Jackson Conserver-24LTF Service Manual

CONSERVER 24LT
SERVICE MANUAL
Visit Jackson on the Internet at:
www.jacksonmsc.com
November 29, 1999 P/N 7610-002-10-45
MANUFACTURERS WARRANTY
ONE YEAR LIMITED PARTS & LABOR WARRANTY
ALL NEW JACKSON DISHWASHERS ARE WARRANTED TO THE ORIGINAL PURCHASER TO BE FREE FROM DEFECTS IN MATERIAL OR WORKMANSHIP, UNDER NORMAL USE AND OPERATION FOR A PERIOD OF (1) ONE YEAR FROM THE DATE OF PURCHASE, BUT IN NO EVENT TO EXCEED (18) EIGHTEEN MONTHS FROM THE
DATE OF SHIPMENT FROM THE FACTORY.
Jackson MSC agrees under this warranty to repair or replace , at its discretion, any original part which fails under normal use due to faulty material or workmanship during the warranty period, providing the equipment has been unaltered, and has been properly installed, main­tained and operated in accordance with the applicable factory instruction manual furnished with the machine and the failure is reported to the authorized service agency within the warranty period. This includes the use of factory specified genuine replacement parts, purchased directly from a Jackson authorized parts distributor or service agency. Use of generic replacement parts may create a hazard and void warranty certification.
The labor to repair or replace such failed part will be paid by Jackson MSC, within the continental United States, Hawaii and Canada, dur ­ing the warranty period provided a Jackson MSC authorized service agency, or those having prior authorization from the factory, performs the service. Any repair work by persons other than a Jackson MSC authorized service agency is the sole responsibility of the customer. Labor coverage is limited to regular hourly rates, overtime premiums and emergency service charges will not be paid by Jackson MSC.
Accessory components not installed by the factory carry a (1) one year parts warranty only. Accessory components such as table limit switches, pressure regulators, pre rinse units, etc. that are shipped with the unit and installed at the site are included. Labor to repair or replace these components is not covered by Jackson MSC.
This warranty is void if failure is a direct result from shipping, handling, fire, water, accident, misuse, acts of god, attempted repair by unau ­thorized persons, improper installation, if serial number has been removed or altered, or if unit is used for purpose other than it was origi­nally intended.
TRAVEL LIMITATIONS Jackson MSC limits warranty travel time to (2) two hours and mileage to (100) one hundred miles. Jackson MSC will not pay for travel
time and mileage that exceeds this, or any fees such as those for air or boat travel without prior authorization. WARRANTY REGISTRATION CARD The warranty registration card supplied with the machine must be returned to Jackson MSC within 30 days to validate the warranty. REPLACEMENT PARTS WARRANTY Jackson replacement parts are warranted for a period of 90 days from the date of installation or 180 days from the date of shipment from
the factory, which ever occurs first. PRODUCT CHANGES AND UPDATES Jackson MSC reserves the right to make changes in design and specification of any equipment as engineering or necessity requires. THIS IS THE ENTIRE AND ONLY WARRANTY OF JACKSON MSC. JACKSON’S LIABILITY ON ANY CLAIM OF ANY KIND, INCLUD-
ING NEGLIGENCE, WITH RESPECT TO THE GOODS OR SERVICES COVERED HEREUNDER, SHALL IN NO CASE EXCEED THE PRICE OF THE GOODS OR SERVICES OR PART THEREOF WHICH GIVES RISE TO THE CLAIM.
THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING FOR FITNESS OR MERCHANTABILITY, THAT ARE NOT SET FORTH HEREIN, OR THAT EXTEND BEYOND THE DURATION HEREOF. UNDER NO CIRCUMSTANCES WILL JACKSON MSC BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECT OR CONSEQUENTIAL, OR FOR THE DAMAGES IN THE NATURE OF PENALTIES, ARISING OUT OF THE USE OR INABILITY TO USE ANY OF ITS PRODUCTS.
ITEMS NOT COVERED This warranty does not cover adjustments to timer cams or thermostats, cleaning wash arms or strainers, or replacement of wear items
such as curtains, squeeze tubes, drain balls, door guides, or gaskets beyond 30 days from installation of unit. Also not covered are condi ­tions caused by the use of incorrect (non commercial) grade detergents, excessive supply water temperature or pressure, or hard water conditions.
