Jackson CONSERVER 24LTP Service Manual

Company

CHEMICAL SANITIZING UNDERCOUNTER DISHMACHINES

TECHNICAL MANUAL

INSTALLATION MANUAL FOR EXPORT UNITS

SERVICE MANUAL FOR DOMESTIC UNITS

FOR JACKSON MODELS:

CONSERVER 24LT

CONSERVER 24LTP

February 20, 2004 P/N 7610-002-10-45 (Revision D)

www.jacksonmsc.com

Section Description Page

I. General Section

Specifications 1 Installation Instructions 2 Detergent Control 4 Chemical Dispensing Equipment 5 Operating Instructions 6 Preventative Maintenance 7 Conserver 24LT Cam Timer Operation Instructions 8 Conserver 24LTP Cam Timer Operation Instructions 10

II. Troubleshooting Section 12

III. Dimensions 14

IV. Parts Section

Control Panel Assembly 15 Electrical Panel Assembly 16 Ordering Replacement Wire 17 Conduit & Fittings 18 Kickplate Assembly 19 Chemical Feeder Pump Mounting Assembly 20 Chemical Feeder Pump Assembly 21 Chemical Feeder Pump Wiring Assembly 22 Incoming Plumbing Assembly 23 Vacuum Breaker & Wash Arm Assemblies 24 1/2” Solenoid Valve & 1/2” NPT Vacuum Breaker Repair Parts Kits 25 Wash Manifold Assembly 26 Drain Plumbing Assembly 27 Drain Valve Assembly 28 Wash Motor to Wash Tub Assembly 29 Wash Motor Assembly 30 Door Assembly 31 Miscellaneous Door Sub-Assemblies 32 Miscellaneous Parts 33 Frame, Shroud & Panel Components 34

V. Electrical Diagrams

Conserver 24LT (115 volt, 60 Hz, single phase) 35 Conserver 24LTP (115 volt, 60 Hz, single phase) 36

VI. Important Information Data Sheet 37

SPECIFICATIONS

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

TEMPERATURES

WASH ---°F (MINIMUM) 120

WASH ---°F (RECOMMENDED) 140

RINSE ---°F (MINIMUM) 120

RINSE ---°F (RECOMMENDED) 140

ELECTRICAL REQUIREMENTS

WASH PUMP MOTOR HORSEPOWER 3/4

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

RINSE TYPICAL HEATER TOTAL ELECTRICAL

VOLTS PH HZ RATINGS AMPS CIRCUIT

115 1 60 N/A 10 15 AMP

WATER REQUIREMENTS

INLET TEMPERATURE (RECOMMENDED) 140°F

INLET TEMPERATURE (MINIMUM) 120°F

GALLONS PER HOUR 28.8

WATER LINE SIZE NPT (MINIMUM) 1/2”

DRAIN LINE SIZE NPT (MINIMUM) 1 3/8”

FLOW PRESSURE P.S.I. 20A5

MINIMUM CHLORINE REQUIRED (PPM) 50

FRAME DIMENSIONS

WIDTH 24 1/4”

DEPTH 22 5/8”

HEIGHT 33 1/4”

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

Jackson MSC Inc. provides technical support for all of the dishmachines detailed in this manual. We strongly recommend that you refer

refer you, if necessary, to the proper page. Technical support is available from 8:00 a.m. to 5:00 p.m. (EST), Monday through Friday.

Technical support is not available on holidays. Contact technical support toll free at 1-888-800-5672. Please remember that technical

Before installing the unit, check the container and machine for damage. A damaged container is an indicator

tainer. The dishmachine has been inspected and packed at the factory and is expected to arrive to you in new, undamaged condition.

However, rough handling by carriers or others may result in there being damage to the unit while in transit. If such a situation occurs,

to the unit and to complete an inspection report. You must contact the carrier within 48 hours of receiving the machine. Also, contact

All plumbing connections must comply with all applicable local, state, and national plumbing codes.

The plumber is responsible for ensuring that the incoming water line is thoroughly flushed prior to connecting it to any component of

The Conserver 24 series machines are a pumped (pressure) drain capable of pumping waste water

that a water shut-off valve be installed in the water line between the main supply and the machine to allow access for service. The water

It is also recommended that a shock absorber (not supplied with the Conserver 24 series models) 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.

Slowly turn on the water supply to the machine after the incoming fill line and the drain line have been installed.

INSTALLATION INSTRUCTIONS

to this manual before making a call to our technical support staff. Please have this manual with you when you call so that our staff can

support is available for service personnel only.

