Jackson DELTA 5 D User Manual

INSTALLATION/OPERATION & TECHNICAL
MANUAL
FOR JACKSON MODELS:
Delta 5
Delta 5 D
Jackson MSC LLC.
P.O. BOX 1060
HWY. 25E
PHONE (606) 523-9795
FAX (606) 523-9196
www.jacksonmsc.com
CHEMICAL SANITIZING DISHMACHINE
October 4, 2007 P/N 7610-003-37-08
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 EVENTT O 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, during 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 unau­thorized persons, improper installation, if serial number has been removed or altered, or if unit is used for purpose other than it was origi­nally intended.
TRAVELLIMITATIONS 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, INCLUDING
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, THATARE 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 cleaning or deliming of the unit or any component such as, but not limited to, wash arms, rinse arms or strain-
ers at anytime. Nor does it cover adjustments such as, but not limited to timer cams, thermostats or doors, beyond 30 days from the date of installation. In addition, the warranty will only cover the replacement of wear items such as curtains, drain balls, door guides or gaskets during the first 30 days after installation. Also, not covered are conditions caused by the use of incorrect (non-Commercial) grade detergents, incorrect water temperature or pressure, or hard water conditions.
MANUFACTURERS WARRANTY
ONE YEAR LIMITED PARTS & LABOR WARRANTY
STOP! PARE!
ARRET!
CALL 1-888-800-5672 TO REGISTER THIS PRODUCT!
FAILURE TO DO SO WILL VOID THE WARRANTY!
LLAME AL 1-888-800-5672 PARA REGISTRAR ESTE PRODUCTO!
AL NO HACERLO LA GARANTIA SERA ANULADA!
S.V.P. APPELER 1-888-800-5672 POUR ENREGISTRER CE PRODUIT,
LA GARANTIE SERA ANNULEE POUR TOUT PRODUIT NON- ENREGISTREE
REVISION/
PAGE
REVISION
DATE
MADEBYAPPLICABLE
ECN
DETAILS
A 05-25-2007 MAW N/A Release to production.
24 10-04-2007 MAW 7934 Changed cover on power junction box.
i
ii
NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL
Delta 5
Delta 5 - Low temperature, chemically sanitizing, with a booster tank. Detergent, rinse aid & sanitizer
chemical feeder pumps
Delta 5 D - Dual door. Low temperature, chemically sanitizing, with a booster tank. detergent, rinse
aid & sanitizer chemmical feeder pumps
Model:
Serial No.:
Installation Date:
Service Rep. Name:
Phone No.:
Jackson MSC LLC. provides technical support for all of the dishmachines detailed in this manual. We strongly recommend that you refer 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 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 support is available for service personnel only.
SECTION
DESCRIPTION PAGE
I. SPECIFICATION INFORMATION
Specifications 2 Dimensions 3
II. INSTALLATION/OPERATION INSTRUCTIONS
Installation Instructions 5 Electrical Installation Instructions 6 Operation Instructions 7 Chemical Dispensing Equipment 9 Universal Timer Operation 10 Detergent Control 11
III. PREVENTATIVE MAINTENANCE 13
IV. TROUBLESHOOTING SECTION
Common Problems 16
V. PARTS SECTION
Chemical Feeder Pump Assembly 18 Solenoid Valve Repair Parts 19 Control Box Assembly 22 Peripump Box Assembly 23 Electrical Connection Box Assembly 24 Frame Assembly 25 Hood Assembly 26 Switch Panel Assembly 27 Tub Assembly 29 Frame & Motor Assembly 31 Pump and Motor Assembly 32 Booster Tank Assembly 33 Incoming Plumbing Assembly 34 Door Components 35 Front Panel Assembly 36
VI. ELECTRICAL SCHEMATICS
Delta 5 (115 Volt, 60 Hz, Single Phase) 38
