Insinger GalleyMaster Series User Manual

TECHNICAL MANUAL

GalleyMaster Series

NSN		MODEL		APL	HEAT
7320-01-537-7467	GalleyMaster 60-LH-S			43A070069
7320-01-537-7471	GalleyMaster 60-RH-S			43A070070
7320-01-537-7473	GalleyMaster 85-LH-S			43A070071
7320-01-537-7476	GalleyMaster 85-RH-S			43A070072
7320-01-537-7477	GalleyMaster 135-LH-S			43A070068
7320-01-537-7507	GalleyMaster 135-LH-S (W/UL)			43A070067
7320-01-537-7478	GalleyMaster 135-RH-S			43A070066
7320-01-537-7502	GalleyMaster 135-RH-S (W/UL)			43A070065	STEAM
7320-01-537-7481	GalleyMaster 185-LH-S			43A070064
7320-01-537-7515	GalleyMaster 185-LH-S (W/UL)			43A070063
7320-01-537-7485	GalleyMaster 185-RH-S			43A070062
7320-01-537-7518	GalleyMaster 185-RH-S (W/UL)			43A070061
7320-01-537-7488	GalleyMaster 250-LH-S			43A070060
7320-01-537-7519	GalleyMaster 250-LH-S (W/UL)			43A070059
7320-01-537-7491	GalleyMaster 250-RH-S			43A070058
7320-01-537-7522	GalleyMaster 250-RH-S (W/UL)			43A070057
7320-01-537-7561	GalleyMaster 60-LH-E			43A070056
7320-01-537-7896	GalleyMaster 60-RH-E			43A070055
7320-01-537-7899	GalleyMaster 85-LH-E			43A070054
7320-01-537-7900	GalleyMaster 85-RH-E			43A070053
7320-01-537-7907	GalleyMaster 135-LH-E			43A070052
7320-01-537-7917	GalleyMaster 135-LH-E (W/UL)			43A070051
7320-01-537-7909	GalleyMaster 135-RH-E			43A070050
7320-01-537-7922	GalleyMaster 135-RH-E (W/UL)			43A070049	ELECTRIC
7320-01-537-7912	GalleyMaster 185-LH-E			43A070048
7320-01-537-7926	GalleyMaster 185-LH-E (W/UL)			43A070047
7320-01-537-7913	GalleyMaster 185-RH-E			43A070046
7320-01-537-7930	GalleyMaster 185-RH-E (W/UL)			43A070044
7320-01-537-7914	GalleyMaster 250-LH-E			43A070045
7320-01-537-7935	GalleyMaster 250-LH-E (W/UL)			43A070039
7320-01-537-7916	GalleyMaster 250-RH-E			43A070043
7320-01-537-7936	GalleyMaster 250-RH-E (W/UL)			43A070042
7320-01-537-2379	PUL1-L-NSU (PWR UNLDR LH)			43A070041
7320-01-537-1497	PUL1-R-NSU (PWR UNLDR RH)			43A070040
6245 State Road		Philadelphia, PA 19135-2996
800.344.4802	Fax [phone]		www.insingermachine.com

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Thank you for purchasing this quality Insinger product.

On the space provided below please record the model, serial number and start-up date of this unit:

Model:__________________________________

Serial Number:___________________________

Start-Up Date:____________________________

When referring to this equipment please have this information available.

Each piece of equipment at Insinger is carefully tested before shipment for proper operation. If the need for service should arise please contact your local Authorized Insinger Service Company.

A Service Network Listing is provided on our web site, www.insingermachine.com or call Insinger at 800-344-4802 for your local authorized servicer.

Please read the Insinger Limited Warranty and all installation and operation instructions carefully before attempting to install or operate your new Insinger product.

To register your machine for warranty by phone, fax or the internet or for answers to question concerning installation, operation, or service contact our Technical Services Department:

TECHNICAL SERVICE CONTACTS

Factory Support

Insinger Machine Company: 6245 State Road Philadelphia, PA 19135 800-344-4802 215-624-4800 215-624-6966 (Fax) www.insingermachine.com

Authorized Service Agencies

California:

Magna Mechanical 724 Ave. B, Suite A

National City, CA 91950 619-239-8008

Florida:

AMSEC LLC, Mayport Division 2920 Mayport Road

Atlantic Beach, FL 32233 904-247-1632 904-247-5381 (Fax)

Virginia:

D. W. Boyd Company 4003 Colley Ave. Norfolk, VA 23508 757-423-2268 757-423-1868 (Fax)

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TABLE OF CONTENTS

Part 1
Technical Information	3-14

∙Introduction

∙Cut-sheets & Installation Drawings

∙Warranties

Part 2
Start-Up Instructions	15
∙ Start-Up Procedures
Part 3
Cleaning Instructions	16-17
∙ Daily and Weekly Procedures
Part 4	18-26
Maintenance & Repair Procedures
∙ Maintenance & Repair Procedures
∙ Basic Service Guide
∙ Troubleshooting
Part 5	27-30
Spare Parts List
Part 6	31-35
Installation Instructions
Part 7	36-49
Electrical Schematics & Replacement Parts
∙ Machine Wiring Diagrams
∙ Control Panel Layout & Component Drawings
Part 8	50-80
Replacement Parts

∙ Overall Assembly Drawings for: GalleyMaster

∙ Drain Assembly

∙ Motor/Pump Assembly

∙ Conveyor & Chain Tensioner Assemblies

∙ Rinse Converter

∙ Scrap Screen Arrangement

∙ Top Baffles and Curtain Location

∙ Drive Mechanism Assembly

∙ Final Rinse Assemblies

∙ Electric Heaters & Boosters

∙ Steam Coils, Injectors and Boosters

∙ Discharge Lines Assemblies

∙ Rear Track Assemblies

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PART 1 TECHNICAL INFORMATION

GalleyMaster Series

INTRODUCTION

Purpose

The purpose of this technical manual is to provide installation, operation, cleaning and maintenance directions.

A section is provided for replacement parts.

Scope

This manual contains all pertinent information to assist in the proper installation, operation, cleaning, maintenance, and parts ordering for Insinger GalleyMaster series dishwashers

The installation instructions are intended for qualified equipment installers. The operation and cleaning instructions are intended for the daily users of the equipment. The maintenance and parts sections are intended for qualified service and/or maintenance technicians. Replacement parts may be ordered directly from our factory

or from your local Insinger Authorized Service Agency. You can speak to the Insinger Technical Services Department, 800/344-4802, or e-mail us at [e-mail]. When calling for warranty information or replacement parts please provide the model and serial number of your Insinger Equipment. These important numbers should be noted in this manual on the spaces provided on the opening page.