VISUAL INSPECTION:

that there may be some damage to the machine. If there is damage to both the container and machine, do not throw away the con

do not return the unit to Jackson; instead, contact the carrier and ask them to send a representative to the site to inspect the damage

the dealer through which you purchased the unit.

UNPACKING THE DISHMACHINE: Once the machine has been removed from the container, ensure that there are no missing parts from the machine. This may not be obvious at first. If it is discovered that an item is missing, contact Jackson immediately to have the missing item shipped to you.

LEVEL THE DISHMACHINE: The dishmachine is designed to operate while being level. This is important to prevent any damage to the machine during operation and to ensure the best results when washing ware. The unit comes with adjustable bullet feet, which can be turned using a pair of channel locks or by hand if the unit can be raised safely. Ensure that the unit is level from side to side and from front to back before making any connections.

PLUMBING THE DISHMACHINE:

the dishmachine. It is necessary to remove all foreign debris from the water line that may potentially get trapped in the valves or cause an obstruction. Any valves that are fouled as a result of foreign matter left in the water line, and any expenses resulting from this foul ing, are not the responsibility of the manufacturer.

CONNECTING THE DRAIN LINE:

to a height of 24 inches from the floor to the kitchen’s drain system. The dishmachines are supplied with a 10 foot long hose that extends from the rear side of the machine. There must also be an air gap between the machine drain line and the floor sink or drain. If a grease trap is required by code, it should have a flow capacity of 5 gallons per minute.

WATER SUPPLY CONNECTION: Ensure that you have read the section entitled “PLUMBING THE DISHMACHINE” above before pro ceeding. Install the water supply line (1/2” pipe size minimum) to the dishmachine line strainer using copper pipe. It is recommended

supply line is to be capable of 20 A5 PSI “flow” pressure at the recommended temperature indicated on the data plate.

Do to areas where the water pressure fluctuates or is greater than the recommended pressure, it is recommended installing supplied water pressure regulator. Do not confuse static pressure with flow pressure. Static pressure is the line pressure in a “no flow” condition (all valves and services are closed). Flow pressure is the pressure in the fill line when the fill valve is opened during the cycle.

PLUMBING CHECK:

Check for any leaks and repair as required. All leaks must be repaired prior to placing the machine in operation.

This equipment is not recommend for use with deionized water or other aggressive fluids. Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components. Use of deionized water or other

aggressive fluids will void the manufacturer's warranty.

Electrical and grounding connections must comply with the applicable portions of the National

To install the incoming power lines, remove the kick panel. This will require taking a phillips head screwdriver and removing the two (2)

1/4 turn screws at the bottom of the kickplate; open the door slightly while carefully lifting the kickplate up and out of the way. Install

being for the dishmachine. Advise all proper personnel of any problems and of the location of the service breaker. Replace the control

INSTALLATION INSTRUCTIONS (CONTINUED)

ELECTRICAL POWER CONNECTION:

Electrical Code ANSI/NFPA 70 (latest edition) and/or other electrical codes.

Disconnect electrical power supply and place a tag at the disconnect switch to indicate that you are working on the circuit.

The dishmachine data plate is located on the front of the machine. Refer to the data plate for machine operating requirements, machine voltage, total amperage load and serial number.

3/4” conduit into the pre-punched holes in the back of the control box. Route power wires and connect to power block and grounding lug. Install the service wires (L1 and L2) to the appropriate terminals as they are marked on the terminal block. Install the grounding wire into the lug provided. It is recommended that “DE-OX” or another similar anti-oxidation agent be used on all power connections.

VOLTAGE CHECK: Ensure that the power switch is in the OFF position and apply power to the dishmachine. Check the incoming power at the terminal block and ensure it corresponds to the voltage listed on the data plate. If not, contact a qualified service agency to examine the problem. Do not run the dishmachine if the voltage is too high or too low. Shut off the service breaker and mark it as

box cover and tighten down the screws.

The Conserver 24LT dishmachine is not supplied with integral chemical dispensing feeder pumps. Instead, an independent chemical

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

4. Detergent is dispensed as required during the wash cycle by the cam timer. The amount of detergent may need to be increased or

decreased depending on water quality and type of detergent. It is adjusted by changing Cam 7 on the cam timer. See the Conserver

5. Rinse additive is dispensed as required into the final rinse. The amount of rinse aid may need to be adjusted depending on water

the concentration and type of sanitizer used. It is adjusted by changing Cam 8 on the cam timer. See the Conserver 24LTP cam timer

CHEMICAL DISPENSING EQUIPMENT

dispensing system must

the dispenser.

The Conserver 24LT 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 bulkhead fitting in the back lower portion of the unit.

