Jackson 64C Service Manual

1060
40906
MODEL 64/86
C/RPW
TWO TANK RACK CONVEYOR
DISHWASHER
SERVICE MANUAL
INCLUDES:
-Warranty Policy -Basic Functions of Dishwasher
-Operating Instructions -Illustrated Parts List
-Description of Components -Electrical Diagrams
WORLD HEADQUARTERS & MANUFACTURING OPERATIONS
Highway 25E, P.O. Box
Barbourville, KY
888/800-JMSC
Fax: 606/523-9196
April 4, 1997 7610-100-40-00 Rev A
INDEX
WARRANTY 2 SPECIFICATIONS 3 GENERAL INSTRUCTIONS (Installation) 8 GENERAL INSTRUCTIONS (Operation) 9 GENERAL INSTRUCTIONS (Preventive Maintenance) 10 REPLACEMENT of SWITCHES in CONTROL PANEL 11 THERMOSTAT 12 WASH TANK and RINSE TANK HEATER SYSTEM 13 WATER LEVEL CONTROL (ELS Heat Circuits) 15 SERVICE INSTRUCTIONS (Incoming Water Solenoid Valve) 17 REPLACING SEAL and CERAMIC on WASH PUMPS 18 CONVEYOR CLUTCH ADJUSTMENT 22 TROUBLE SHOOTING GUIDE 27 ELECTRICAL DRAWINGS 29 PARTS LIST 53 PARTS DISTRIBUTORS 56
SPECIFICATIONS
Electric Tank Heat
Steam Tank
Heat
230
Volts
118.1
75-9
18.1 18.1
208
Volts
133.4
86.7 22.8 22.8
380
Volts
N/A 48.3 N/A 13.3
OPERATING CAPACITY (NSF RATED)
Model 64C Model 86CRPW
Racks per hour 239 239 Dishes or glass per hour 5975 5975 REQUIREMENTS Flow pressure 20 PSI 20 PSI Pre-wash tank temperature (maximum)
120°F Wash tank temperature (mini mum) 150°F 150°F Recirculated rinse tank temperature (minimum) 160°F 160°F Final fresh water rinse temperature (minimum) 180°F 180°F Incoming water pipe size — machine 1/2" IPS 1/2" IPS Incoming water pipe size — pre-wash
1/2" IPS Drain pipe size 2" IPS 2" IPS Maximum water usage (final rinse flow rate) 3.8 GPM 3.8 GPM DIMENSIONS Length — between dishtables 64" 86" Width 25" 25" Height — door closed ± 1/2" 633/4" 633/4" Height — door open ± 1/2" 70" 70" Standard table height ± 1/2" 34" 34" Maximum dish clearance 18" 18" TANK CAPACITIES Pre-wash tank
14 Gals. Wash tank 18 Gals. 18 Gals. Rinse tank 18 Gals. 18 Gals. PUMPS AND MOTORS Pre-wash motor Pre-wash pump capacity
1/2 HP
80 GPM Wash motor 1 HP 1 HP Wash pump capacity 175 GPM 175 GPM Recirculating rinse motor 1 HP 1 HP Recirculating rinse pump capacity 175 GPM 175 GPM Conveyor motor 1/4 HP 1/4 HP Conveyor speed (feet/minute) 6.56 6.56 ELECTRIC HEAT (WHEN SPECIFIED) Wash tank 10 KW 10 KW Rinse tank 13 KW 13 KW STANDARD RACKS Dish racks 19 3/4" x 19 3/4" 3 3 Combination racks 19 3/4" x 19 3/4" 1 1 SHIPPING WEIGHT (APPROX.) 750 LBS. 850 LBS. SHIPPING DIMENSIONS (L x D x H) 120" x 40" x 72" 120" x 40" x 72" CUBIC FEET 222 ft.3 222 ft.3 ELECTRICAL REQUIREMENTS: 208V/60 HZ/1 or 3
230V/60 HZ/1 or 3 phase 380V/60 HZ/3 phase 460V/60 HZ/3 phase 50 HZ also available in these voltages
Approximate Total Load Amperes
Model 64C
1-Phase 3-Phase 1-Phase 3-Phase
208 Volts 129.1 82.4 18.5 18.5
380 Volts N/A 46.3 N/A 11.3 460 Volts N/A 37.1 N/A 6.9
Model 86CRPW
230 Volts 122.4 80.2 22.4 22.4
460 Volts N/A 39.3 N/A 9.1
All specifications subject to change without notice. 3
Approximate Total Load Amperes Electric Tank Heat Steam Tank Heat
1-Phase 3-P hase 1-Phase 3-Phase
64CE LEFT TO RIGHT
LEGEND
A — MACHINE WATER INLET 1/2" I.P.S. 180°F MIN.