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TABLE OF CONTENTS
GENERAL PAGE
Specifications .............................................................................................. 1
Detail of Data Plate...................................................................................... 2
General Notes............................................................................................... 3
INSTALLATION
Unpacking..................................................................................................... 4
Plumbing Connections.................................................................................. 5
Electrical Connections.................................................................................. 6
Chemical Dispensing Equipment.................................................................. 7
Detergent Control.......................................................................................... 8
Installation Checklist..................................................................................... 9
OPERATING INSTRUCTIONS
Preparing Dishes.......................................................................................... 10
Daily Machine Preparation........................................................................... 10
Washing a Rack of Ware............................................................................. 10
Daily Cleaning of Dishwasher...................................................................... 10
UNIT OPERATION
Cam Timer Operation................................................................................... 11
Cam Timer Detail.......................................................................................... 13
TROUBLESHOOTING SECTION............................................................................ 14
DRAWINGS
Dimensions.................................................................................................. 18
Main Assembly............................................................................................. 19
Control Panel Assembly............................................................................... 21
Electrical Panel Assembly............................................................................ 22
Kickplate Assembly...................................................................................... 23
Incoming Plumbing Assembly...................................................................... 24
Solenoid Valve, 1/2”, 110V........................................................................... 25
Vacuum Breaker Assembly.......................................................................... 26
Wash Arm Assembly.................................................................................... 27
Wash Manifold Assembly............................................................................. 28
Drain Plumbing Assembly............................................................................ 29
Drain Valve Assembly.................................................................................. 30
Wash Motor to Wash Tub Assembly............................................................ 32
Wash Motor Assembly................................................................................. 33
Door Assembly............................................................................................. 34
Miscellaneous Door Sub-Assemblies.......................................................... 35
Conserver 24 LTF Option Side Panels........................................................ 36
Miscellaneous Rinse Plumbing Parts.......................................................... 37
Rinse Assembly Hose/Strainer Weldment................................................... 38
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TABLE OF CONTENTS (CONTINUED)
Schematic.................................................................................................... 39
JACKSON MAINTENANCE & REPAIR CENTERS (USA)................................... 40
JACKSON MAINTENANCE & REPAIR CENTERS (CANADA) ............................. 47
IMPORTANT INFORMATION DATA SHEET......................................................... 48
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SPECIFICATIONS of CONSERVER 24LT
PERFORMANCE/CAPABILITIES
OPERATING CAPACITY (RACKS/HOUR)
RACKS PER HOUR 24 DISHES PER HOUR 600 GLASSES PER HOUR 600
OPERATING CYCLE (SECONDS)
WASH TIME 56 DRAIN TIME 29 RINSE TIME 35 TOTAL CYCLE TIME 120
TOTAL WATER CONSUMPTION
GALLONS PER HOUR (80% CAP.) 28.8 GALLONS PER RACK 1.2
ELECTRICAL REQUIREMENTS
WASH PUMP MOTOR HORSEPOWER 3/4
VOLTS PHASE AMPS
115 1 9.4
WATER REQUIREMENTS
INLET TEMPERATURE (RECOMMENDED) 140°F INLET TEMPERATURE (MINIMUM) 120°F GALLONS PER HOUR 28.8 WATER LINE SIZE I.P.S. (Minimum) 1/2” DRAIN LINE SIZE I.P.S. (Minimum) 1 3/8” FLOW PRESSURE P.S.I. (Optimum) 20 MINIMUM CHLORINE REQUIRED (PPM) 50
FRAME DIMENSIONS
TEMPERATURES
WASH---°F (MINIMUM) 120 WASH---°F (RECOMMENDED) 140 RINSE ---°F (MINIMUM) 120 RINSE---°F (RECOMMENDED) 140
WIDTH 24 1/4” DEPTH 22 5/8” HEIGHT 33 1/4”
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MINIMUM PARAMETERS (SEE NOTE #1)
DETAIL OF DATA PLATE
COMPANY LOGO
MODEL DESIGNATION (I.E. CONSERVER 24LT)
NSF LOGO (SEE NOTE #2)
COMPONENT
MANUFACTURER’S ADDRESS INFORMATION
UL LOGO (SEE NOTE #3)
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GENERAL
Before connecting, operating or adjusting this dishmachine, please read this manual carefully to familiarize yourself with your unit and its proper operation.