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.

TO PREPARE PUMPS FOR OPERATION

The Conserver 24LTP dishmachine is supplied with detergent, rinse additive and sanitizer dispensing feeder pumps. Locate the open ends of the chemical tubes with the tube stiffeners and place each one in the appropriate container.

A. Red Tubing = Detergent

B. Blue Tubing = Rinse Aid

C. White Tubing = Sanitizer

PRIMING CHEMICAL FEEDER PUMPS

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

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

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

2. Use the toggle switches on the right side of control box to prime each pump. There are two (2) switches mounted by the chemical feeder pumps. One will prime the sanitizer pump only, and the second will prime either the detergent or rinse aid pump, depending upon which way it is depressed.

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

24LTP cam timer operation instructions.

hardness and results. It can be changed by changing Cam 6 on the cam timer. See the Conserver 24LTP cam timer operation instruc tions.

6. Sanitizer (either chlorine or iodine) is dispensed into the final rinse. The amount of sanitizer may need to be adjusted depending on

operation instructions.

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

solved calcium and magnesium in the water supply. The more dissolved solids in the water, the greater the water hardness. Hard water

works against detergent, thereby causing the amount of detergent required for washing to increase. As you use more detergent, your

ing program for operators. Using too much detergent has as detrimental effects as using too little. The proper amount of detergent must

be made aware of this. Experience in using the dishmachine under a variety of conditions, along with good training in the operation of

ed on each unit details what the minimum temperatures must be for either the incoming water supply, the wash tank and the rinse tank,

There are several factors to consider when installing your dishmachine to ensure that you get the best possible results from it and that

DETERGENT CONTROL

Detergent usage and water hardness are two factors that contribute greatly to how efficiently your dishmachine will operate. Using detergent in the proper amount can become, in time, a source of substantial savings. A qualified water treatment specialist can tell you what is needed for maximum efficiency from your detergent, but you should still know some basics so you’ll understand what they are talking about.

First, you must understand that hard water greatly effects the performance of the dishmachine. Water hardness is the amount of dis

costs for operating the dishmachine will increase and the results will decrease. The solids in hard water also may build-up as a scale on wash and rinse heaters, decreasing their ability to heat water. Water temperature is important in removing soil and sanitizing dish es. If the water cannot get hot enough, your results may not be satisfactory. This is why Jackson recommends that if you have installed the machine in an area with hard water, that you also install some type of water treatment equipment to help remove the dissolved solids from the water before it gets to the dishmachine.

Second, hard water may have you adding drying agents to your operating cycle to prevent spotting, when the real problem is deposit ed solids on your ware. As the water evaporates off of the ware, the solids will be left behind to form the spotting and no amount of dry ing agent will prevent this. Again, using treated water will undoubtedly reduce the occurrences of this problem.

Third, treated water may not be suitable for use in other areas of your operation. For instance, coffee made with soft water may have an acid or bitter flavor. It may only be feasible to install a small treatment unit for the water going into the dishmachine itself. Discuss this option with your qualified water treatment specialist.

Even after the water hardness problems have been solved, there still must be proper training of dishmachine operators in how much detergent is to be used per cycle. Talk with your water treatment specialist and detergent vendor and come up with a complete train

be used for job. It is important to remember that certain menu items may require extra detergent by their nature and personnel need to

the machine, can go a long way in ensuring your dishmachine operates as efficiently as possible.

Certain dishmachine models require that chemicals be provided for proper operation and sanitization. Some models even require the installation of third-party chemical feeders to introduce those chemicals to the machine. Jackson does not recommend or endorse any brand name of chemicals or chemical dispensing equipment. Contact your local chemical distributor for questions concerning these subjects.

Some dishmachines come equipped with integral solid detergent dispensers. These dispensers are designed to accommodate deter gents in a certain sized container. If you have such a unit, remember to explain this to your chemical distributor upon first contacting them.

As explained before, water temperature is an important factor in ensuring that your dishmachine functions properly. The data plate locat

depending on what model of dishmachine you have installed. These temperatures may also be followed by temperatures that Jackson recommends to ensure the highest performance from you dishmachine. However, if the minimum requirements are not met, the chances are your dishes will not be clean or sanitized. Remember, a dish can look clean, but it may not be sanitized. Instruct your dish machine operators to observe the required temperatures and to report when they fall below the minimum allowed. A loss of tempera ture can indicate a much larger problem such as a failed heater or it could also indicate that the hot water heater for your operation is not up to capacity and a larger one may need to be installed.

it operates at peak efficiency for many years. Discuss your concerns with your local chemical distributor and water treatment special ist before there is a problem.

