Jackson / Dalton Dishwasher AJ-54CE-208/230 Service Manual

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AJ-54 SERIES RACK CONVEYOR DISHMACHINES

(ELECTRICALLY HEATED)

MODELS COVERED IN THIS MANUAL:

AJ-54CE AJ-76CE

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AJ-90CE

February 16, 2001 P/N 7610-002-30-90 (Revision A)

www.jacksonmsc.com

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 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.

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, 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, 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 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.

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

I. GENERAL SECTION

Nomenclature 1 Specifications 2 Data Plate Details 3 General Notes Section 4

II. INSTALLATION & OPERATION SECTION

Installation Instructions 5 Detergent Control 7 Installation Checklist 8 Operation Instructions 9

III. DIMENSIONS

AJ-54 (Left to Right) Dimensions 10 AJ-76 (Left to Right) Dimensions 11 AJ-76 (Right to Left) Dimensions 12 AJ-90 (Left to Right) Dimensions 13 AJ-90 (Right to Left) Dimensions 14

IV. ELECTRICAL DIAGRAMS

AJ-54CE (208-230V/60 Hz/1 Phase) Schematic 15 AJ-54CE (208-230V/60 Hz/3 Phase) Schematic 16 AJ-44CE (460V/60 Hz/3 Phase) Schematic 17 AJ-76CE - AJ-90CE (208-230V/60 Hz/1 Phase) Schematic 18 AJ-76CE - AJ-90CE (208-230V/60 Hz/3 Phase) Schematic 19 AJ-76CE - AJ-90CE/CEL (480V/60 Hz/3 Phase) Schematic 20

V. JACKSON MAINTENANCE & REPAIR CENTERS 21 VI. IMPORTANT INFORMATION DATA SHEET 28

NOMENCLATURE

This service manual covers three separate models of the AJ line of Jackson rack conveyor dishmachines. A brief description of these models is included here for your reference.

The AJ-54CE is a hot water sanitizing dishmachine. This model employs incoming water at a temperature of 180 individual machine data plate for incoming water temperature requirements. The water for the rinse is heated prior to being introduced to the machine. The wash tank temperature is maintained through the use of an internal wash tank heater. The AJ-54CE, as stated above, is a hot water sanitizing machine, in that it uses heat, rather than chemicals, to clean and sanitize ware. The AJ-54CE still requires a separate detergent hookup in order to function correctly.

The AJ-76CE is a hot water sanitizing dishmachine. This model employs incoming water at a temperature of 180 individual machine data plate for incoming water temperature requirements. This model employs a 22” prewash section to aid in the removal of soil from ware. The water for the rinse is heated prior to being introduced to the machine. The wash tank temperature is maintained through the use of an internal wash tank heater. The AJ-76CE, as stated above, is a hot water sanitizing machine, in that it uses heat, rather than chemicals, to clean and sanitize ware. The AJ-76CE still requires a separate detergent dispenser in order to function correctly.

The AJ-90CE is a hot water sanitizing dishmachine. This model employs incoming water at a temperature of 180 individual machine data plate for incoming water temperature requirements. This model employs a 36” prewash section to aid in the removal of soil from ware. The water for the rinse is heated prior to being introduced to the machine. The wash tank temperature is maintained through the use of an internal wash tank heater. The AJ-90CE, as stated above, is a hot water sanitizing machine, in that it uses heat, rather than chemicals, to clean and sanitize ware. The AJ-90CE still requires a separate detergent dispenser in order to function correctly.