NSF 3-2003 requirements for detergent

and chemical sanitizer dispensers.

This machine must be operated with an automatic detergent dispenser and, if applicable, an automatic chemical sanitizer feeder, including a visual means to verify that detergents and sanitizers are delivered or a visual or audible alarm to signal if detergents and sanitizers are not available for delivery to the respective washing and sanitizing systems. Please see instructions for electrical and plumbing connections located in this manual and in the feeder equipment manual.

Definitions

Throughout this guide you will find the following terms: WARNING, CAUTION, & NOTE.

WARNING indicates potential physical danger. CAUTION indicates potential equipment damage. NOTE indicates helpful operating hints or tips.

You will visually be able to identify each as shown below:

!	WARNING:
	Indicates potential physical danger.

þ NOTE:

Indicates helpful operating hints or tips.

CAUTION:

Indicates potential equipment damage.

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PART 1 TECHNICAL INFORMATION

SAFETY SUMMARY

The following general safety notices supplement the specific warnings and cautions appearing in this manual:

All service except for routine shut-down procedures and operator's troubleshooting procedures must be performed by qualified maintenance personnel.

Prior to any work on the dishwasher involving service of electrical, steam, or water systems, the dishwasher and booster heater must be de-energized by turning the electrical supply power "Off" and closing appropriate steam and water valves.

The following is a summary of the warnings and cautions appearing in the text of this manual to alert personnel to potentially hazardous situations:

WARNINGS

! Warning definition: A warning designates potential bodily harm.

Do not open the access doors while the machine is running, as hot water is being sprayed inside the machine. Machines have an interlock to stop the machine if either door is opened, but some hot water may escape.

Inside of the machine is hot. Allow the machine to cool to 110° F. before proceeding. Wear rubber gloves.

Float switches, probes and heating elements must be cleaned daily. Accumulations of grease, minerals or debris will cause faulty operation of detergent monitoring and heating systems. Use Scotch-Brite or equivalent cleaning pads on heavy dirt.

Inside of the machine is hot. Allow the machine to cool to 110° F. before proceeding. Wear rubber gloves.

Do not use a hose to clean the exterior of the machine.

Turn off power supply to the control enclosure. This inspection should only be done by a qualified electrician.

Prior to any work on the dishwasher involving service of electrical, steam, or water systems, the dishwasher and booster must be de-energized by turning the electrical supply power "Off" and closing appropriate valves.

Wear rubber gloves while performing the following steps. Do not drink, eat or smoke.

Troubleshooting of certain electrical functions requires access to live electrical circuits inside the electrical control enclosure. Troubleshooting or repair of the electrical equipment should only be done by a qualified electrician.

Prior to any work on the dishwasher involving service of electrical, steam, or water systems, the dishwasher and booster must be de-energized by turning the electrical supply power "Off" and closing appropriate valves.

Wear rubber gloves while performing the following steps. Do not drink, eat or smoke.

Troubleshooting of certain electrical functions requires access to live electrical circuits inside the electrical control enclosure. Troubleshooting or repair of the electrical equipment should only be attempted by a qualified electrician.

The following steps require testing with machine power on. These tests should only be made by a qualified electrician.

All portions of the installation must comply with applicable Navy shipboard regulations, specifications, and requirements.

The dishwasher, booster heater, and unloader must be securely bolted to deck plates.

Dangerous voltages are present on connections to the electrical control enclosure and electric booster heater. Observe normal safety precautions for high voltage electrical equipment when connecting to the local distribution system. All work should be done by a qualified electrician.

At startup, and after any draining of the electric booster, turn off the 440 volt power to the booster during the initial operation of the final hot fresh rinse. This will allow the booster reservoir to fill and trapped air to be purged without overheating of booster heating elements.

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PART 1 TECHNICAL INFORMATION

CAUTION:

Caution definition: A caution designates potential equipment harm.

The operator should become thoroughly familiar with the equipment and these operating instructions prior to starting the machine.

Be careful not to damage parts during cleaning.

The plunger pin must enter into the hole in the boss of the vertical manifold to lock the manifold in position. If the pin is not in the hole, the manifold will come off when the pumps are started.

Do not over-tighten nuts, or studs may be broken.

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PART 1 TECHNICAL INFORMATION

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PART 1 TECHNICAL INFORMATION

FUNCTIONAL DESCRIPTION

The GalleyMaster Dishwasher consists of a wash section and a rinse section, each with a solution tank, upper spray chamber, and front access door. Solutions in each tank are heated to the operating temperatures (150° F. wash, 160°rinse) by either submerged steam coils or electric immersion heaters. Dishware is carried in 20" by 20" racks, through the wash and rinse sections, by a double chain conveyor system.

In the tank of each section, a centrifugal pump draws the hot solution through a suction strainer and then forces the solution under pressure to the upper and lower spray manifolds, where the solution exits through slots and impacts against the dishware in the moving rack. The spent solutions return to their respective tanks through the scrap trays, where debris from the dishware is captured for later disposal.

In the wash tank, the detergent strength is maintained by a concentration sensing controller and detergent supply reservoir.

A hot fresh final rinse zone follows the recirculated rinse zone. The incoming fresh water supply is first reduced to 20 psig. by a pressure reducing valve and then heated to 180° F. (minimum) by either a steam powered heat exchanger or an electrically powered booster heater, located adjacent to the dishwasher. The hot rinse water enters the rinse chamber through upper and lower rinse manifolds, and exits through rinse nozzles and impacts against the dishware in the moving rack. The spent rinse water returns to the re-circulated rinse tank through the scrap screens.

Both the steam and electric powered boosters have a low water temperature interlock that prevents or interrupts washing when the water in the booster is below 180° F.

The residual heat in the final rinse water helps to maintain the recirculated rinse tank temperature. The additional volume of fresh rinse water, when added to the rinse tank, increases the solution level and then overflows into the drain, carrying away any floating grease and debris.

A feed pump injects a conditioner into the final hot rinse water. This conditioner improves the rinsing and drying of the dishware by promoting a "sheeting" action of the rinse water.

A remote electrical control enclosure contains magnetic contactors, overload protection for the pump and drive motors, control relays, selector switches, and pilot lights.

A second machine mounted enclosure contains similar controls for the optional power unloader.

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PART 1 TECHNICAL INFORMATION

DATA CHARACTERISTICS

Manufacturer:

Insinger Machine Company, Philadelphia, PA

Type:

Insinger GalleyMaster Dishwasher with rack capacity, hand of feed, tank heat, booster, and unloader options.