VII. JACKSON MAINTENANCE & REPAIR CENTERS 40
TABLE OF CONTENTS
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1
SECTION 1:
SPECIFICATION INFORMATION
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 1: SPECIFICATION INFORMATION
SPECIFICATIONS OF THE DELTA 5
2
OPERATING CAPACITY ( NSF RATED):
RACKS PER HOUR 29 DISHES PER HOUR 725 GLASSES PER HOUR 725
OPERATING CYCLES (SECONDS):
NORMAL
CYCLE:
WASH TIME 45 RINSE TIME 25 TOTAL CYCLE TIME 90
WASH TANK CAPACITY (GALLONS): 1.2
WASH PUMP CAPACITY (GPM): 61
OPERATING TEMPERATURES:
WASH (MINIMUM) (48.9°C) 120°F WASH (RECOMMENDED) (60.0°C) 140°F RINSE (MINIMUM) (48.9°C) 120°F RINSE (RECOMMENDED) (60.0°C) 140°F
WATER REQUIREMENTS:
WATER LINE SIZE NPT 1/2” DRAIN LINE SIZE NPT 2” FLOW PRESSURE 20 ±5 PSI
MINIMUM CHLORINE REQUIRED (PPM): 50
ELECTRICAL REQUIREMENTS:
WASH PUMP MOTOR HP 3/4
RINSE TYPICAL HEATER TOTAL ELECTRICAL
VOL
TS PH HZ RATINGS AMPS CIRCUIT
115 1 60 2KW@110V *16 A 20 AMP
* This dishmachine is designed so that the wash motor is never running when the wash heater is on. Service load is based upon the higher of the two amperages.
NOTE: Typical Electrical Circuit is based upon (1) 125% of the full amperage load of the machine and (2) typical fixed-trip circuit breaker sizes as listed in the NEC 2002 Edition. Local codes may require more stringent protection than what is displayed here. Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes. These numbers are provided in this manual simply for reference and may change without notice at any given time.
FRAME DIMENSIONS:
WIDTH (622.3mm) 24 1/2” DEPTH (641.35mm) 25 1/4” DEPTH, WITH FRONT DOOR OPEN (933.45mm) 36 3/4” HEIGHT (990.6mm) 39” MAXIMUM WASH CHAMBER CLEARANCE (292.1mm) 11 1/2”
FRAME DIMENSION (DOUBLE DOOR): WIDTH (622.3MM) 24 1/2” DEPTH (714.375MM) 28 1/8” DEPTH, WITH DOOR OPEN (1311.275MM) 51 5/8” HEIGHT (990.6MM) 39” CHAMBER CLEARANCE (292.1MM) 11 1/2”
NOTE: Always refer to the machine data plate for specific electrical and water requirements. The material provided on this page is for reference only and may be subject to change without notice.
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 1: SPECIFICATION INFORMATION
DIMENSIONS
3
21 1/4
(540 mm)
17
(432 mm)
20
(508 mm)
C
A
21 1/4
(540 mm)
B
7 3/4
(197 mm)
39
(991 mm)
6 3/4 (171 mm)
6 (152 mm)
12 1/4
(311 mm)
36 3/4
(933 mm)
24 1/2
(622 mm)
25 1/4
(642 mm)
C
A
B
3 (76 mm)
A - Incoming Water Connection B - Drain Connection - 2" IPS C - Electrical Connection Point NOTE: All vertical dimensions are
at lowest point due to adjustable bullet feet and may be raised an additional 2 3/4".
11 1/2
(292 mm)
DISH
CLEARANCE
4
SECTION 2: INSTALLATION/OPERATION
INSTRUCTIONS
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS
5
VISUAL INSPECTION: Before installing the unit, check the container and the machine for any damage. Adamaged container could be an indication of damage to the unit. If there is damage to both the container and the unit, DO NOT throw away the container. The dishmachine has been inspected and packed at the factory with the expectation that it will arrive to you in new, undamaged condition. However, rough handling by carriers or others may damage the unit while in transit. If this situation does occur, do not return the unit to Ecolab; instead contact the carrier and ask them to inspect the damage to the unit and to com­plete an inspection report. You must contact the carrier within 48 hours of receiving the machine. Also, cont act your Ecolab rep­resentative.
