 5 Screw, 10-32 x 1/2’’Long, Phillips Tusshead 96022140 05305-011-39-36 10 3 Locknut, 10-24 S/S Hex with Nylon Insert 88429063 05310-373-01-00 11 3 Tube Stiffener (Not Shown) 96572573 05700-002-66-49 12 1 Tubing, 1/4’’ OD x 60” Long, Blue See Page 24 05700-002-52-34 13 1 Tubing, 1/4’’ OD x 60” Long, White See Page 24 05700-002-52-33 14 1 Tubing, 1/4’’ OD x 60” Long, Red See Page 24 05700-011-63-18 15 1 Terminal Board (Not Shown) 96030424 05940-001-97-91

Sanitizer

Detergent

Rinse Aid

Page 37

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: 10-04-2007

SECTION 6: PARTS SECTION

ELECTRICAL CONNECTION BOX ASSEMBLY

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Box, Power Junction Weldment 96633058 05700-003-30-58

2 1 Terminal Block Spacer 96025127 05700-011-40-05 3 1 Terminal Block 96025119 05940-500-09-61 4 1 Locknut, 6-32 with Nylon Insert 88460050 05310-373-03-00 5 5 Locknut, 10-24 with Nylon Insert 88429063 05310-373-01-00 6 1 Lug, Ground 83118000 05940-200-76-00 7 1 Decal, Power Connection 96028402 09905-011-47-64 8 1 Decal, Warning to Disconnect Power 96039821 09905-100-75-93 9 1 Screw, 10-32 x 1/2’’Long, Phillips Trusshead N/A 05305-011-39-36 10 2 Decal, Copper Conductors Only 96021365 09905-011-47-35 11 1 Cover, Solenoid Box 96634672 05700-003-46-72

If your unit uses a different style cover than shown in the assembly, please order the following. Cover, Solenoid Box Ecolab No.: 96632246 Mfg. No.: 05700-003-22-46

Page 38

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

FRAME ASSEMBLY

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Frame Weldment N/A 05700-003-09-40 2 4 Foot, 3” Adjustable 96582039 05340-002-14-55 3 1 Plate, Hinge Weldment 96631011 05700-003-10-11 4 1 Washer, Hinge Weldment N/A 05700-002-54-62 5 1 Spacer, PB Bolt 96582788 05700-000-29-40 6 1 Clamp, Pipe 96572466 05700-000-35-05 7 8 Washer, 1/4”-20 S/S 88520000 05311-174-01-00 8 1 Keeper, Door Panel Latch 96630931 05700-003-09-31 9 4 Locknut, 1/4”-20 S/S Hex with Nylon Insert 88429113 05310-374-01-00 10 5 Nut, Hex 1/4”-20 88420104 05310-274-01-00 11 1 Booster Mounting Plate Weldment N/A 05700-002-51-93 12 1 Bracket, Temperature Gauge 96631453 05700-003-14-53 13 1 Bolt, 1/4”-20 x 1/2” Long 88020433 05305-274-02-00

Page 39

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Hood Weldment N/A 05700-003-09-56 2 1 Switch, 115V Reed 96027990 05930-002-36-80 3 1 Bracket, Limit Switch 96021472 05700-021-71-18 4 4 Locknut, 10-24 with Nylon Insert 88429063 05310-373-01-00 5 2 Clamp, Pipe 5/8” 87301149 05700-000-35-06 6 2 Rack Rail Weldment 96040001 05700-002-45-67 7 2 Washer, 1/4”-20 I.D. 88530589 05311-174-01-00 8 1 Gasket, Side Panel (5.3 Feet) N/A 05700-003-35-51

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

HOOD ASSEMBLY

Page 40

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: 08-27-07

SECTION 6: PARTS SECTION

SWITCH PANEL ASSEMBLY

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

Complete Side Panel Assembly N/A 05700-003-24-38 1 1 Side Panel Weldment N/A 05700-003-24-36 2 2 Switch, Prime Assembly 96027103 05700-003-14-91 3 1 Switch, On/Off Assembly 96027102 05700-003-14-92 4 1 Light, Amber 96581822 05945-504-06-18 5 1 Light, Red 83630392 05945-504-07-18 6 1 Decal, Switch Panel 96630863 09905-003-08-63 7 1 Fitting, .25-.546 96039110 05975-011-65-51 8 3 Plug, 3/4” hole 83115002 04730-011-60-21 9 6 Locknut, 10-24 with Nylon Insert 88429063 05310-373-01-00 10 6 Washer, #10 N/A 05311-173-02-00