Characteristics:

Type: Double tank, rack conveyor dishwasher. Capacity: (based on 20" by 20" racks, manually loaded).

Modular Construction:

If required, the GalleyMaster Dishwasher may be partially disassembled for passage through a standard 26" x 66" hatch.

Tank Capacities:

Wash Tank: 24 gal.

Rinse Tank: 24 gal.

Rinse Water Requirements:

Final rinse flow: 4.0 gpm at 20 psig.

Wash tank make-up: 0.9 gpm (max) at 20 psig. Supply temperature: 140° F. minimum.

	Model	Racks per hour	Conveyor Speed
			(ft/min)
	GalleyMaster	60	1.6
	GalleyMaster	85	2.3
	GalleyMaster	135	3.7
	GalleyMaster	185	5.1
	GalleyMaster	250	7.0

Ventilation (Exhaust) Requirements:

Entrance: 200 scfm

Exit: 500 scfm

Electrical Power Requirements:

Power supply: 440 vac, 3 phase, 60 Hz.

Operating current::

Steam heated:

4.9 amps (dishwasher & booster)

Electrically heated:

4.9amps (motors & controls)

16.5amps (wash tank heater)

24.8amps (rinse tank heaters)

59.5amps (booster)

Power loader: 0.8 amps additional

Power unloader: 0.9 amps additional

Steam Requirements (Steam heat option only):

Pressure (dry saturated steam): 16 psig. minimum

50 psig. Maximum

Pressure to booster must be regulated to 16-25 psig.

Flow Rates:

Wash tank heat: 55 lb/hr

Rinse tank heat: 82 lb/hr

Booster: 109 lb/hr

Component Ratings:

Wash Heater: (2): 7.5 KW each

Rinse Heaters (3): 7.5 KW each

Electric booster: 54 KW

Wash and Rinse Pumps: 1.0 hp each

Conveyor Drive Gearmotor: 1/15 hp

Unloader Pushout Gearmotor: 1/4 hp

Unloader Roller Gearmotor: 1/15 hp

Loader Roller Gearmotor: 1/3 hp

Weight:

Shipping: 1175 lbs.

Operating: 950 lbs.

Volume:

Crated: 59" lg. x 40" w. x 76" h.

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PART 1 TECHNICAL INFORMATION

INSINGER MACHINE COMPANY LIMITED WARRANTY

Insinger Machine Company, Inc. (Insinger) hereby warrants to the original retail purchaser of this Insinger Machine Company, Inc. product, that if it is assembled and operated in accordance with the printed instructions accompanying it, then for a period of either 15 months from the date of shipment from Insinger or 1 year (12 months) from the date of installation, that said Insinger product shall be free from defects in material and workmanship. Whichever one of the two aforestated limited warranty time periods is the longest shall be the applicable limited warranty coverage time period.

Insinger may require reasonable proof of your date of purchase; therefore, you should retain your copy of invoice or shipping document.

This limited warranty shall be limited to the repair or replacement of parts which prove defective under normal use and service and which on examination shall indicate, to Insinger’s satisfaction, they are defective. Any part that is claimed to be defective and covered by this limited warranty must be returned to Insinger, this may be done through an Authorized Service Agency. Furnish serial number of machine with shipment and send to:

Insinger Machine Company

6245 State Road

Philadelphia, PA 19135-2996

If Insinger’s inspection confirms the defect and the claim, Insinger will repair or replace such part without charge and return it to you freight or postage prepaid.

This limited warranty does not cover any failure or accident, abuse, misuse, alteration, misapplication, improper installation, fire, flood, acts of God or improper maintenance or service, or failure to perform normal and routine maintenance as set out in

the instruction booklet (operating instructions) or for improper operation or failure to follow normal operating instructions (as set out in the instruction booklet). Insinger is not responsible nor liable for any conditions of erosion or corrosion caused by corrosive detergents, acids, lye or other chemicals used in the washing and or cleaning process.

Service must be done by either Insinger Appointed Service Agencies or agencies receiving prior authorization from Insinger.

All warranty work must be done during normal working hours, unless purchaser receives prior authorization from Insinger.

There are no other express warrants except as set forth herein and any applicable implied warranties of merchantability and fitness are limited in duration to the period of coverage of this express written limited warranty. This limited warranty supersedes all other express warranties, implied warranties of merchant-ability and fitness or limited warranties as of this date, January 1, 1998. Some states do not allow limitation on how long an implied warranty lasts so this limitation may not apply to you.

Insinger is not liable for any special, indirect or consequential damages. Some states do not allow the exclusion or limitation of incidental or consequential damages, so this limitation nor exclusion may not apply to you.

Insinger does not authorize any person or company to assume for it any other obligation or liability in connection with the sale, installation, use, removal, return or replacement of its equipment: and no such representations are binding on Insinger.

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PART 1 TECHNICAL INFORMATION

INSINGER MACHINE COMPANY LIMITED WARRANTY COMMERCIAL MARINE USE

Insinger Machine Company, Inc. (Insinger) hereby warrants to the original retail purchaser of this Insinger Machine Company, Inc. product, that if it is assembled and operated in accordance with the printed instructions accompanying it (installation manual), then for a period of 18 months from the date of installation on board the vessel, that said Insinger product shall be free from defects in material and workmanship.

Insinger may require reasonable proof of your date of equipment install, therefore, you should retain your copy of invoice or shipping document.

This limited warranty shall be limited to the replacement of parts which prove defective under normal use and service and which on examination shall indicate, to Insinger's satisfaction, they are defective. Any part that is claimed to be defective and covered by this limited warranty must be returned to Insinger. Furnish serial number of machine with shipment and send to:

Insinger Machine Company, Inc.

6245 State Road

Philadelphia, PA 19135-2996

If Insinger's inspection confirms the defect and the claim, Insinger will repair or replace such part without charge and return it to you freight or postage prepaid. If part damages are not covered, Insinger will contact the customer and advise.

If a factory trained authorized technician is required to repair or replace defective parts or material during the 18 month warranty period, the cruise line will be responsible for the payment of travel expense and a minimum of four hours labor.

Labor will be billed to the customer at a reduced rate of $40.00 per hour. If sailing with a vessel is required, then an eight hour per day minimum will apply.

This limited warranty does not cover accident, abuse, misuse, alteration, misapplication, improper installation, fire, flood, or improper maintenance or service, or failure to perform normal and routine maintenance as set out in the instruction booklet (operating instructions) or for improper operation or failure to follow normal operating instructions (as set out in the instruction booklet).