Hereafter, the water level is controlled by the timer that has been preset at the factory. Verify that there are no other leaks on the unit

The machine runs a complete cycle to drain and fill. If the machine is not allowed to drain, the water will build up inside the tub. After

water is out of the system and to verify that the unit is operating correctly. To cycle the machine, ensure that the power is on and that

water. If the nozzles appear to be clogged, use a toothpick to remove the obstruction. Wipe the inside of the unit out, removing all soil

OPERATION INSTRUCTIONS

PREPARATION: Before proceeding with the start-up of the unit, verify the following:

1. The strainer is in place and is clean.

2. That the wash arms are screwed securely into place and that their endcaps are tight. The wash arms should rotate freely.

3. Verify all chemical levels for machine chemical feeder pumps are correct.

POWER UP: To energize the unit, turn on the power at the service breaker. The voltage should have been previously verified as being correct. If not, the voltage will have to be verified.

FILLING THE WASH TUB: For the initial fill, close the door and ensure that the auto/manual switch is 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. For the initial fill, run the machine through 3 cycles to fill the tub sump. The machine will run a partial cycle and fill to the bottom of the pan strainer. Open the door and verify that the water level is correct.

before proceeding any further. The wash sump must be completely filled before operating the wash pump to prevent damage to the component. Once the wash tub is filled, the unit is ready for operation.

the initial fill, the rinse water for the current cycle will become the wash water for the next cycle.

WARE PREPARATION: Proper preparation of ware will help ensure good results and less re-washes. If not done properly, ware may not come out clean and the efficiency of the dishmachine will be reduced. It is important to remember that a dishmachine is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether of washing the ware. Scraps should be removed from ware prior to being loaded into a rack. Pre-rinsing and pre-soaking are good ideas, especially for silverware and casserole dishes. Place cups and glasses upside down in racks so that they do not hold water during the cycle. The dishmachine is meant not only to clean, but to sanitize as well, to destroy all of the bacteria that could be harmful to human beings. In order to do this, ware must be properly prepared prior to being placed in the machine.

DAILY MACHINE PREPARATION: Refer to the section entitled “PREPARATION” at the top of this page and follow the instructions there. Afterwards, check that all of the chemical levels are correct and/or that there is plenty of detergent available for the expected workload.

WARM-UP CYCLES: For a typical daily start-up, it is recommended to run the machine through 3 cycles to ensure that all of the cold

the tub has filled to the correct level.

WASHING A RACK OF WARE: To wash a rack, open the door completely and slide the rack into the unit. Close 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. Replace with a rack of soiled ware and close the door. The process will then repeat itself.

OPERATIONAL INSPECTION: Based upon usage, the pan strainer may become clogged with soil and debris as the workday pro gresses. Operators should regularly inspect the pan strainer to ensure it has not become clogged. If the strainer does, it will reduce the washing capability of the machine. Instruct operators to clean out the pan strainer at regular intervals or as required by work load.

SHUTDOWN AND CLEANING:At the end of the workday, close the door. Start a cycle. Wait approximately five seconds and then place the power switch to the “OFF/DRAIN” position. The machine will run a wash cycle, drain and turn off. DO NOT spray water into the machine, it will not drain without running another drain cycle. Once the wash tub is drained, remove the pan strainer. Remove soil and debris from the strainer and set to the side. Unscrew the wash arms from their manifolds. Remove the endcaps and flush the arms with

and scraps. Reassemble the wash arms and replace them in the unit. The arms only need to be hand tight, do not use tools to tighten them down. Reinstall the strainer and close the door.

switch. Wash pump will run approximately 58 seconds. The machine will drain and fill. The rinse cycle will start after the fill,

and allowed to drop into the notch to operate the drain valve. The pumped drain and fill cams require adjustment due to varying water

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

CONSERVER 24LT CAM TIMER OPERATION INSTRUCTIONS

The Conserver 24LT 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

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

pressure. The drain must be adjusted to remove whatever water the fill brings into the machine.

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 the wash 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

remove what the fill cycle brings in.)

CONSERVER 24LT CAM TIMER OPERATION INSTRUCTIONS (CONTINUED)

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 touch es 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 vol ume 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.

switch. Wash pump will run approximately 58 seconds. The machine will drain and fill. The rinse cycle will start after the fill,

and allowed to drop into the notch to operate the drain valve. The pumped drain and fill cams require adjustment due to varying water

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

CONSERVER 24LTP CAM TIMER OPERATION INSTRUCTIONS

The Conserver 24LTP 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.