This manual contains important operating, safety and maintenance information on your dishma­chine. You must follow the instructions given in the manual to ensure that your warranty remains in effect.
Notes Concerning the Conserver 24LT/LTF Data Plates:
1) Minimum parameters must be met in order for this dishmachine to function at its intended level of operation and efficiency. Different machines from different manufacturers have different minimum requirements. Follow those details found on the data plate of your machine, do not use the parame­ters listed on the example for this manual. If you are unsure, contact your nearest authorized Jackson service representative. Failure to ensure that the machine meets the minimum parameters as expressed on its individual data plate may result in sub-standard performance.
2) The NSF logo on the data plate indicates that this machine has been inspected, reviewed, tested, and approved under the guidelines and regulations set forth by NSF International Inc., specifically Standard 3.
COMPONENT
3) This symbol indicates that this product is Listed by Underwriter’s Laboratories Inc. Representative samples of this product have been evaluated by UL and meet the
R
applicable U.S. safety standards.
The Conserver 24LT/LTF requires that a separate chemical feeder be connected to it to pro­vide the required sanitizer. This feeder needs to be able to provide 2.271 ml of a 10% Chlorine sanitizer for every machine cycle.
Chemical feeder dispensing tubes are fed into the Conserver 24LT through the white bulk ­head fitting in the back lower portion of the unit. If the bulkhead plug is missing or damaged, it may be ordered using part number 4730-609-05-00.
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INSTALLATION INSTRUCTIONS
NOTE: Before any connections are made, visually check the entire machine for any possible
shipping damage. If any damage is found, proceed to “CONCEALED DAMAGE OR MISSING PARTS”.
UNPACKING THE DISHWASHER
STEPS: 1. Remove all protective packing material from machine.
2. Place machine in its operating location and remove skid.
CAUTION: ENSURE WEIGHT OF MACHINE IS EVENLY DISTRIBUTED
WHEN REMOVING FROM SKID INTO POSITION.
3. Adjust all four (4) adjustable bullet (or flanged) feet so contact is made to floor.
For proper operation, the dishmachine should be leveled from side to side and from front to back. Using a level placed on the flat area at top of unit, adjust leveling feet up or down.
NOTE: The dishwasher must be positioned and leveled before making any connections to
the unit.
CONCEALED DAMAGE OR MISSING PARTS
IMPORTANT: FOR YOUR PROTECTION, PLEASE READ AND OBSERVE THE FOLLOWING: This dishwasher has been thoroughly inspected and carefully packed before leaving our ware-
house. Concealed loss or damage means loss or damage which does not become apparent until the dish-
washer has been unpacked. The contents may be damaged in transit due to rough handling even though the carton may not show external damage.
If it is found that the shipment has concealed damage, PLEASE DO NOT RETURN IT TO JACK ­SON, but notify the carrier (within 48 hours) asking them to send their agent to fill out an inspection report. Save the cartons so he may inspect them and be sure to note in the report any black marks, creases, tears, crushed corners or any other marks indicating rough handling. Also, notify the JACKSON dealer immediately.
If it is discovered that there are missing parts such as: strainers, spray assemblies, rinse assembly, owner’s manual or racks, please notify JACKSON immediately.
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PLUMBING
NOTE: ALL CONNECTIONS MUST COMPLY WITH ALL APPLICABLE LOCAL, STATE AND NATIONAL PLUMBING CODES.
The plumber is responsible for ensuring that the water line is THOROUGHLY FLUSHED BEFORE connecting it to any manual or solenoid valve. It is necessary to remove all foreign matter such as chips (resulting from cutting or threading pipes), pipe joint compound or, if soldered fittings are used, bits of solder or cuttings from the lines. This debris, if not removed, may lodge in the valves and render them inoperative.
Any valves fouled by foreign matter, and any expenses resulting from this fouling, are not the responsibility of the manufacturer.