Insinger is not responsible nor liable for any conditions of erosion or corrosion caused by corrosive detergents, acids, lye or other chemicals used in the washing, caring and or cleaning process.

Warranty service must be done by either Insinger Appointed Service Agencies or agencies, customers galley engineers receiving prior authorization from Insinger.

There are no other express warrants except as set forth herein and any applicable implied warranties of merchantability and fitness are limited in duration to the period of coverage of this express written limited warranty. This limited warranty supersedes all other express warranties, implied warranties of merchantability and fitness or limited warranties as the above date.

Insinger does not authorize any person or company locally or overseas to assume for it any other obligation or liability in connection with the sale, installation, use, removal, return or replacement of its equipment; and no such representations are binding on Insinger.

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PART 1 TECHNICAL INFORMATION

GENERAL INFORMATION

INTRODUCTION

This technical manual provides information for the installation, operation, inspection and maintenance of the GalleyMaster series of dishwashers manufactured by Insinger Machine Company, Philadelphia, PA.

EQUIPMENT DESCRIPTION

The GalleyMaster dishwasher is a double tank, rack conveyor dishwasher used for the washing of plates, glassware, and small utensils in 20" by 20" racks. The machine processes the racks through recirculated wash, recirculated rinse and fresh hot rinse zones at various conveyor speeds, depending on the specific machine model.

The GalleyMaster dishwashers are replacements for earlier 20M-NSU units. Footprint, services (verify wash tank heat electric circuit capacity) and function are the same.

EQUIPMENT SUPPLIED

Dishwashers are supplied with wash and rinse tank and fresh rinse water booster heating options as follows:

	Heat	Wash	Rinse	Booster
	Option	Tank	Tank	Heat
	Steam	Steam Coil	Steam Coil	Steam
	Electric	15.0 kW	22.5 kW	54 KW
		heater	heater	heater

In addition to the tank and booster heat options listed above, the dishwasher may be supplied with optional accessories as follows:

Power rack unloader, located at the machine exit. Power rack loader, located at the machine entrance.

Dishwashers are designed for left to right, or right to left conveyor operation, as specified at time of order.

Each dishwasher is supplied with a loose electrical control enclosure which should be mounted adjacent to the machine by the installing activity.

The following may also be supplied; quantities vary by machine as specified on the applicable order:

Plate racks.

Cup, bowl and cutlery racks.

Cylinder transport rack.

Stainless steel cylinders.

Plastic cylinders

Manifold cleanout brushes.

DETERGENT AND RINSE ADDITIVE DISPENSERS

This machine must be operated with an automatic detergent feeder, including a visual means to verify that the detergents are delivered or a visual or audible alarm to signal if detergents are not available for delivery to the washing system. Please see instructions for electrical and plumbing connections located in this manual and in the feeder equipment manual.

The requirement for a detergent dispenser and a rinse additive dispenser to be supplied by the manufacturer of this dishwasher has been deleted by the Navy's Life Cycle Manager for Shipboard Food Service Equipment.

Contact your local port detergent supplier for detergent and rinse additive dispensing equipment to meet the above requirement.

Questions should be addressed to:

Naval Surface Warfare Center Carderock Division

Ship Systems Engineering Station Naval Business Center

5001 South Broad Street

Philadelphia, PA 19112

POC: James Brechka, 215-897-7311

[e-mail]

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PART 1 TECHNICAL INFORMATION

	INTRODUCTION				CAUTION:
	The GalleyMaster Dishwasher is a heavy
					The operator should become thoroughly familiar with the equipment and
	duty machine designed for daily use in a
					these operating instructions prior to starting the machine.
	naval shipboard environment.
	CONTROLS AND INDICATORS (ELECTRICALLY HEATED MACHINES)
	ITEM	CONTROL			TYPE	FUNCTION
	1	Control power switch	Off-On selector switch on control panel			Controls 24 vac power to control cir-
						cuit
	2	Control power light	Yellow pilot light on control panel			Signals control power state
	3	Start switch	Green pushbutton on control panel			Starts pumps and conveyor(s)
	4	Stop switch	Red pushbutton on control panel			Stops pumps and conveyor(s)
	5	Wash tank heat indicator	Yellow pilot light on control panel			Signals heating element energized in
						wash tank
	6	Rinse tank heat indicator	Yellow pilot light on control panel			Signals heating elements energized
						in rinse tank
	7	Check conveyor indicator	Red pilot light on control panel			Signals conveyor jam
	8	5 amp circuit breaker	White circuit breaker on control panel			Over-current protection for control
						circuit
	9	Water ball valves	Valve located on respective piping string			Opens or closes incoming water line
	10	Damper blade position	Handle (90° rotation) at vent duct connections			Regulates vent duct exhaust flow
		control
	11	Wash tank water level	Porthole located on front of wash tank			Indicates level of water in wash tank
		sight glass
	12	Rinse tank water level	Porthole located on front of rinse tank			Indicates level of water in rinse tank
		sight glass
	13	Thermometers - wash	Dial gauges located on front of wash and			Indicate water temperature in wash
		and rinse	rinse tanks			and rinse tanks
	14	Thermometer - final rinse	Dial gauge located on top of final rinse piping			Indicates final rinse temperature
	15	Pressure gauge - final	Dial gauge located on top of final rinse piping			Indicates final rinse pressure
		rinse
	16	Temperature control -	Round slotted adjustment knob located on the			Regulates temperature of the wash
		wash and rinse	wash or rinse tank temperature control board			and rinse tank water
			in the control panel
	17	Low water level switch	Float switch located in wash and rinse tanks			Disables respective tank heating
						element(s)
	18	High water temperature	Thermostat on wash and rinse heaters			Disables respective tank heating
		limit switch				element(s)
	19	Final rinse temperature	Slotted adjustment screw located inside the			Controls temperature of final rinse
		control	lower front of the booster			water
	20	Final rinse high tempera-	Manual reset thermostat located inside the			Disables booster heating elements
		ture limit switch	lower front of the booster

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PART 1 TECHNICAL INFORMATION

CONTROLS AND INDICATORS (STEAM HEATED MACHINES)

