CONSERVER XL
SERVICE MANUAL
Visit Jackson on the Internet at: www.jacksonmsc.com
October 24, 2001 |
P/N 7610-002-10-23 (Revision B) |
TABLE OF CONTENTS
GENERAL |
PAGE |
Specifications .............................................................................................. |
1 |
INSTALLATION INSTRUCTIONS.............................................................................. |
2 |
CHEMICAL DISPENSING EQUIPMENT................................................................... |
3 |
OPERATIONAL INSTRUCTIONS.............................................................................. |
4 |
UNIT OPERATION |
|
Cam Timer Operation................................................................................... |
5 |
Timing Sequence (Conserver XL)................................................................ |
6 |
TROUBLESHOOTING SECTION............................................................................... |
7 |
DRAWINGS |
|
Dimensions.................................................................................................. |
12 |
Table Dimensions......................................................................................... |
13 |
Main Assembly............................................................................................. |
14 |
Control Box Assembly.................................................................................. |
16 |
8 Cam Timer................................................................................................. |
18 |
Peristaltic Pump Assembly........................................................................... |
19 |
Hood Assembly............................................................................................ |
20 |
Cantilever Arm Assembly............................................................................. |
21 |
Wash Tub Assembly..................................................................................... |
22 |
Accumulator Assembly................................................................................. |
23 |
Frame Assembly........................................................................................... |
24 |
Incoming Plumbing Assembly...................................................................... |
25 |
Solenoid Valve Repair Kits (3/4”, 110V)........................................................ |
26 |
Vacuum Breaker Repair Kit (3/4” NPT)........................................................ |
27 |
Wash Motor Assembly................................................................................. |
28 |
Wash Arm Assembly.................................................................................... |
29 |
Wash Manifold Assembly............................................................................. |
30 |
Drain Solenoid Assembly.............................................................................. |
31 |
Door Wrap Assembly.................................................................................... |
32 |
ELECTRICAL DIAGRAMS |
|
Schematic (115 Volt, 60 Hz, Single Phase).................................................. |
33 |
i
SPECIFICATIONS of CONSERVER XL
PERFORMANCE/CAPABILITIES |
|
OPERATING CAPACITY (RACKS/HOUR) |
|
RACKS PER HOUR |
37 |
DISHES PER HOUR |
925 |
GLASSES PER HOUR |
925 |
OPERATING CYCLE (SECONDS) |
|
WASH TIME |
42 |
RINSE TIME |
25 |
TOTAL CYCLE TIME |
87 |
TANK CAPACITY (GALLONS) |
|
WASH TANK (MINIMUM) |
1.49 |
WASH PUMP CAPACITY |
|
GALLONS PER MINUTE |
61 |
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 |
|
VOLTS |
PHASE |
AMPS |
115 |
1 |
11.4 |
WATER REQUIREMENTS |
|
|
INLET TEMPERATURE (MINIMUM) |
120°F |
|
INLET TEMPERATURE (RECOMMENDED) |
140°F |
|
GALLONS PER HOUR |
55.13 |
|
WATER LINE SIZE I.P.S. (Minimum) |
3/4” |
|
DRAIN LINE SIZE I.P.S. (Minimum) |
2” |
|
FLOW PRESSURE P.S.I. (Optimum) |
20 |
|
MINIMUM CHLORINE REQUIRED (PPM) |
50 |
|
FRAME DIMENSIONS |
|
|
WIDTH |
|
25 1/4” |
DEPTH |
|
25 1/4” |
HEIGHT |
|
65 1/2” |
STANDARD TABLE HEIGHT |
34” |
|
MAXIMUM INSIDE CLEARANCE |
19” |
|
1
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 thoroughly 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 Conserver XL is a gravity discharge drain. All piping from the 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 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 5 gallons per minute.
WATER SUPPLY CONNECTION: Ensure that you have read the section entitled “PLUMBING THE DISHMACHINE” above before proceeding. 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.
In areas where the water pressure fluctuates or is greater than the recommended pressure, it is suggested that a water pressure regulator be installed.