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SPECIFICATIONS

DATA PLATE DETAILS

MANUFACTURER’S LOGO

MODEL: SERIAL #

60 HZ 1 PHASE 2 WIRE

208 V 230 V

2.0 HPWASH MOTOR 8.5 A .25 HPDRIVE MOTOR 1.8 A .25 HP 1.8 A 20 KWWASH HEATER LOAD 96.0 A 20 KW 87.0 A

TOTAL AMP LOAD 106.3 A 97.3 A

CONVEYOR SPEED FPM8.0

WASH TANK TEMPERATURE 160° F MIN. FINAL RINSE TEMPERATURE 180° F MIN. INLET WATER REQUIRED

OPTIMUM FLOW PRESSURE 20 PSI

2.0 HP 8.5 A

5.83 GPM

MODEL DESIGNATION (I.E. “AJ-54CE”)

AMPERAGE LOAD INFORMATION

MINIMUM PARAMETERS (SEE NOTE 1)

MANUFACTURERS ADDRESS INFORMATION

NSF LOGO (SEE NOTE 2)

UL LOGO (SEE NOTE 3)

GENERAL NOTES SECTION

Before connecting, operating, or adjusting any of the dishmachines covered in this manual, please carefully read through the entire manual to familiarize yourself with the machine and its proper operation. This manual contains important operating, safety, and maintenance information concerning your dishmachine. You must follow the instructions and guidelines provided in this manual to ensure that your warranty remains in effect.

FOR SERVICE PERSONNEL: Jackson MSC Inc. 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 avaliable 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. Non-service personnel should refer to the list of provided service agencies in this manual for local service support.

NOTES CONCERNING THE AJ-54 SERIES DATA PLATES: NOTE 1: This area of the data plate denotes the minimum parameters that must be met in order for your dishmachine to operate at the

designed level of efficiency. Not meeting the required parameters can result in substandard performance of the dishmachine. Do not refer to the data plate example in this manual for the parameters of your machine; instead, refer to the data plate affixed to the machine. Not every machine operates the same way. If you are unsure of whether or not you are meeting the required minimum parameters, contact your nearest Jackson authorized service agency.

NOTE 2: The NSF logo on the data plate indicates that this machine has been approved to be listed under NSF Standard 3 by NSF International Inc. All of Jackson MSC’s Standard 3 approved dishmachines are listed on the NSF website at www.nsf.org. For more information concerning the NSF mark, their testing procedures, or NSF standards, you may visit their website or write to: NSF International Inc., 789 Dixboro Road, Ann Arbor, MI., 48105.

NOTE 3: The UL logo on the data plate indicates that this machine is Listed by Underwriters Laboratories Inc. Representative samples of this product have been evaluated by UL and meet applicable U.S. and Canadian safety standards and requirements. Dishmachines are evaluated under UL Standard 921. For more information, you may visit UL on the internet at www.ul.com, or you may write to: Underwriters Laboratories Inc., 333 Pfingsten Road, Northbrook, IL., 60062.

INSTALLATION INSTRUCTIONS

VISUAL INSPECTION: Before installing the unit, check the container and machine for damage. A damaged container is an indicator that there may be some damage to the machine. If there is damage to both the container and machine, do not throw away the container. 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, 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 to the unit and to complete an inspection report.. You must contact the carrier within 48 hours of receiving the machine. Also, contact 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: 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 throroughly flushed prior to connecting it to any component of 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 fouling, are not the responsibility of the manufacturer.

CONNECTING THE DRAIN LINE: The drain for the models covered in this manual are gravity disharge drains. All piping from the 1-1/2” MNPT connection on the waste accumulator must be pitched (1/4” per foot) to the floor or sink drain. All piping from the machine to the drain must be a minimum 1-1/2” I.P.S. and shall not be reduced. 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 30 gallons per minute.

WATER SUPPLY CONNECTION: Ensure that you have read the section entitled “PLUMBING THE DISHMACHINE” above before proceding. Install the water supply line (3/4” 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 the machine to allow access for service. The water supply line is to be capable of 20 PSI “flow” pressure at the recommended temperature indicated on the data plate.

ulator be installed. The models covered in this manual do not come with water pressure regulators as standard equipment. Please notify Jackson immediately if this component is not present on your machine.

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.

It is also recommended that 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.

PLUMBING CHECK: Slowly turn on the water supply to the machine after the incoming fill line and the drain line have been installed. Check for any leaks and repair as required. All leaks must be repaired prior to placing the machine in operation.