	ITEM #	CONTROL	TYPE	FUNCTION
	1	Control power switch.	Off-On selector switch on control panel.	Controls 24 vac power to control
				circuit.
	2	Control power light.	Yellow pilot light on control panel.	Signals control power state.
	3	Start switch.	Green pushbutton on control panel.	Starts pumps and conveyor(s).
	4	Stop switch.	Red pushbutton on control panel.	Stops pumps and conveyor(s).
	5	Wash tank heat indicator.	Yellow pilot light on control panel.	Signals steam coil energized in wash
				tank.
	6	Rinse tank heat indicator.	Yellow pilot light on control panel.	Signals steam coil energized in rinse
				tank.
	7	Final rinse heat indicator.	Yellow pilot light on control panel.	Signals booster steam flow ener-
				gized.
	8	Check conveyor indicator.	Red pilot light on control panel.	Signals conveyor jam.
	9	5 amp circuit breaker.	White circuit breaker on control panel.	Over-current protection for control
				circuit.
	10	Water and steam ball valves.	Valve located on respective piping	Opens or closes incoming steam or
			string.	water line.
	11	Damper blade position control.	Handle (90° rotation) at vent duct	Regulates vent duct exhaust flow.
			connections.
	12	Wash tank water level sight	Porthole located on front of wash tank.	Indicates level of water in wash tank.
		glass.
	13	Rinse tank water level sight	Porthole located on front of rinse tank.	Indicates level of water in rinse tank.
		glass.
	14	Thermometers - wash and	Dial gauges located on front of wash	Indicate water temperature in wash
		rinse.	and rinse tanks.	and rinse tanks.
	15	Thermometer - final rinse.	Dial gauge located on top of final rinse	Indicates final rinse temperature.
			piping.
	16	Pressure gauge - final rinse.	Dial gauge located on top of final rinse	Indicates final rinse pressure.
			piping.
	17	Temperature control -	Round slotted adjustment knob located	Regulates temperature of the wash
		wash and rinse.	on the wash or rinse tank temperature	and rinse tank water.
			control board in the control panel.
	18	Low water level switch.	Float switch located in wash and rinse	Disables respective tank steam coil.
			tanks.
			Left slotted adjustment screw inside the	Controls temperature of final rinse
	19	Final rinse temperature control.	round dual thermostat on front of steam	water.
			booster.
		Final rinse low temperature	Right slotted adjustment screw inside	Disables pumps and conveyor(s)
	20		the round dual thermostat on front of
		cutoff switch.		when water is below 180° F.
			steam booster.

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PART 2 START-UP INSTRUCTIONS

START-UP PROCEDURE

1.Before starting the machine, inspect the inside of each tank and make sure that:

a.The drain overflow tube is in place.

b.The suction strainer is in place over the pump intake.

c.The scrap screens are clean and in place.

d.The upper and lower spray manifolds are securely installed.

e.The plastic plugs at the ends of all manifolds are installed and hand tight.

f.The wash and rinse tank drain valves are closed.

g.The entrance, center, and exit curtains are in place.

2.Check that the booster hot water supply valve is open and all electric power services are on.

3.Fill the detergent dispenser reservoir in accordance with the detergent supplier's recommendations. Only flake, beaded, or pelletized detergents should be used.

4.Connect the rinse injector supply line to a source of rinse water conditioner.

5.Using the manual valves on the top of the machine, fill the wash and rinse tanks to the level of the overflow tube. Portholes on the front of the machine indicate this water level. Water level should be at the red line in the center of the porthole. Close the manual valves after filling is complete.

6.Close both access doors on the front of the machine.

7.On electrically heated machines, turn the Control Power switch on the electrical control enclosure to the "On" position. The adjacent yellow pilot light will come on.

8.On steam heated machines, open the wash tank, rinse tank, and booster steam supply valves. On the electrical control enclosure, turn the Control Power switch to the "On" position. The adjacent yellow pilot light will come on.

9.At this point, for both steam and electrically heated machines, the thermostatically controlled tank heat will be activated. Allow the wash tank temperature to reach 155° F. and the rinse tank temperature to reach 165° F. before washing dishes.

þ	NOTE:
	The pumps	and conveyor(s) will not start if
	the water in the rinse booster is below 180° F.
	Allow time for the water to reach this
	temperature.

!	WARNING:
	Do not open the access doors while the
	machine is running, as hot water is being
	sprayed inside the machine. Machines
	have an interlock to stop the machine if
	either door is opened, but some hot water
	may escape.

10. Start the machine by pressing the green "Start" pushbutton. Pumps and conveyor(s) will start. Operate the machine for 3 minutes to allow time for detergent to be dispensed (automatically) from the detergent dispenser and mix with the wash tank water.

11. When the tanks have reached the operating temperatures, and detergent has been added and mixed, washing may begin. Insert a rack of soiled dishware into the machine entrance. The machine conveyor will automatically transport the rack through the wash, rinse, and final hot rinse zones, and then eject the rack from the machine exit. On machines with power unloaders, the conveyor will transfer the rack onto the unloader rollers, from which the rack will be automatically ejected at 90° to the path of the machine conveyor.

12. During operation, periodically add water to the wash and rinse tanks to maintain the water levels at the centers of the portholes on the front of the machine.

13. Temporarily stop machine operation (using the red "Stop" pushbutton) if no dishware will be washed for a 3 to 5 minute period.

þ NOTE:

Overloading racks will impede the proper cleaning of dishware.

On machines with power loaders, slide the rack into the power loader. The rollers of the power loader will move the rack onto the machine conveyor.

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PART 3 CLEANING INSTRUCTIONS

CONVEYOR OVERLOAD PROTECTION

The conveyor chains move in a smooth continuous motion. Driving power is transmitted from a gearmotor, through a timing belt and sprocket assembly, to the conveyor drive shaft.

Conveyor jams or overloads will cause the drive belt tension to increase, activating an electrical switch which will stop the pumps and conveyor drive motor. A red "Check Conveyor" light on the electrical control enclosure will come on.

To restore conveyor motion, open the access doors, clear the jam or remove the overload, close the doors, and restart the machine.

SHUT-DOWN PROCEDURE

1.The machine should be cleaned at the end of each meal service. Press the "Stop" pushbutton to stop the pumps and conveyor(s).

2.Turn the Control Power switch to the "Off" position. Adjacent yellow pilot light will go off.

3.Drain the wash and rinse tanks by opening the drain valves.

Remove the following from the inside of the machine:

1.Wash and rinse scrap trays and tray spacers.

2.The entrance, center, and exit curtains.

Remove the wash and rinse pump suction strainers and overflow tubes from their respective openings, and place on tank bottom.

Remove the end plugs from the wash and rinse manifolds and clean with the provided brush. Flush after cleaning and replace plugs.

Clean and flush the scrap trays and tray spacers, the pump suction strainers, the drain overflow tubes, and the curtains.

Clean and flush the entire inside of both tanks, the upper wash and rinse chambers, and doors. Wipe the inside of each drain body and the outside of the seal on each overflow tube (Fig. 7-5). Pay special attention to moving float switches (Fig. 6-13), detergent dispenser probes, electric heater elements (Fig. 6-2) and steam coils (Fig. 7-7).