Page 41

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

TUB ASSEMBLY

14c

14b

14a

27b

27a

16b

16a

30d

30e

30c

30b

30a

17b

17a

17c

Page 42

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Tub Weldment N/A 05700-003-09-51 2 1 Lower Manifold Weldment 96039920 05700-002-45-51 3 2 Manifold Gasket 96552864 05700-111-35-03 4 1 Drain Seat Insert 96582929 05700-021-34-38 5 1 Spillway Gasket 96582903 05700-111-34-52 6 1 Spillway Weldment 96583000 05700-031-37-86 7 23 Locknut, 1/4”-20 S/S Hex with Nylon Insert 88429113 05310-374-01-00 8 1 Manifold O-Ring 87203154 05330-111-35-15 9 1 Modified Casting Wedge 96583497 09515-011-46-61 10 2 Bolt, 3/8”-16 x 1 1/4” S/S 88021050 05305-276-10-00 11 2 Washer, 3/8” Bevel-Square Iron 88500000 05311-011-35-36 12 2 Lockwasher, 3/8” 88521109 05311-276-01-00 13 2 Nut, 3/8”-16 S/S Hex 88422068 05310-276-01-00 14 1 Complete Wash Arm Assembly N/A 05700-003-31-60 14a 1 Wash Arm Weldment w/ End Plugs 96585187 05700-003-31-61

1 Wash Arm End Plugs 96633159 05700-003-31-59 14b 1 Wash Arm O-ring 87200013 05330-002-60-69 14c 1 Wash Arm Bearing Assembly 96552567 05700-021-35-97 15 1 Sump Strainer 96582029 05700-002-60-50 16a 1 Stand Pipe Weldment 96582747 05700-021-33-29 16b 1 Stopper, Stand Pipe 96557475 05700-121-35-54 17 1 Drain Link Assembly N/A 05700-002-45-52 17a 1 Drain Link 96039938 05700-002-40-83 17b 1 Nut, Hex, 5/16”-18 88422043 05310-275-01-00 17c 1 Drain Link Connector 96028261 05700-002-38-10 18 1 Hair Pin, 1/8” to 1” 96035241 05315-011-60-09 19 1 Fill Tube Weldment 96039896 05700-002-45-61 20 18 Washer, 1/4”-20 I.D. 88530589 05311-174-01-00 21 3 Chemical Tube Grommet N/A 05325-002-42-65 22 1 Pivot Plate, Left Door Complete Assembly N/A 05700-002-45-62 22a 1 Door Pivot Plate Left Weldment 96039953 05700-002-45-63 22b 1 Door Pivot Plate Bearing 96039961 03110-002-45-09 23 1 Pivot Plate, Right Door Complete Assembly N/A 05700-002-52-95 23a 1 Door Pivot Plate Right Weldment 96039953 05700-002-52-94 23b 1 Door Pivot Plate Bearing 96039961 03110-002-45-09 24 3 Bolt, 1/4”-20 x 1/2” Long 88020433 05305-274-02-00 25 6 Screw, 1/4”-20 x 5/8” Long 88000013 05305-274-24-00 26 1 Air Gap Weldment N/A 05700-003-23-48 27 1 Halo Assembly N/A 05700-003-23-49 27a 1 Halo Weldment N/A 05700-003-16-65 27b 4 Spray Nozzle and Receptacle 96042031 04730-002-55-61 28 1 Gasket, Air Gap N/A 05330-003-24-17 29 2 Clamp, 1” Nylon (Not Shown, located on bottom of tub.) N/A 04730-002-41-88 30 1 Drain Solenoid Box Assembly N/A 05700-003-09-61 30a 1 Solenoid Box Weldment 96633588 05700-003-35-88 30b 1 Drain Solenoid, 115V 83999078 04810-200-11-00 30c 4 Locknut, 10-24 with Nylon Insert 88429063 05310-373-01-00 30d 1 Decal, Warning 96039821 09905-100-75-93 30e 1 Solenoid Box Cover 96633025 05700-003-30-25 31 1 Fitting, Thermometer Bulkhead (Not Shown) 96631001 05700-003-10-01