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 with the Conserver XL model) 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 operating requirements, machine voltage, total amperage load and serial number.
To install the incoming power lines, open the control box. This will require taking a phillips head screwdriver and removing the one(1) screw on the front cover of the control box. Install 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 & N) 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 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.
2
CHEMICAL DISPENSING EQUIPMENT
TO PREPARE PUMPS FOR OPERATION
The Conserver XL dishmachine is supplied with detergent, rinse additive and sanitizer dispensing peristaltic-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 PERISTALTIC-PUMPS
Peristaltic 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 peri- staltic-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.
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 6 on the cam timer. See the timer instructions on Page 5.
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. It can be changed by changing Cam 7 on the cam timer. See the timer instructions on Page 5
6.Chlorine based sanitizer is dispensed into the final rinse. The amount of sanitizer may need to be adjusted depending on the concentration and type of sanitizer used. It is adjusted by changing Cam 5 on the cam timer. See the timer instructions on Page 5.
3
OPERATION INSTRUCTIONS
PREPARATION: Before proceeding with the start-up of the unit, verify the following:
1.The sump strainer is in place and is clean.
2.The drain stopper is installed.
3.That the wash and rinse arms are screwed securely into place and that their endcaps are tight. The wash and rinse arms should rotate freely.
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 doors and depress and hold the OFF/ON/FILL rocker switch in the FILL position for approximately 8 - 10 seconds. Open the doors and verify that the water level is correct. Hereafter, the water level is controlled by the timer that has been preset at the factory. Verify that the drain stopper is preventing the wash tub water from pouring out excessively. There may be some slight leakage from the drain hole. Verify that there are no other leaks on the unit before proceeding any further. The wash tub 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 water level was set at the factory. If the water level is not at the level noted above, it will require adjustment. Check to ensure that the recommended water pressure is being supplied to the machine (20 PSI). If the water pressure is correct then the fill valve will need adjustment. Use the following steps to adjust the cam. Turn power off at the machine circuit breaker. Open the control box cover. Locate the timer fill valve cam (Cam 4 from the timer motor). Locate the spanner wrench taped to the electrical panel. The spanner wrench is used to adjust the cam.
To increase the water level, open the notch of the adjustable cam. To decrease the water level, close the notch. Care must be taken that the set point does not extend into the home position of the timer. Do not move the side of the cam that starts the fill; this will change the sequence of cycle operation. With the door closed turn the power circuit breaker on. Open and close the door to run a cycle, then check the water level. Adjust as necessary then close the control box cover.
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 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-soak- ing 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 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 the tub has filled to the correct level. Lift the doors and the cycle light will illuminate. When the light goes out, close the doors, the unit will start, run through the cycle, and shut off automatically. Repeat this two more times. The unit should now be ready to proceed with the washing of ware.
WASHING A RACK OF WARE: To wash a rack, open the doors completely (being careful for hot water that may drip from the doors) and slide the rack into the unit. Close the doors and the unit will start automatically. Once the cycle is completed, open the door (again watching for the dripping hot water) and remove the rack of clean ware. Replace with a rack of soiled ware and close the doors. The process will then repeat itself.
OPERATIONAL INSPECTION: Based upon usage, the pan strainer may become clogged with soil and debris as the workday progresses. 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 doors. When the unit completes the cycle, turn the power switch to the OFF position and open the doors. Manually remove the drain stopper from the tub and allow the tub to drain (NOTE: the wash tank water will be hot so caution is advised). Once the wash tub is drained, remove the pan strainer and the pump suction strainer. Remove soil and debris from the strainer and set to the side. Unscrew the wash and rinse arms from their manifolds. Remove the endcaps and flush the arms with water. Use a brush to clean out the inside of the arms. If the nozzles appear to be clogged, use a toothpick to remove the obstruction. Wipe the inside of the unit out, removing all soil and scraps. Reassemble the wash and rinse 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 strainers and close the doors.