B — DRAIN CONNECTION 2" I.P.S. DRAIN CAN BE CONNECTED TO EITHER END.
C — ELECTRICAL CONNECTION.
D — ALLOW 12" FOR REMOVAL OF PAWL BAR DRIVE UNIT COVER. E — VENT COLLAR 4" x 16" x 3" TALL, OPTIONAL.
F — VENT COWL, STANDARD. *G — INCOMING STEAM CONNECTION, OPTIONAL. 3/4" FPT. (GATE VALVE SUPPLIED.) *H — CONDENSATE RETURN CONNECTION 3/4" FPT. (RETURN TO BOILER OR OPEN DRAIN.)
*STEAM TANK HEAT ONLY
4
64CE RIGHT TO LEFT
LEGEND
A —MACHINE WATER INLET 1/2" I.P.S. 180°F MIN.
B — DRAIN CONNECTION 2" I.RS. DRAIN CAN BE CONNECTED TO EITHER END.
C — ELECTRICAL CONNECTION.
D — ALLOW 12" FOR REMOVAL OF PAWL BAR DRIVE UNIT COVER. E — VENT COLLAR 4" x 16" x 3" TALL, OPTIONAL.
F — VENT COWL, STANDARD. *G — INCOMING STEAM CONNECTION, OPTIONAL. 3/4" FPT. (GATE VALVE SUPPLIED.) *H —CONDENSATE RETURN CONNECTION 3/4" FPT. (RETURN TO BOILER OR OPEN DRAIN.)
*STEAM TANK HEAT ONLY
5
86CERPW RIGHT TO LEFT
LEGEND
A — MACHINE WATER INLET 1/2" I.P.S. 180°F MIN. B — DRAIN CONNECTION 2" I.RS. DRAIN CAN BE CONNECTED TO EITHER END. C — ELECTRICAL CONNECTION. D — ALLOW 12" FOR REMOVAL OF PAWL BAR DRIVE UNIT COVER. E — PRE-WASH WATER INLET 1/2" I.P.S. 140°F. F — VENT COLLAR 4" x 16" x 3" TALL, OPTIONAL.
G — VENT COWL, STANDARD. *H — INCOMING STEAM CONNECTION, OPTIONAL. 3/4" FPT (GATE VALVE SUPPLIED.) *l — CONDENSATE RETURN CONNECTION 3/4" FPT. (RETURN TO BOILER OR OPEN DRAIN.)
*STEAM TANK HEAT ONLY
6
86CERPW LEFT TO RIGHT
LEGEND
A — MACHINE WATER INLET 1/2" I.RS. 180°F MIN. B — DRAIN CONNECTION 2" I.P.S. DRAIN CAN BE CONNECTED TO EITHER END. C — ELECTRICAL CONNECTION. D — ALLOW 12" FOR REMOVAL OF PAWL BAR DRIVE UNIT COVER.
E — PRE-WASH WATER INLET 1/2" I.P.S. 140°F. F — VENT COLLAR 4" x 16" x 3" TALL, OPTIONAL. G — VENT COWL, STANDARD. *H — INCOMING STEAM CONNECTION, OPTIONAL. 3/4" FPT. (GATE VALVE SUPPLIED.) *l — CONDENSATE RETURN CONNECTION 3/4" FPT. (RETURN TO BOILER OR OPEN DRAIN.
*STEAM TANK HEAT ONLY
7
GENERAL INSTRUCTIONS
(INSTALLATION for 64C/86CRPW)
Note: Read the following instructions carefully. Proper installation of your Jackson
Dishwasher will assure proper machine operation.