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

TUB ASSEMBLY CONTINUED

Page 43

See Frame Assembly Page

See Booster Assembly Page

See Motor Assembly Page

See Plumbing Assembly Page

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

FRAME AND MOTOR ASSEMBLY

Page 44

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Discharge Tube Connector 96028253 05700-011-70-34 2 1 Pump Suction Hose 96039763 05700-002-40-82 3 1 Discharge Hose Assembly N/A 05700-002-45-58 3a 2 Fitting, 1/2” Pushlock, Female, Brass 96039870 04730-011-93-99 3b 1 Hose, 1/2” x 22 1/2” Long 96039888 05700-002-45-59 4 1 Wash Restrictor 96628469 05700-002-84-69 5 1 Accumulator Strainer Weldment N/A 05700-003-33-25 6 1 Accumulator Weldment 96042023 05700-002-51-95 7 8 Bolt, 1/4”-20 x 1/2” Long 88020433 05305-274-02-00 8 18 Locknut, 1/4”-20 S/S Hex with Nylon Insert 88429113 05310-374-01-00 9 18 Washer, 1/4”-20 S/S 88530589 05311-174-01-00 10 1 Hose Clamp, 13/16 TO 1 1/2” 96020292 04730-719-06-09 11 3 Hose Clamp, 1 1/16” to 2 1/4” 96020417 04730-719-18-00 12 1 Close Nipple, 1/2” Brass 85141208 04730-207-15-00 13 1 Gauge, Thermometer 96021316 06685-111-68-48

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

FRAME AND MOTOR ASSEMBLY (CONTINUED)

Page 45

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

MOTOR & PUMP ASSEMBLY

Impeller Assembly

Ecolab No.: 96582103

Mfg. No.: 05700-002-81-86

Mechanical Seal Ecolab No.: 96582026 Mfg. No.: 05330-002-34-22

Other parts not shown.

Drain Plug

Ecolab No.: 96582100

Mfg. No.: 04730-002-81-89

Case O-Ring

Ecolab No.: 96582105

Mfg. No.: 05330-002-81-83

Seal Plate

Ecolab No.: 96582104

Mfg. No.: 05700-002-81-87

Case Capscrew

Ecolab No.: 96582099

Mfg. No.: 05305-002-81-88

Motor Only

Ecolab No.: 96582070

Mfg. No.: 06105-002-79-61

Complete Pump & Motor Assembly

Ecolab No.: N/A

Mfg. No.: 06105-002-16-29

Pump Only Assembly

Ecolab No.: 96582071

Mfg. No.: 05700-002-79-49

Shim Kit

Ecolab No.: 96582102

Mfg. No.: 05700-002-82-58

Motor Mounting Bracket

Ecolab No.: 96582190

Mfg. No.: 05700-002-55-52

Lockwasher, 3/8”

Ecolab No.: 88521109

Mfg. No.: 05311-276-01-00

Nut, Hex 3/8”-16 S/S

Ecolab No.: 88422068

Mfg. No.: 05310-276-01-00

Bolt, 3/8” x 3/4” Long Hex Head

Ecolab No.: N/A

Mfg. No.: 05306-011-71-60

Pump Casing

Ecolab No.: N/A

Mfg. No.: 05700-002-84-99

Page 46

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Booster Tank Weldment 96039839 05700-002-45-56 2 1 Heater, 120V, 2000 Watts 96039862 04540-002-45-13 3 1 Heater Gasket N/A 05330-100-01-10 4 1 Thermostat 96631365 05930-003-13-65 5 1 Fitting, Imperial Brass 96024344 05310-924-02-05 6 1 Plug, 1/4” Brass 86135019 04730-209-01-00 7 4 Lockwasher, 5/16” 88521117 05311-275-01-00 8 4 Nut, 5/16”-18 S/S Hex 88422043 05310-275-01-00 9 2 Locknut, 6-32 S/S Hex w/ Nylon Insert 88460050 05310-373-03-00 10 1 Booster Tank Cover 96039847 05700-002-39-07 11 1 Decal, Warning, Disconnect Power 96039821 09905-100-75-93 12 1 Screw, 10-32 x 3/8” 88120878 05305-173-12-00 13 1 Fitting, 1/2” NPT x 90 Deg. Elbow 96633532 05975-003-35-32 13a 1 Nut, 1/2” NPT Nylon 96633533 05975-003-35-33