DRAIN LINE CONNECTION
The drain for the Conserver 24LT/LTF dishmachine is a pumped discharge. This unit comes with a drain hose which should be connected to a system drain. It is recommended that the drain hose be used as opposed to hard or permanent drain piping.
Ensure that the drain connection has an airgap (indirect) to allow proper draining. The drain height should not exceed 24” above floor height. Ensure that this unit is installed in accordance with all applicable codes. 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” pipe size minimum) to the dishmachine line strainer using copper pipe. It is recommended that a water shut-off valve be installed in the water line between the main supply and machine to allow access for service. The water supply line is to be capable of 20 PSI “flow” pressure at a recommended temperature of 140°F (minimum of 120° F required).
In areas where the water pressure fluctuates or is greater than the recommended pressure a water pressure regulator valve must be installed. This item should be located before the “Y”-strainer and after the shut-off valve.
Do not confuse static pressure with flow pressure. Static pressure is the line pressure with no flow (all valves and services are closed). Flow pressure is the pressure in the fill line when the fill valve is open and the machine is in the fill cycle.
It is recommended a shock absorber (not supplied) be installed in the incoming water line. This prevents line hammer (hydraulic shock), induced by the solenoid valve as it operates, from causing damage to the equipment.
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ELECTRICAL
WARNING: Electrical and grounding connections must comply with applicable portions of the National Electrical Code ANSI / NFPA 70 (latest edition) and/or other electrical codes.
WARNING: Disconnect electrical power supply and place a tag or lock at the disconnect
ELECTRICAL POWER CONNECTION
This dishmachine comes with a standard 3 prong 120V outlet power cord attached. Prior to plug­ging the unit into the outlet, have an electrician verify that the incoming power is at the proper volt­age and to further verify L1 and N to ground individually to ensure neither is connected to a high or “wild” leg.
Prior to installation, verify that the electrical service agrees with the specifications on the machine data plate located on the right side and to the front of the machine. Refer to the data plate for machine operating requirements, machine voltage, total amperage load and serial number.
VOLTAGE CONNECTIONS
STEPS:
1. Place machine’s POWER SWITCH into the off position.
2. Apply power to the dishmachine.
3. Check incoming power at power block for proper voltage per the data plate.
4. Turn off power at service breaker. Mark breaker for dishmachine and advise the
proper personnel.
DO NOT APPLY POWER OR TURN MACHINE ON AT THIS TIME. ALL PLUMBING AND WATER CONNECTIONS MUST BE COMPLETED BEFORE MACHINE CAN BE OPERATED.
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CHEMICAL DISPENSING EQUIPMENT
The Conserver 24LT/LTF dishmachine is not supplied with integral chemical dispensing peri-pumps. Instead, an independent chemical dispensing system must be connected to the unit prior to use in order to achieve required cleanliness and sanitation. Please consult the literature that accompanied your independent chemical dispensing system for information concerning installation and operation of the dispenser.
The Conserver 24LT/LTF requires that a separate chemical feeder be connected to it to pro­vide the required sanitizer. This feeder needs to be able to provide 2.271 ml of a 10% Chlorine sanitizer for every machine cycle.
Chemical feeder dispensing tubes are fed into the Conserver 24LT through the white bulk ­head fitting in the back lower portion of the unit. If the bulkhead plug is missing or damaged, it may be ordered using part number 4730-609-05-00.
WARNING: CHLORINE-BASED SANITIZERS CAN BE DETRIMENTAL TO YOUR MACHINE IF THE CHEMICAL SOLUTION IS TOO STRONG. SEE YOUR CHEMICAL PROFESSIONAL TO ENSURE YOUR DISPENSER IS SET UP CORRECTLY.
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DETERGENT CONTROL
Using detergent in the proper amount can become, in time, a source of substantial savings. In some cases, controlling detergent use can depend on a number of variables in the warewashing cycle. Of course, a qualified water treatment specialist can tell you what is needed for maximum efficiency from your detergent, but you should know some basics so you’ll understand what he is talking about.