1. Open the front doors and hook open. Remove dish, cup, and glass racks and set aside for later use. Remove the tape holding the overflow tubes, the pump intake strainers, and the wash and recirculating rinse tubes that are in the machine.
2. Cut the straps holding the machine to the base of the crate. Ease the machine on to the floor and slide into place of installation.
3. Remove the plug provided on either end of the drain plumbing (whichever side is convenient), and connect the drain (2" female IPS) with the proper slope to conform with local and/or national codes. Drain is a gravity feed system from the machine.
4. Connect incoming 1/2" water line with capacity to supply 3.8 gallons per minute at 20 PSI flow pressure and at a temperature of 180°F minimum. For the 86CRPW, another 1/2" water line must be connected to the pre-wash section to supply 140°F. These connections are just before the Y­strainer on top of the machine. Make connections to conform to local and/or national codes.
5. Electrical connections should be made through the hole in the back of the control box to the terminal board on the back right -hand side. This terminal board is accessible by removing the control box cover. The terminals are marked L1, L2 (single-phase), or L1, L2, L3 (three phase). Be sure all connections conform to local and/or national codes . Refer to data plate for voltage and amperage totals.
6. DO NOT APPLY POWER UNTIL STEP 9!!!!
7. Make sure drains are closed and the curtains are in place. The long curtains go on the outside of the vent cowls. The short curtains go on the inside of the ve nt cowls. A medium curtain goes between the pre-wash and wash tanks. A long curtain goes between the wash and recirculating rinse tanks. A short curtain goes between the recirculating rinse and final rinse.
8. Turn lever operated drains (if so equipped) to the closed position. Turn on hand valves controlling water supply to machine. Check for any leaks in the plumbing.
9. To energize electrically, proceed as follows: a. Turn on customer's circuit breaker controlling the machine. b. Check voltage at the incoming terminals L1, L2, and L3 (if applicable). It should match the
data plate voltage. Voltage at L1 and L2 should be checked to ground individually to ensure that a high (or wild) leg is not connected to L1 or L2.
c. If voltages are in the required range, turn on the 20-amp circuit breaker. The 20-amp circuit
breaker protects the control circuits only; it is not meant to protect the wash and recirculating rinse heaters or motors.
10. a. Turn fill handle(s) on the top of the machine to supply the unit with water. When the required level is reached, turn the fill handle(s) back to the original position. Open the doors and check the water level. It should be within 1/4" below the overflow level.
b. If unit is equipped with the Auto-Fill option, fill by turning on the power switch and pushing and
releasing the Auto-Fill Switch. (Warning: If unit does not continue to fill when switch is released, immediately turn power switch off. Clean probes located in wash tank [and pre- wash, if 86CRPW] and try again. If problem persists, call service agency.) Fill will shut off automatically when proper level is reached.
11. When the water has reached the proper level, close the doors and turn on the power switch. The
heaters are in the wash and recirculating rinse tanks. They are utilized to maintain the wash water temperature at 150°F, and the recirculating rinse water temperature at 160°F.
12. Turn the manual switch on by pushing and releasing the momentary side of the switch. This will
activate a hold circ uit and the pumps, conveyor, and final rinse will come on and run continuously. Turn manual switch off.
13. Turn the auto switch on by pushing and releasing the momentary side of the switch. This will
activate a hold circuit, but nothing will come on until a rack is inserted into the machine. Insert rack into the soiled side of the machine. The pumps, conveyor, and final rinse will come on. Allow the rack to travel all the way through the unit. The pumps, conveyor, and final rinse will shut off automatically when the rack leaves the unit.
8
14. The unit is now ready to proceed with the washing of dishes in accordance with the operating instructions.
Note: As the racks leave the unit, do not allow them to accumulate more than three in a row.
GENERAL INSTRUCTIONS
(OPERATION of 64C/86CRPW)
Note: Read instructions carefully. Proper operation of your Jackson Dishwasher will asssure clean and sanitized glasses and dishes at optimum efficiency.
Dish Preparation:
1. Scrape the dishes thoroughly.
2. Pre-rinse the dishes by soaking or by spraying off with a pre-rinse hose.
3. Place the dishes and cups in the dish rack with the cups upside down.
4. Place the glasses and silverware in the combination glass-silverware rack with the glasses upside down. Scatter the silverware loosely on the bottom of the rac k. DO NOT put glasses on top of the silverware.