UNPACKING THE DISHMACHINE: Remove the machine from the container and inspect for any missing parts. If an item appears to be missing, contact your Ecolab representative immediately to report it.
LEVEL THE DISHMACHINE: The dishmachine(s) covered in this manual are designed to operate on a level surface. Ensure that the machine is level from side to side and from front to back; adjust the unit’s bullet feet as required. Failure to level the dishmachine may cause decreased washing perfor­mance.
PLUMBING THE DISHMACHINE: All plumbing connections must comply with all applicable local, state and national plumbing codes. The plumber is responsible for flushing the incoming water line prior to connecting it to remove all foreign debris that may get trapped in the valves or cause an obstruction. Any valves that are fouled by matter left in the water line and the expens­es resulting are not the responsibility of the manufacturer.
CONNECTING THE DRAIN LINE: The Omega 5 drain requires a minimum 2” NPT piping that is pitched at least 1/4” per foot. There must also be an air gap between the machine drain line and the floor sink or drain. If a grease trap is required by code, it should have a flow capacity of 5 gallons per minute.
WATER SUPPLY CONNECTION: Install the water supply line (1/2” NPT minimum) to the dishmachine line y-strainer using copper pipe. It is recommended that a water shut-off valve be installed between the main supply and the machine to allow for service. The water supply line must be capable of 20 ±5 PSI “flow” pressure at the recommended temperature as indicated on the data plate.
In areas where the water pressure fluctuates or is greater than the recommended pressure, it is sug­gested that a water pressure regulator be installed. The Omega 5 does not come with a water pressure regulator as standard equipment.
It is also recommended that a shock absorber (not supplied with the Omega 5) be installed in the incom­ing water line. This prevents line hammer (hydraulic shock), induced by the solenoid valve, which can cause damage to the equipment.
PLUMBING CHECK: Slowly turn on the water supply to the machine after connecting the incoming fill line and drain line. Check for leaks and repair as required. Leaks must be repaired prior to placing the machine in operation.
Frame with Adjustable Foot
Drain Connection
Y-Strainer
Raise
Lower
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
ELECTRICAL INSTALLATION INSTRUCTIONS
6
ELECTRICAL POWER CONNECTION: Electrical and grounding connections must comply with all applicable portions of the National Electric Code (ANSI/NFPA 70) and/or other electrical codes that may apply.
Disconnect the electrical power supply and lockout the disconnect switch to indicate that you are working on the circuit. The dishmachine data plate is located on the left front corner of the machine. Refer to this data plate for information concern-
ing the unit’s specific electrical requirements. To install the incoming power lines, open the connection box by removing the con-
nection box lid. Install 1/2” conduit into the pre-punched holes in the back of the con­nection box. Route the power wires and connect to the power block and grounding lug. Install the service wires (L1 and N) to the appropriate terminals as they are marked on the terminal block. Install the grounding wire into the lug provided. Wires should be firmly secured in place.
It is recommended that “De-Ox” or another similar anti-oxidation agent be used on all voltage connections.
VOLTAGE CHECK: Ensure that the machine is off and apply power to the machine. Check the incoming power at the terminal block and ensure it corresponds to the voltage on the machine data plate. Do not run the dishmachine if the voltage is too high or too low. Shut off the service breaker and mark it as being for the dishma­chine. Advise all personnel of the location of the service breaker. Replace all covers and tighten the screws.
NOTE: Always refer to the machine data plate for specific electrical and water requirements. The material provided on this page is for reference only and may be subject to change without notice.