1. The amount of detergent needed is related in one way to water hardness. Water hardness is the amount of dissolved calcium and magnesium in the supply. The greater the amount of dis ­solved solids the harder the water. Hard water does not allow the detergent to act as it should in the washing cycle, and requires more detergent to do the job. Soft water actually enhances the effect of the detergent and you can use less to do the job and will also reduce or eliminate scaling, a major problem with hard water.
2. It is important to understand water hardness because of the problems it causes. You may, for instance, be adding drying agents to reduce water spotting, when the problem may be hard water. Minerals in hard water are left on glassware and dishes after water evaporates, which may be the cause of the water spots.
3. Remember, treated water may be an advantage for your warewashing system and a disadvantage in other areas. For instance, coffee made with soft water may have an acid or bitter flavor; so magnetically treat the water for your warewashing system to give better results and use less detergent.
4. Once your water problems are solved, make sure that your dishmachine operators keep the detergent dispenser full and in operating order at all times.
In addition to the points outlined, other factors about the detergent are important too. Certain menu items, for instance, call for an extra-powerful detergent. Extra-hard water may require a different type of detergent.
Also, remember that more detergent won’t do a better job of cleaning--in fact it may do worse. Too much soap can build up just like hard water scale, so always use the recommended amount.
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INSTALLATION CHECKLIST
AFTER INSTALLATION, CHECK OFF THE FOLLOWING ITEMS AS THEY ARE COMPLETED PRIOR TO PROCEEDING TO OPERATION OF DISHMACHINE.
Has dishmachine been checked for concealed damage? Has the dishmachine been properly ventilated? Has the dishmachine been properly leveled? Is the drain plumbing installed to applicable codes? Is the service voltage the same as noted on the data plate? Has the machine been properly grounded? Has the machine circuit breaker been sized correctly? Has the machine circuit breaker been marked for the dishwasher? Has the hot water supply been flushed for debris?
Is hot water supply at 12 0oF. minimum (140oF. recommended)? Is the hot water supply flow pressure 20 P.S.I.? Is a water pressure regulator needed? Is the hot water supply line 1/2 inch minimum? Have the chemical tubes been installed in the proper supply container ? Have the peri-pumps been primed ? Has the Sanitizing peri-pump been adjusted to inject 50 parts per million (ppm) chlorine solution into the final rinse line ?
PROCEED TO OPERATIONAL START-UP AND CHECK
9
OPERATING INSTRUCTIONS
PREPARING DISHES
Scrape dishes thoroughly. Pre-wash by soaking or spraying with a pre-rinse hose. Place dishes and cups in dish rack; cups upside down. Place glasses and flatware in combination glass/flatware rack; glasses - upside down. Scatter flatware loosely on bottom. Do not put glasses on top of flat­ware.
NOTE: Flatware may be washed upright in a special compartment flatware rack
for best results.
DAILY MACHINE PREPARATION
Open door and verify strainer is in wash tub sump. Check all levels in the chemical containers and replace with full containers if empty. Check that the wash arms are installed and securely tightened. For the initial fill, Close the door, place the Auto/Manual switch in the Auto position and turn the power switch to the ON position. The machine will automatically fill. Allow the cycle light to turn off. Open the door and check the water level. Close the door, the machine will now automatically run a warm up cycle.
NOTE: Never operate wash pump without water in sump or damage to the pump
may occur.
NOTE: The correct water level should be just below the strainer.
WASHING A RACK OF DISHES
Open the door and insert a rack of soiled dishes and shut the door. The cycle will then automatical­ly begin and cycle light will come on. When the cycle light goes out, open the doors and remove the rack of clean dishes. Place another rack of soiled dishes in the machine and repeat the process until all the dishware is clean.
NOTE: The unit should be drained after all dishes have been cleaned and before leaving it over­night.
DRAINING THE DISHWASHER
Open and close the door to start a cycle. Wait 5 seconds then turn the Power switch to the OFF/DRAIN position. The machine will run a wash cycle, drain and turn off.
DAILY CLEANING OF DISHWASHER
Clean any food debris out of the wash tub strainer and clean wash arms if necessary, then replace them into the machine. Wipe the machine down as necessary. DO NOT spray water into the machine, it will not drain without running another OFF/DRAIN cycle.