Note: When the silverware is in any upright position, it washes and rinses better than
lying flat. These compartment silverware racks are available through your dealer or service agency.
Machine Operation:
1. Open the doors and insert pump intake strainers, overflow tubes, pan strainers, and the upper and lower wash and rinse tubes.
2. Make sure drains are closed and the curtains are in place. The long curtains go on the outside of the vent cowls. The short curtains go on the inside of the vent cowls. A medium curtain goes between the pre-wash and wash tanks. A long curtain goes between the wash and recirculating rinse tanks. A short curtain goes between the recirculating rinse and final rinse.
3. Close the doors.
4. a. Turn on the fill valve handle(s) on top of the unit. When the proper level is reached, turn off
the fill valve(s).
b. If the unit is equipped with the Auto-Fill option, fill by turning on the power switch and pushing
and releasing the auto fill switch. (Warning: If unit does not continue to fill when switch is released, immediately turn power switch off. Clean probes located in wash tank [and pre- wash, if 86CRPW] and try again. If problem persists, call an authorized service agency.) Fill will shut off automatically when proper level is reached.
5. Turn on the power switch and allow the wash and rinse water to reach proper temperature (wash 150°F, recirculating rinse 160°F).
6. Select either automatic mode or manual mode. In the manual mode, the dishwasher will run continuously. In the automatic mode, the dishwasher will run only when a rack of dishes is in the machine. Activate desired mode by pushing the proper mode switch to the momentary position and releasing. Make sure the opposite mode switch is in the 'off' position.
7. Slide in a rack of dirty dishes. If machine is in the automatic mode, the rack will activate the paddle switch, and the machine will remain on long enough for the rack to pass through. Then, the unit will shut off. Each successive rack will reset the cycle. This is an energy -saving feature when intermittent use is required rather than continuous use.
8. When the rack leaves the other end of the machine, it should be removed and not allowed to accumulate more than three rac ks on the table. Failure to remove the racks could result in damage to the conveyor system. (If so equipped, accumulated racks will open the table limit switch which will shut down the machine until the racks are removed.)
9. At the end of a meal period, shut off the power switch. Drain the unit by operating the drain valves (if so equipped) or by removing the overflow tubes. Clean all the strainers and flush out the unit.
9
GENERAL INSTRUCTIONS
(PREVENTIVE MAINTENANCE for 64C/86CRPW)
(To be performed as needed*)
Note: Read carefully. Proper maintenance of your Jackson Dishwasher will ensure optimum
service with a minimum of down time.
1. Remove all lime and corrosion deposits.
a. Fill the machine with water as normal. b. Open doors and place de-liming compound into the wash and rinse water in accordance with
the directions on the label. (Both tanks hold 18 gallons.) Close doors. c. Turn on the machine in the manual mode and allow to run for 5 minutes. d. Turn off the machine, open doors and inspect the interior. All lime should be removed and
parts should appear shiny. If not, allow to run for a longer period. e. When the interior of the machine is clean, drain the water and refill. f. After refilling, allow machine to run for 2 minutes and drain again. g. Refill machine and resume normal operation.
2. Clean strainers (every meal period or more). a. Turn off unit and drain water. b. Remove and clean all strainers thoroughly. c. Replace strainers and refill machine. Resume normal operation.
3. Clean wash and rinse tubes.
a. Remove wash and rinse heads by lifting the holding clip and sliding out. b. Remove end plugs by unscrewing. c. Flush tubes with water until clean. d. Reassemble and replace.
4. Clean final rinse heads.
a. Remove end plugs.
b. Clear spray nozzles using a pointed tool. c. Close doors and activate cycle momentarily. d. Replace end plugs.
5. Clean Y-strainer on incoming water line. a. Turn off water to the machine. b. Relieve line pressure by opening fill valve. c. Remove plug and strainer. Clean using a brush and de-limer. d. Replace strainer and plug.
6. Clean exterior of the machine using a stainless steel polish.
10
REPLACEMENT of SWITCHES
1.
CONNECTION TERMINALS
2. RETAINING CUPS
3. FRONT PANEL
4. SWITCH BEZEL
5. ROCKER BUTTON
in CONTROL PANEL
There are three switches installed in the control box front panel. These are the power, automatic wash and manual wash switches.