CAUTION:

Be careful not to damage the above parts during cleaning.

!	WARNING:
	Inside of the machine is hot. Allow
	the machine to cool to 110° F. before
	proceeding. Wear rubber gloves.

Remove the upper and lower wash and rinse spray manifolds:

1.On each manifold, pull the head of the spring pin plunger (item 30, Fig. 7-1) straight out, about 1/4". Rotate the plunger head 90° to hold the pin in the retracted position.

2.Move the manifold straight out, away from the vertical discharge tube. After about 1/4" of movement, the manifold may be rotated to aid in removal.

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PART 3 CLEANING INSTRUCTIONS

WARNING:

! Float switches, probes and heating elements must be cleaned daily. Accumulations of grease, minerals or debris will cause faulty operation of detergent monitoring and heating systems. Use Scotch-Brite or equivalent cleaning pads on heavy dirt.

Use a small wire or pin to clean mineral accumulations from the final hot rinse nozzles.

Replace the wash and rinse spray manifolds:

1.Slide the hub of each manifold over the boss on the vertical discharge tube. The slots in the manifold hub must engage the pins in the boss of the vertical discharge tube.

2.When the slots in the manifold hub are fully engaged over the pins, rotate the plunger head 90°. The plunger pin must enter into the hole in the boss.

CAUTION:

The plunger pin must enter into the hole in the boss of the vertical manifold to lock the

manifold in position.

If the pin is not in the hole, the manifold will come off when the pumps are started.

Replace all removed parts in reverse order. Re-install wash and rinse pump suction strainers and overflow tubes.

þ NOTE:

Center curtain has a yellow stripe. Enter and exit curtains have red stripes.

Doors should remain open to allow interior surfaces to dry. Drains should be closed.

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PART 4 MAINTENANCE & REPAIR PROCEDURES

SCHEDULED MAINTENANCE

The GalleyMaster Dishwasher is a rugged and simple machine. The scheduled maintenance described in this chapter is mostly a periodic set of inspections and cleaning.

WEEKLY REQUIREMENTS FOR INSPECTION AND MAINTENANCE

Inspect for external leakage.

Inspect the outside of the machine, including all piping, piping components, rinse water booster, and the tank side and bottom seams for leakage. Tighten or repair as necessary.

Inspection of probes and moving float switches.

Stop the machine and drain both tanks, see page ____

for detailed instructions.

WARNING: Inside of the machine is

!hot. Allow the machine to cool to 110° F. before proceeding. Wear rubber gloves.

After draining, manually move each float switch to verify that there is no binding or sticking. See Figure 6-13. Check all electrical probes for dirt and mineral accumulation. Clean as required.

De-liming.

Accumulated mineral deposits must be removed from the inside surfaces of the machine on a periodic basis. The frequency of de-liming depends on the hardness of the water, the type and concentration of detergents used, and the amount of washing time. Until the proper frequency can be determined, de-lime on a weekly schedule. Follow the instructions supplied with the deliming chemicals.

Exterior Cleaning.

Wipe down the exterior surfaces of the machine, using a commercial stainless steel cleaner.

WARNING: Do not use a hose to clean

!the exterior of the machine.

QUARTERLY REQUIREMENTS FOR INSPECTION AND MAINTENANCE

Check and adjust final rinse pressure.

The final hot rinse pressure must be 20 psig. while the rinse water is flowing. Adjust the pressure reducing valve during a rinse cycle (CW to increase, CCW to decrease pressure).

If the supply pressure to the booster is 20 psig. or greater, and the rinse pressure is below 20 psig and can not be increased, the strainer in the pressure reducing valve may be clogged. Clean the strainer per 6.2.1.

Clean steam strainers (steam heated machine only).

Close the manual valves on the wash tank, rinse tank, and booster steam supplies.

Remove the plug and strainer basket from each "Y" type steam strainer and flush clean.

Replace strainer and plug.

Open steam supply valves.

Inspect condensate traps (steam heated machines only).

Condensate traps (Fig. 6-14; Fig. 7-7, item 13; Fig. 7-8, item 23;) are located below the steam booster and below each tank.

Check to see that each trap is operating correctly, allowing condensate to flow when the supply valve is open. A condensate trap that is stuck shut, possibly due to corrosion, will not allow the condensate to flow, and no heat will be released within the booster or tank. A trap that is stuck open will not allow the heated unit to reach full operating temperature. A faulty trap should be replaced.

Inspect inside of control enclosures and junction boxes.

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PART 4 MAINTENANCE & REPAIR PROCEDURES

TROUBLESHOOTING

This chapter contains information to assist the operator and/or maintenance personnel in troubleshooting abnormal operation. Personnel involved must be familiar with the description of the equipment and the functioning of all components, as described in Chapters 2 and 3.

The following tables list the more common symptoms which may be experienced, their causes, and the recommended corrective action. The tables are separated into operator and maintenance actions.

WARNING: Prior to any work on the

!dishwasher involving service of electrical, steam, or water systems, the dish-

washer and booster must be deenergized by turning the electrical supply power "Off" and closing appropriate valves.

Wear rubber gloves while performing the following steps. Do not drink, eat or smoke.

Troubleshooting of certain electrical functions requires access to live electrical circuits inside the electrical control enclosure. Troubleshooting or repair of the electrical equipment should only be done by a qualified electrician.

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PART 4 MAINTENANCE & REPAIR PROCEDURES

þThis section covers actions that can be performed by the operator, without the use of tools.NOTE:

OPERATOR'S TROUBLESHOOTING GUIDE

		SYMPTOM OF TROUBLE	POSSIBLE CAUSE	SOLUTION
1.		Machine will not operate.	a. No power.	a. Move POWER switch to ON.
			b. Control circuit breaker tripped.	b. Reset circuit breaker.
2.		Tank will not hold water.	a. Drain overflow tube not installed.	a. Install drain overflow tube.
			b. Pump petcock opened.	b. Close pump petcock.
			c. Drain not closed.	c. Close drain.
3.		Tank fills beyond overflow level.	a. Obstruction in drain overflow tube.	a. Remove obstruction
			b. Clogged drain line.	b. Remove drain overflow tube
				(water is HOT!),if water does not
				drain, maintenance must "snake"
				drain line.
4.		Water leaks from around door.	a. Door is not seated.	a. Check for proper seating.
			b. Clogged spray pipes.	b. Clean with brush provided.
5.		Weak or ineffective wash or rinse	a. Clogged spray pipes.	a. Clean with brush provided.
		spray.	b. Manifolds not installed properly.	b. Ensure proper placement of upper
				and lower manifolds.
			c. Suction strainer clogged.	c. Clean suction strainer.
6.		Weak or ineffective final rinse spray.	a. Lime deposit on spray nozzles.	a. Clean nozzles.
			b. Low water pressure.
			c. Closed supply valve.	b. Should be 20 PSI flowing.
				c. Open valve.
7.		Poor washing results.	a. Scrap screens clogged.	a. Remove and clean screens.
			b. Pump suction strainer clogged.	b. Remove and clean suction
			c. Spray arms clogged.	strainer.
				c. Clean with brush provided.
	8.	Conveyor overload stops conveyor	a. Foreign object caught in conveyor	a. Remove object.
		motion.	chain.
	9.	Tank and/or booster will not hold	For Electric Heat:	For Electric Heat:
		specified temperature.	a. Booster power off.	a. Check circuit breaker.
			b. Tank power off.	b. Check circuit breaker.
			c. Control power off.	c. Turn control power switch on.
			d. Tank empty or low.	d. Fill tank.
			For Steam Heat:	For Steam Heat:
			e. Steam turned off.	e. Turn steam supply on.
			f. Control power off.	f. Turn contol power switch on.
			g. Tank empty or low.	g. Fill tank.

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PART 4 MAINTENANCE & REPAIR PROCEDURES

þThis section covers actions that can be performed by qualified maintenance personnel.NOTE:

MAINTENANCE TROUBLESHOOTING GUIDE

SYMPTOM OF TROUBLE	POSSIBLE CAUSE	SOLUTION
1. Machine will not operate.	a. No power.	a. Check power supply. If red tagged, verify
		maintenance complete and remove tag.
	b. Blown fuse/breaker.	b. Replace fuse; reset breaker and troubleshoot
		source of problem.
	c. Power shut off at disconnect switch.	c. Move disconnect switch to ON.
	d. Motor overload protection tripping.	d. If motor overload trips repeatedly, check
		overload setting and motor current.
	e. Door magnet missing.	e. Replace magnet.
2. Tank will not hold water.	a. Drain overflow tube not installed.	a. Install drain overflow tube.
	b. Pump petcock open.	b. Close pump petcock.
	c. Drain not closed	c. Close drain.
	d. Dirty or worn V seal on overflow	d. Clean or replace V seal.
	tube.
3. Tank fills beyond overflow	a. Obstruction in drain overflow tube.	a. Remove obstruction.
level.	b. Clogged drain line.	b. Remove overflow tube (water is HOT!), if wa-
		ter does not drain, clean the drain line with a
		"snake."
4. Water leaks from around	a. Door is not seated.	a. Check for proper seating and		repair as nec-
door.	b. Clogged spray pipes.	essary.
		b. Clean with brush	provided.
5. Weak or ineffective wash or	a. Clogged spray pipes.	a. Clean with brush	provided.
rinse spray.	b. Manifolds not installed properly.	b. Ensure proper placement of		upper and lower
		spray pipes.
	c. Suction strainer clogged.	c. Clean suction strainer.
	d. Pump motor running in the wrong	d. Correct electrically, proper pump direction
	direction.	indicated by arrow on pump housing.
	e. Pump impeller worn.	e. Replace pump impeller.
	f. Pump blockage.	f. Clean obstruction through pump inspection
		plate.
6. Weak or ineffective final rinse	a. Lime deposit on spray nozzles.	a. Clean or replace nozzles.
spray.	b. Closed supply valve.	b. Open valve.
	c. Low water pressure.	c. Adjust to 20 PSI flowing.
	d. Final rinse nozzles worn.	d. Replace final rinse nozzles.
	e. Clogged line strainer.	e. Remove line strainer and clean.
	f. Worn solenoid diaphragm.	f. Replace with repair kit.
7. Final rinse spray will not turn	a. Clogged final rinse solenoid valve.	a. Turn off water supply, disassemble valve &
off.		clean internal parts of lime & scale.
	b. Worn diaphragm in final rinse sole-	b. Turn off water supply, disassemble valve and
	noid valve.	replace with repair kit.
	c. Solenoid valve still powered up.	c. Check final rinse actuating circuit for proper
		operation.

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PART 4 MAINTENANCE & REPAIR PROCEDURES

þThis section covers actions that can be performed by qualified maintenance personnel.NOTE:

MAINTENANCE TROUBLESHOOTING GUIDE

	SYMPTOM OF TROUBLE	POSSIBLE CAUSE	SOLUTION
8.	Water hammer.	a. Excessive line pressure.	a. Install shock arresters.
9.	Machine vibrates	a. Worn motor bearing.	a. Replace motor.
	(See also water hammer, #8.)	b. Reversed pump rotation.	b. Correct electrically, proper pump direction
			indicated by arrow on pump housing.
10. Tank and/or booster will not		a. No power.	a. Check power supply.
hold specified temperature.		b. Thermostat not adjusted or defec-	b. Adjust or replace thermostat.
		tive.	c. Troubleshoot heat circuitry using wiring dia-
		c. Heat circuitry not working.	gram provided in this manual.
		d. Thermometer inaccurate or defec-	d. Replace thermometer.
		tive.
		For Electric Heat:
		e. Power turned off.	e. Turn power on.
		f. Immersion heaters limed or defective.	f. De-lime or replace immersion heaters.
		g. Low level float switch stuck in down	g. Clean or replace float switch.
		position.
		For Steam Heat
		h. Steam turned off.	h. Turn steam supply on.
		i. Low level float switch stuck in down	i. Clean or replace float switch.
		position.
		j. Not enough steam.	j. Adjust steam pressure per machine specs.
		k. Steam solenoid clogged.	k. Turn off steam supply, disassemble valve
		l. Worn solenoid piston and seat.	and clean internal parts.
			l. Turn off steam supply, remove and replace
		m. Steam condensate trap clogged.	valve.
			m. Turn off steam supply: disassemble steam
			trap and clean, repair or replace.
		n. Clogged line strainer.	n. Turn off steam supply and clean strainer.
11. Poor washing results.		a. Scrap screens clogged.	a. Remove and clean screens.
		b. Pump suction strainer clogged.	b. Remove and clean suction strainer.
		c. Spray arms clogged.	c. Remove and clean with brush provided.
12. Tank heat coming on with		a. Low level float switch dirty or defec-	a. Clean or replace level float.
no water in tank.		tive.	b. Troubleshoot heater control circuitry using
			wiring diagram provided in this manual.