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

BOOSTER TANK ASSEMBLY

Page 47

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

INCOMING PLUMBING ASSEMBLY

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

1 1 Y-Strainer 96027024 04730-217-01-10 2 1 Nipple, Close, 1/2’’ NPT, Brass 85141208 04730-207-15-00 3 1 Valve, Solenoid, 1/2’’ NPT, 115V 85260743 04810-100-12-18 4 1 Adapter, 1/2’’Fitting (CU to Male) 96580907 04730-401-03-01 5 2 Tube, Copper, 1/2’’ x 1 1/4’’ Long Buy Locally 05700-001-08-28 6 1 Union, 1/2’’, Copper to Copper 85726081 04730-412-05-01 7 1 Elbow, 607, 1/2’’Copper to Copper Buy Locally 04730-406-01-01 8 1 Tube, Copper, 1/2’’ x 4 1/4’’ Long Buy Locally 05700-001-01-60 9 1 Elbow, 90° (CU to MSPS) 85634442 04730-406-32-01

Page 48

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

DOOR ASSEMBLY

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

Complete Door Assembly N/A 05700-003-24-73 1 1 Door Weldment N/A 05700-003-23-60 2 1 Magnet, Reed Switch N/A 05930-002-68-53 3 2 Locknut, 6-32 S/S Hex with Nylon Insert 88460050 05310-373-03-00 4 1 Locknut, 1/4”-20 S/S Hex with Nylon Insert 88429113 05310-374-01-00 5 1 Nut, Hex 1/4”-20 S/S 88420104 05310-274-01-00 6 1 Bolt, 1/4”-20 Eye, S/S N/A 05306-002-55-59 7 1 Spring, Door 96583489 05340-011-44-58

Page 49

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

FRONT PANEL ASSEMBLY

Magnet Switch Bracket

1 per machine

Ecolab No.: 96021472

Mfg. No.: 05700-021-71-18

Reed Switch

1 per machine

Ecolab No.: 96027990

Mfg. No.: 05930-002-36-80

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

Complete Panel Assembly N/A 05700-003-09-53 1 1 Panel Weldment 96630954 05700-003-09-54 2 1 Handle 96031075 05340-001-96-30

Page 50

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 6: PARTS SECTION

RETROFIT KIT, SWITCH BOX ASSEMBLY

ITEM QTY DESCRIPTION ECOLAB No. Mfg. No.

Complete Switch Box Assembly N/A 05700-003-35-98 1 1 Decal, Switch Panel 96630863 09905-003-08-63 2 2 Switch, Prime Assembly 96027103 05700-003-14-91 3 1 Switch, On/Off Assembly 96027102 05700-003-14-92 4 1 Light, Amber 96583703 05945-504-06-18 5 1 Light, Red 83630392 05945-504-07-18 6 1 Terminal Board 96030424 05940-001-97-91 7 1 Fitting, .25-.546 96039110 05975-011-65-51 8 1 Switch Box Retrofit, Weldment 96630135 05700-003-01-35 9 1 Decal, Warning - Disconnect Power 96039821 09905-100-75-93 10 2 Locknut, 10-24 with Nylon Insert 88429063 05310-373-01-00 11 2 Gasket, Top Switch Box (Not shown) 96633598 05700-003-36-26 12 2 Gasket, Side Switch Box (Not shown) 96633598 05700-003-36-27

Page 51

SECTION 7:

ELECTRICAL SCHEMATICS

Page 52

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 7: ELECTRICAL SCHEMATICS

OMEGA 5E 115V, 50/60 HERTZ, SINGLE PHASE

Page 53

Omega 5E Installation & Operation Manual 7610-003-28-32

Issued: 04-03-2007 Revised: N/A

SECTION 7: ELECTRICAL SCHEMATICS

TIMING CHART