Before working on the machine, it is important that power be turned off at customer's circuit breaker. To prevent the possibility of electrical shock, trip breaker to "off" position. Then turn the machine breaker located on the right side of the power box to "off".
Remove the cover from the control box by unlocking latch and lifting off cover. If a switch is found to be defective, insert a new one into the cutout in the control box. Replace the
wires from the used switch, terminal by terminal, ont o the new switch. Power can now be applied to the dishwasher and run through cycles checking all operations.
11
THERMOSTAT
The electronic thermostat can be adjusted on both the 'HI' (off) setting, and the 'LO' (on) setting by use of the corresponding control pot. Turning the control pot counterclockwise (CCW) will lower the setting. Clockwise (CW) will raise the set ting. When adjusting the thermostat, adjust the 'HI' setting first.
To Adjust the Thermostat:
1. Fill unit with water, then turn the power switch "on".
2. Allow the water to reach the desired 'HI' (or turn off) temperature. This temperature should be approximately 160°F for the wash, or 170°F for the power rinse. (It may be necessary to turn 'HI' control pot CW all the way to stop in order to prevent heaters from shutting off before temperature is reached.)
3. When desired temperature is reached, slowly turn 'HI' control pot CCW until relay cube clicks "off" (N.C.).
4. Turn the 'LO' control pot CCW all the way to stop.
5. Turn on the manual wash and allow the unit to run until water temperature reaches the desired 'LO' (or turn on) temperature. This temperat ure should be approximately 153°F for wash, and 163°F for power rinse.
6. Turn the 'LO' control pot CW until relay cube clicks "on" (N.O.).
Note: If relay will not operate, check power to thermostat. Thermostat can be tested by
placing jumper wire across T.C. terminals, bypassing thermocouple.
12
WASH TANK and RINSE TANK
HEATER SYSTEM
Function:
The wash and rinse tank heater system are electrically connected in the circuit so that they are dependent upon the dishwasher being property filled with and maintaining a safe water level.
The circuits are controlled by a power switch (mounted on the front control panel), two thermostats (mounted in the junction box behind the lower front panel), two water level controls (mounted in the control box), and two heater relays (mounted in the control box), with the coils being activated by the thermostats.
indicators of Possible Malfunction: Once the machine has been properly filled, the heat circuit should operate by merely turning on the
power switch. Should the tank heat, be it either too high, too low, or no indication of temperature at all, the following checkouts should be made.
Checkout the Heater System for Tank (Refer to drawing, figure 1): Note: The following checkouts should be done by a qualified service person or electrician.
1. If temperature is too high, adjust thermostat, using thermostat instructions in this manual.
2. If temperature is too low, adjust thermostat as above, then: a. Turn off power to machine by tripping customer's circuit breaker to "off" position. Turn off machine circuit breaker located on right side of power box.
b. Remove cover from control box on top of machine. c. Make sure water temperature is below 140°F (preferably about 130°F). d. Turn on both circuit breakers. Observe heat relay (3 or 4 pole, mounted lower left inside
power box) while power switch is turned "on" and "off". If relay contacts move in and out, heat relay is ok; if not, proceed to "A".
If Heat Relay Closes:
1. Check power supply at incoming terminal board L1, L2, L3. It should be data plate voltage across each leg.
2. Check power at positions 4, 5, and 6, figure 1. It should be data plate voltage. If not, check wires for breaks or bad connections.
3. Check power at positions 7, 8, and 9. It should be data plate voltage. If not, check wires for breaks or bad connections.
4. Temperature should rise as explained in "A-1", and amperages may be checked according to those instructions. Replace any defective elements.
13
FIGURE NO. 1 HEATER SYSTEM 3-PHASE
A. POWER SWITCH B. WATER LEVEL CONTROL C. THERMOSTAT D. HEATER RELAY E. TANK HEATERS F. AMPROBE TEST POSITION X. TERMINAL BOARD (TERMINALS)
A. If Heat Relay Does Not Close:
1. There is an insulated movable bar on the relay across the top of the contacts. With insulated probe, depress this bar and observe the thermometer; the temperature should rise noticeably in a minute or two. If it moves slowly, it would indicate that the element is faulty. If it moves constantly higher at a good rate, elements should be ok.