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CAM TIMER OPERATION
The Conserver 24LT/LTF cam timer is a 2 minute, 8 cam timer with an OFF-DRAIN function.
The following is a description of set points for each cam and function for each switch. CAM 1: Cam 1 is a cut cam with a single notch and serves as the Cycle/Reset. FUNCTION: When the machine is in the operation mode the notch is the home position. The
machine will set 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 back to the home position and hold.
CAM 2: Cam 2 is a cut cam and provides the off/drain function. FUNCTION: The function of the off/drain cam is controlled by the power switch. When the power
switch is in the ON position the off/drain function is disabled. To use the off/drain, start a cycle and place the power switch in the OFF position. The machine will run a wash cycle, drain and stop. The machine will hold this state of operation until the power switch is turned on, when turned on the machine will fill, run a rinse cycle and stop at the home position.
The off/drain cam works off the normally open contacts of cam 2. This requires the switch to be held closed by the cam. The off/drain cam switch will pick up just after the cycle cam switch and drop back down just after the wash cycle cam switch.
CAM 3: Cam 3 is a cut cam and controls the wash and rinse cycles. FUNCTION: The wash and rinse cam works off the normally open contacts of cam 3. This requires
the switch to be held closed by the cam. The wash/rinse cam switch will pick up just after the cycle cam switch and drop back down just before the off/drain cycle cam switch. Wash pump will run approximately 58 seconds. The machine will drain and fill. The rinse cycle will start after the fill, approximately at the 82 second mark and will last 35 seconds. The machine will then return to the home position.
NOTE: The last 5 cams are adjustable. The following instructions will require that the timer position have the cams to the front and the motor to the left. (See the attached drawing)
CAM 4: Cam 4 is an adjustable cam and controls the drain valve. FUNCTION: The drain 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 drain valve. The pumped drain and fill cams require adjustment due to varying water pressure. The drain must be adjusted to remove whatever water the fill brings into the machine.
11
CAM TIMER OPERATION (CONTINUED)
SETTINGS: The right side of cam 4 must be set to pick up the switch arm just before the wash cycle cam switch drops. If the drain valve does not close first, the water in the drain hose will back up into the pump housing and wash tank.
Any adjustment made to the drain should be made with the left side of cam 4. The adjustment must be moved back into the wash time until all water is drained from thewash tank.
CAM 5: Cam 5 is an adjustable cam and controls the fill valve. FUNCTION: The fill valve cam works off the normally closed contacts of cam 5. This requires the
switch to be held open by the cam and allowed to drop into the notch to operate the fill valve. The pumped drain and fill cams require adjustment due to varying water pressure. Cam 5 must be adjusted to fill the wash tank to the proper operating water level. (Remember, the drain cycle must remove what the fill cycle brings in.)
SETTINGS: The left side of cam 5 must be set to drop in just past the stop point of the off/drain cam. There must be a dwell between the off/drain and the fill, so that the fill will not run while the machine is in the off state.
Any adjustment made to the fill should be made with the right side of cam 5. Proper water level will be achieved when the water touches the bottom of the strainer pan.
CAM 6: Cam 6 is an adjustable cam and controls the sanitizer pump. FUNCTION: The sanitizer pump cam works off the normally closed contacts of cam 6. This requires
the switch to be held open by the cam and allowed to drop into the notch to operate the pump. SETTINGS: The left side of cam 6 must be set to drop in just past the starting point of the fill cam.
The adjustment for sanitizer volume must be made with the right side of the cam. CAM 7: Cam 7 is an adjustable cam and controls the detergent pump. FUNCTION: The detergent pump cam works off the normally closed contacts of cam 7. This
requires the switch to be held open by the cam and allowed to drop into the notch to operate the pump.
SETTINGS: The left side of cam 7 must be set to drop in just past the starting point of the wash cam. The adjustment for detergent volume must be made with the right side of the cam.
CAM 8: Cam 8 is an adjustable cam and controls the rinse aid pump. FUNCTION: The rinse aid pump cam works off the normally closed contacts of cam 8. This requires
the switch to be held open by the cam and allowed to drop into the notch to operate the pump. SETTINGS: The left side of cam 8 must be set to drop in just past the starting point of the fill cam.
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