ELECTRICAL POWER CONNECTION: Electrical and grounding connections must comply with the applicable portions of the National 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 right side and to the front of the machine. Refer to the data plate for machine operat ing requirements, machine voltage, total amperage load and serial number.

To install the incoming power lines, open the control box. Install 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, L2, and L3 (3 phase only)) to the appropriate terminals as they are marked on the terminal block. Install the grounding wire into the lug provided. Tighten the connections. It is recommended that “DE-OX” or another similar antioxidation 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 volt age 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 being for the dishmachine. Advise all proper personnel of any problems and of the location of the service breaker. Replace the control box cover and tighten down the screws.

VENTILATION OF DISHMACHINE: The dishmachine should be located with provisions for venting into an adequate exhaust hood or ventilation system. This is essential to permit efficient removal of the condensation exhaust. Ensure that the exhaust system is acceptable in accordance with all applicable codes and standards.

In areas where the water pressure fluctuates or is greater than the recommended pressure, it is suggested that a water pressure reg

INSTALLATION INSTRUCTIONS (CONTINUED)

NOTE: Damage caused by steam or moisture due to improp er ventilation is NOT covered under the warranty.

This units covered in this manual have the following exhaust requirements:

Load End: 200 CFM Unload End: 400 CFM

The exhaust system must be sized to handle this volume for the dishmachine to operate as it was designed to.

ELECTRIC HEAT: The thermostats for the machines covered in this manual are factory set. They should not be adjusted except by an authorized service agent.

Detergent may be introduced into the unit through the removal of the bulkhead plug in the rear of the tub and replacing it with the third party detergent injection fitting. Remove the bulkhead plug in the side of the tub to install the detergent concentration probe.

For more information concerning detergent concerns, please refer to the page entitled “Detergent Control”.

The 1/8” brass plugs on the incoming plumbing rinse injector may be removed to install sanitizer and rinse aid injection fittings.

machine is not delimed, run another time cycle as per the deliming solution’s instructions.

7. When clean, drain and re-fill the machine.

8. Run in MANUAL for 10 minutes to remove residual deliming solution.

9. Drain and re-fill the machine.

All wires for the chemical injectors should be routed through the back of the control box.

Terminals in the control box marked “CVS” provide a constant voltage signal whenever the drive motor is operating.

Terminals in the control box marked “DET” provide a voltage signal whenever the wash motor is operating.

DELIMING OPERATIONS: In order to maintain the dishmachine at its optimum performance level, it will be required to remove lime and corrosion deposits on a frequent basis. A deliming solution should be available from your detergent supplier. Read and follow all instructions on the label of the deliming solution.

To proceed with the deliming operation, fill the dishmachine and add the correct amount of deliming solution as recommended by the deliming solution manufacturer. The water capacity of the various tanks of the dishmachine can be verified on the specification sheet(s) of this manual.

Perform the following operations to delime the dishmachine:

1. Turn the NORMAL/DELIME switch on the back of the control box to the DELIME position.

2. Disconnect or turn off all chemical feeder pumps.

3. Close all doors (after adding the deliming solution).

4. Run the machine for the recommended period of time.

5. Turn the unit off and open the doors.

6. Wait five minutes, then inspect the inside of the machine. If the

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 dissolved 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 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 dishes. 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 drying agent will prevent this. Again, using treated water will undoubtedly reduce the occurences 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 training program for operators. Using too much detergent has as detrimental effects as using too little. The proper amount of detergent must be used for job. It is important to remember that certain menu items may require extra detergent by their nature and personnel need to be made aware of this. Experience in using the dishmachine under a variety of conditions, along with good training in the operation of 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 accomodate detergents 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 located on each unit details what the minimum temperatures must be for either the incoming water supply, the wash tank and the rinse tank, 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 dishmachine operators to observe the required temperatures and to report when they fall below the minimum allowed. A loss of temperature 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.

There are several factors to consider when installing your dishmachine to ensure that you get the best possible results from it and that it operates at peak efficiency for many years. Discuss your concerns with your local chemical distibutor and water treatment specialist before there is a problem.

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