2. With power switch on:
a. Check position 1, figure 1. Voltage should be 220V; if not, checkout power switch and
replace if necessary.
b. Check position 2; there should be no voltage. If there is, readjust thermostat per
thermostat adjustment instructions.
c. Check position 3; voltage should be approximately 120V to ground. d. If voltage being applied on positions 1, 2, and 3 checks out okay, then the relay should be
replaced. Coil is probably defective.
Note: A check with an amp probe at positions shown in figure 1 can be made. The amp
draw on each leg should be appropriate for the voltage and phase as indicated by the data plate.
14
WATER LEVEL CONTROL
(ELS HEAT CIRCUITS)
This control is activated when the power switch is turned on. The primary function is to automatically activate the wash and rinse tank heat circuit. It will also provide cutoff of the wash and rinse heat circuit, should the water be accidentally drained from the machine (with the power switch still on). The power switch should always be turned off before draining.
This water level control is used in conjunction with two probes (sensors), power switch, thermostats, and heat relays.
When the power switch is turned on, the normally closed circuit in the plug-in relay is energized. As the water rises in the wash and rinse tubs it will cover the probe (directly above wash element). At
this time, the plug-in relay coil will be activated and open the normally closed contacts. Simultaneously, the contacts will close on the normally open circuit, energizing the wash and rinse heat circuits. (Checkout and information concerning that part of the circuit are in the wash heater system or rinse heater system instruction page of this manual.)
If the water should be drained from the machine while the power switch is still on, the probe will sense the lack of water and de-energize the plug-in relay, which will de-energize the wash and rinse heat circuit. DO NOT DEPEND ON THIS — always turn power switch off before draining.
Symptoms of Level Control Failure:
1. Wash or rinse heat circuit does not activate.
2. Wash heater remains on (if wash water emptied with power switch on).
3. Rinse heater remains on (if rinse water emptied with power switch on).
Proceed with Checkout:
1. Remove power to machine by turning customer's circuit breaker to its "off" position. Turn machine circuit breaker, located on right side on power unit box, to "off."
2. Remove cover to control box.
3. Locate malfunctioning water level control board and disconnect wires going to terminals marked C, H, and L. Mark and insulate wires for replacement.
4. Be sure affected tank is empty and power switch is off. Carefully reapply power to machine. Begin by turning power switch on. With an insulated jumper wire, touch jumper between terminals C & H; relay in clear plastic cube should activate as wire is touched to terminals. Observe relay contacts — they should pull in. If they do, remove wire and they should return to original position. Repeat several times to verify action. Reconnect wires removed.
5. If relay operates, the control can be deemed operational and other causes should be explored. EXAMPLES: 1. Loose or broken wire to probe or ground (green wire).
2. Dirty probe(s).
3. Thermostat faulty or needs adjustment. (See instruction page concerning thermostat.)
4. Wash element faulty. (See instruction page concerning wash-heat checkout.)
5. Rinse element faculty.
6. If relay does not operate, check voltage being applied to L1 - L2 marked on control. It should be 208-230V. Replace control, if necessary.
15
7. In any case, always locate sensor (probes) inside wash tub and clean off all deposits. (Instruct customer; this should be at least a weekly project.)
8. Remove power to machine and replace panel and any wires that were not replaced previously.
16
SERVICE INSTRUCTIONS
#2
(INCOMING WATER SOLENOID VALVE)
To Take the Valve Apart: Disassembly — These valves may be taken apart by
unscrewing the bonnet and enclosing tube assembly from the valve body assembly. See figure 2. After unscrewing, carefully lift off the bonnet and enclosing tube assembly Don't drop the plunger. The "0" 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 synthetic seat against the pilot port. Make sure the "0" ring is in place, then lower the bonnet and enclosing tube assembly over the plunger. Screw bonnet assembly snugly down on body assembly.
DIAPHRAGM CARTRIDGE
P/N 0145000
Pilot port extension #1 clogged. Hole #2 clogged.
F FIGURE NO. 2
Possible Problems:
Remedy:
Pass heated straight pin through hole
17
or clean hole #1.
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