Ground Lug
Power Block
OPERATIONAL START-UP AND CHECK: Before proceeding with the start-up, verify the following:
1. Open the door and verify that the sump strainer is correctly installed in the sump.
2. Verify that the drain stopper is in position.
3. Check that the plugs are securely screwed into the ends of the wash arm.
4. Check that the wash arm is securely screwed into the stationary base and that it rotates freely.
5. Check the levels in all chemical containers and replace if necessary.
INSTALLATION/INITIAL START-UP PROCEDURE:
1. Turn on dishmachine a) Turn on the incoming power to the machine at the circuit disconnect box. b) Turn on the dishmachine by pressing the ON/OFF button. The red light will come on. c) Check voltage at incoming terminals L1& L2. The voltage measured at these points should match data plate voltage. d) If voltages are in required range, close the control box cover.
2. Fill Rinse Booster Heater with Water
a) Before the heater element can be energized, the rinse booster heater must be initially filled with water. Damage to the heater
element will occur if the element is not submerged in water. To initially fill the booster heater with water:
i) Press and hold the FILL button to turn on the incoming water solenoid valve. Continue holding the button until you hear water
entering the wash chamber through the airgap, then release the button. The rinse booster heater is now filled with water.
ii) Turn off the unit by pressing the on/off switch.
3. Enable Heater Element
a) For the initial start-up only, the heater element must be enabled. The machine is shipped from the factory with the heater ele­ment disabled. This is done to ensure that the heater element is not damaged by energizing the element without the element being submerged in water. To enable the heater element:
i) Remove the booster heater cover panel. ii) Connect the tagged white/blue wires. iii) Replace heater cover. iv) Press the on/off switch, heaters will energize to maintain booster heater temperature.
Note: Water must be in the sump while the machine is running to avoid running the pump dry and causing damage to the pump seal.
4. Adjust dishmachine fill level. If the water level is not between the linses on the drain standpipe, it will require adjustment. Check to ensure that the recommended
water pressure is being supplied to the machine (20 ±5 PSI is required). If the water pressure is correct then the electronic timer will need adjustment. Use the following steps to adjust the fill time. A. Open control box cover. B. Adjust fill time as per instructions on [aseio of this section. C.Open and close the door to run a cycle, then check the water level. Adjust as necessary then close the control box cover.
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
OPERATION INSTRUCTIONS
7
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
OPERATION INSTRUCTIONS (CONTINUED)
8
NOTE: The machine must run a complete cycle to drain and fill. If the machine is not allowed to drain, the water will build up inside the tub. After the initial fill, the rinse water for the current cycle will become the wash water for the next cycle.
The dishmachine is now ready to proceed with the washing of dishes. WARNING: Certain materials, including silver, silver plate, aluminum and pewter, are attacked by sodium hypochlorite sanitizers
(bleach). PREPARING DISHES: Preparation of the ware will help ensure good results and less re-washes. If not done properly the dishes will
not be clean and will reduce the efficiency of the dishmachine. The following steps should be followed to ensure good results: A. Remove all scraps and gross soil into a garbage can.
B. Separate and pre-soak silverware. C. Separate and pre-soak the egg and casserole dishes. D. Scrape all ware with a brush or spatula. E. Flush cups, bowls and glasses with running water. F. Prewash dishware by soaking or spraying with a pre-rinse hose. G. Place dishes and cups in dish rack. Cups should be upside down (so they don’t hold water). H. Place glasses and flatware in their respective racks. Scatter flatware loosely in rack. Glasses should be placed upside down in a properly sized rack. For optimal results, flatware should be washed twice, the first being horizontal, the second in a special rack to hold flatware vertical.
DAILY MACHINE PREPARATION: Before proceeding with start-up, verify the following: A. Open door and verify that the sump strainer is in place in the sump.
B. Verify that the drain stopper is in position. C. Check that the plugs are securely screwed into the ends of all wash arms. D. Check that the wash arms are securely screwed into the stationary bases and rotate freely. E. Check levels in all chemical containers and replace if empty. F. For initial fill, close doors then depress the “FILL” switch to the “FILL” position.