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PART 4 MAINTENANCE & REPAIR PROCEDURES

CORRECTIVE MAINTENANCE

This chapter contains instructions for maintenance and replacement of components that can be damaged or fail in normal operation.

MAINTENANCE AND REPAIR PROCEDURES

Clean the strainer screen and flush with water or a blast of compressed air.

Replace strainer assembly and tighten the large hex nut.

Open the rinse water shut-off valve.

Operate the machine, using a rack to actuate the final rinse. When the final rinse is operating, adjust the rinse water pressure to 20 psig.

WARNING:

! Prior to any work on the dishwasher involving service of electrical, steam, or water systems, the dishwasher and booster must be de-energized by turning the electrical supply power "Off" and closing appropriate valves.

Wear rubber gloves while performing the following steps. Do not drink, eat or smoke.

Troubleshooting of certain electrical functions requires access to live electrical circuits inside the electrical control enclosure. Troubleshooting or repair of the electrical equipment should only be attempted by a qualified electrician.

Clean fresh hot rinse strainer.

Close the rinse water shut-off valve: Steam booster: Figure 7-8, item 16. Electric booster: Figure 7-9, item 13.

Electric booster (hood mount): Figure 7-10, item 14.

The strainer is located within the pressure reducing valve. See Figure 6-1. Loosen the large hex nut on the bottom of the valve. Remove the nut with the attached strainer assembly. It is not necessary to remove the strainer screen from the assembly.

Clean the strainer screen and flush with water or a blast of compressed air.

Replace strainer assembly and tighten the large hex nut.

Open the rinse water shut-off valve.

Removal and replacement of electric tank heater. See Figure 6-2.

Turn off dishwasher power at the main disconnect switch. Drain the appropriate tank.

Remove the external heater cover and disconnect the three power wires. Save the paper insulating strip.

Remove the 3 screws attaching the conduit bracket (with conduit attached) to the brass heater plug. Remove the conduit bracket. One heater in each tank has a capillary probe from a high temperature cut-off switch attached to a heater element. If replacing this heater, remove the 2 hose clamps that hold the capillary to the heater element and move the capillary to the side. Remove the 2 inch brass hex nut from the heater plug. Withdraw the heater from the inside of the tank.

Clean the tank hole and install a new heater, brass washer, and gasket in the tank hole. Use plumber's putty between the brass hex nut and the outside of the tank. Install the brass hex nut and tighten securely. If the capillary probe was removed, clamp the capillary to the UPPERMOST heater element. Replace the conduit bracket and 3 screws and tighten securely.

Reconnect the power wires and replace the paper insulating strip. Replace the heater cover. Fill the tank and check for leaks.

Removal and replacement of thermometers.

If a thermometer is suspected of being defective, first check the unit against a reference thermometer and compare readings. Tolerance is plus or minus 2° F.

To remove a thermometer, first turn the Control Power switch on the electrical control enclosure to the "Off" position. Tanks do not need to be drained to replace thermometers.

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PART 4 MAINTENANCE & REPAIR PROCEDURES

Wash and rinse thermometers. See Figure 6-3.

1.Remove the thermometer guard from the outside of the tank.

2.Using a wrench on the hex of the thermometer (behind the dial), unscrew the thermometer from the thermometer well. Do not unscrew by turning the dial case.

3.Install a new thermometer. Use Teflon tape on the threads, so the thermometer is "snug" with the 100° mark at 12 o'clock. Use a wrench on the hex but do not overtighten.

4.Replace the thermometer guard.

Final hot rinse thermometer. See Figure 6-4.

Using a wrench on the hex boss of the rinse thermometer stem, unscrew the thermometer from the tee in the final rinse line, and replace with a new unit.

Overload relay settings and functions. See Figure 6-5.

Overload current setting. Lift the plastic cover. With a small screwdriver, align the set point on the overload setting dial with the value for the motor nameplate full load current for 440 volts. The nominal full load current for 440 volt operation of a typical 3 phase motor is:

1 hp. (pump)	2.2 amps
1/3 hp. (loader)	0.8 amps
1/4 hp. (unloader pushout drive)	0.7 amps
1/15 hp. (unloader roller & conveyor drive)	0.16 amps

Auto reset selection. The overload relay is factory installed in the auto reset configuration. A blue shutter appears in the reset selector window. Always use this configuration. If set to the manual reset function (which may be the case with a replacement part), a white plastic cover with an "H" covers the reset selector window. To change to auto reset, lift the plastic cover. Use a small screwdriver to pry off and discard the "H" cover. Slide the blue shutter downward until a faint "click" is heard.

Reset test. To test the overload trip function, press the red Stop button. The NC auxiliary contact (only) will open as long as the Stop button is pressed in. This contact is wired in series with other overload relay NC auxiliary contacts and, when opened, will stop all motors.

Adjust tank temperature.

The wash tank temperature should be 150° to 155° F. The rinse tank temperature should be 160° to 165° F.

Temperature adjustment. Tank temperature is sensed by a thermistor on the tank wall and regulated by a temperature control board in the electrical control enclosure. See Figure 6-6. Locate the tan adjustment pot with slot on the wash or rinse tank temperature control board.

Rotate in small increments (CW to increase, CCW to decrease temperature) and allow tank temperature to stabilize between adjustments.

Control board replacement. To replace the tank heat temperature control board or thermistor, disconnect and tag all wires, and then remove the board or thermistor.

Adjust rinse booster temperature.

The booster water outlet temperature should be 190° to 195° F.

Steam heated booster. The temperature controller is on the front of the booster. Unscrew the round cover. See Figure 6-7. The water outlet temperature control switch is on the left, marked "Temp Set 190° F." Use a hex key to rotate the pointer and change the setting. Higher scale settings correspond to higher outlet temperatures. While the rinse is operating, turn the pointer in 1/2 scale increments and observe the rinse temperature over several rinse cycles.

The switch on the right is the low water temperature interlock switch, factory set at 180° F.

To remove this thermostat, first close the manual hot water valve. Disconnect and tag all wires. Remove the electrical conduit from the thermostat housing. Unscrew the entire thermostat assembly from the pipe tee on the booster.

Electrically heated booster.

The thermostat is located inside the lower front of the booster. Remove the access plate marked "Remove for access to thermostats and high limit switch". See Figure 6-8. Rotate the slotted screw "G" in small increments CCW to lower temperature. Rotate nut "F" CCW, while holding "G" against high stop, to raise temperature. Allow tank temperature to stabilize between adjustments. Note that 1/6 turn is approximately 12° F. Observe the rinse temperature over several rinse cycles.

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