WASHING A RACK OF WARE:
A. Open doors, place a full rack into the machine, and close doors. Push the start switch and hold until unit starts (about 2 seconds). B. After cycle is completed open doors and remove rack. C. Repeat steps Aand B.
SHUT DOWN AND CLEANING:
A. At the end of mealtime, move the “ON/OFF” switch to the “OFF” position. B. Open doors and manually remove drain stopper to drain the unit. C. Remove and clean upper and lower wash arms. D. Remove and clean the sump strainer.
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.
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.
T
O PREPARE CHEMICAL
FEEDER PUMPS FOR OPERATION
The Delta 5 dismachines are supplied with detergent, rinse additive and sanitizer dispensing chemical feeder pumps. Locate the open ends of the chemical tubes with the tube stiffeners and place each one in the appropriate container.
A. Red Tubing = Detergent B. Blue Tubing = Rinse Aid C. White Tubing = Sanitizer
PRIMING 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 con centration 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 prime switches located on the control panel at the bottom of the unit to prime each pump. The switches are clear­ly marked as to what chemical feeder pump they are assigned to.
3. To prime the pumps, hold the switch in the momentary position until chemical can be observed entering the sump.
4. Detergent is dispensed as required during the wash cycle by the universal timer. The amount of detergent may need to be increased or decreased depending on water quality and type of detergent.
5. Rinse additive is dispensed as required into the final rinse. The amount of rinse aid may need to be adjusted depending on water hardness and results.
6. Sanitizer (either chlorine or iodine) is dispensed into the final rinse. The amount of sanitizer may need to be adjusted depending on the concentration and type of sanitizer used.
7. Please refer to the next page for instruction on adjusting the chemical feeder pumps on the universal timer.
WARNING: Some of the chemicals used in dishwashing may cause chemical burns if they come in contact with your skin. Wear protective gear when handling these chemicals. If you do come in contact with these chemicals, immediately flush the affected area with fresh water.
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
9
CHEMICAL DISPENSING EQUIPMENT
Delta 5 Installation & Operation Manual 7610-003-37-08
Issued: 05-25-2007 Revised: N/A
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS
10
To access the programming mode, the machine must be ON, and idle (between cycles). On the timer board, press and hold both the MOVE and ENTER buttons on the timer board simultaneously for two seconds. The PROGRAM light will illumniate. Once in the programming mode, the MOVE button is used to scroll between the programming categories and the ENTER but-
ton is used to select the category. Press the MOVE button to move the blinking light between FILL, RINSE AID, DETERGENT or SANITIZER. Press the ENTER button for the chosen category. The PROGRAM light will illuminate. To change the value of a parameter, use the MOVE button to illuminate the light next to the time option (time is in seconds). In
the time categories, each second in use will light up. To deselect the option, press ENTER and the light will go off, press ENTER again and it will illuminate. Once you have set your time category, press the MOVE button to the ACCEPT option and press ENTER. This will save the changed parameters.
Once you press the ENTER button when the ACCEPT option is illuminated, you will exit the programming mode. To change any other values, you will have to return to the programming mode. To revert back to a previous setting, you must return to that option and change the parameter back to the previous setting.
Once in the programming mode, if there have been no keypad inputs for approximately 2 minutes, the system will automati­cally exit out of the programming mode. Any changes to parameters will be saved when the programming mode is automati­cally exited.
The wash and drain settings are not adjustable. All time adjustments are in seconds. Refer to the chart below for the adjustable outputs.
PROGRAMMING INSTRUCTIONS FOR CHEMICAL FEEDER PUMPS (FOR INSTALLATION TECHNICIAN ONLY)
Rinse Aid
Fill
Sanitizer
Detergent
Timer Programming Board
Time in Seconds
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