4
CAM TIMER OPERATION
The Conserver XL cam timer is a 1 minute, 30 second, 8-cam timer (cam 8 is a spare) that controls the operation of the dishmachine. The following is a description of the set points for each cam and the function of each switch.
CAM 1: Cam 1 is a cut cam with a single notch and serves as the cycle/reset control.
FUNCTION: When the machine is in the operation mode the notch is the home position. The machine will remain 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 return to the home position and hold.
CAM 2: Cam 2 is a cut cam and provides the wash cycle timing.
FUNCTION: The wash cam works off the normally open contacts of Cam 2. This requires the microswitch be held closed by the cam. It will close and energize the wash pump 2 seconds after the cycle switch is activated. The pump will operate through the wash cycle (40 seconds) then shut down for the dwell period (20 seconds). As the cam rotates it energizes the pump for the rinse cycle (25 seconds). When cam 1 reaches it’s home position it will deenergize cam 2, shutting down the wash pump.
NOTE: The last 6 cams are adjustable. The following instructions will require that the timer position have the cams to the front and the motor to the left.
CAM 3: Cam 3 is an adjustable cam and controls the drain valve.
FUNCTION: The drain solenoid works off the normally closed contacts of cam 3. When the cycle is initiated, the microswitch will be held open until it is allowed to drop into the notch of the cam. This energizes the drain solenoid which drains the machine. After a 12 second delay the cam reverses the microswitch, de-energizing the drain solenoid. This cam may require adjusting due to varying water pressure. The drain solenoid must remain open long enough to remove whatever water the fill valve solenoid allows in the machine. This could vary due to the water supply line pressure.
SETTINGS: The right side of cam 3 must be set to pick up the switch arm just before the wash/rinse cycle cam switch drops. It will hold the drain solenoid open to drain all the water in the tank from the unit during the dwell period. Any adjustment made to the drain should be made to the left side of cam 3. The cam must be moved back into the wash time until all of the water is drained from the machine.
CAM 4: Cam 4 is an adjustable cam and controls the fill valve and therefore the amount of water used.
FUNCTION: The fill 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 fill valve. This energizes the fill solenoid which opens to start filling the machine with fresh water. After a 10 second delay, the cam reverses the microswitch, de-energizing the fill solenoid. The fill cam may require adjustment due to varying water pressure. The fill solenoid must remain open a sufficient length of time to fill the machine to the correct level.
SETTINGS: The right side of cam 4 must be set to allow the switch arm to drop 2 seconds before the drain solenoid is de-ener- gized which flushes the detergent residue from the unit. It will hold the fill solenoid open until the cam switch arm is raised. At that time the fill solenoid is de-energized, shutting off the incoming water. The tub will be filled to the correct level. Any adjustment made to the timing of the fill solenoid should be made with the left side of cam 4. To increase the water level, open the notch of the cam and for decreasing the level of the notch should be closed.
CAM 5: Cam 5 is an adjustable cam and controls the sanitizer pump.
FUNCTION: The sanitizer pump cam works off the normally closed contacts of cam 5. This requires the switch arm to be held open by the cam and allowed to drop into the notch to operate the pump. The time that the sanitizer pump will remain energized must be determined in the field to suit the chemical used and water conditions.
SETTINGS: The left side of cam 5 must be set to allow the switch arm to drop in past the starting point of the fill cam and after the drain solenoid has closed. The adjustment for sanitizer volume must be made with the right side of the cam. To increase the volume the notch should be increased or to decrease the amount of sanitizer the notch should be closed slightly in increments until the correct level is reached.
CAM 6: Cam 6 is an adjustable can and controls the detergent pump.
FUNCTION: The detergent pump cam works off the normally closed contacts of cam 6. This requires the switch arm to be held open by the cam and allowed to drop into the notch to operate the pump. The time that the detergent pump will remain energized must be determined in the field to suit the chemical used and water conditions.
SETTINGS: The left side of cam 6 must be set to drop in past the starting point of the wash pump cam. The adjustment for detergent volume must be made with the right side of the cam. To increase the volume, the notch should be increased or to decrease the amount of detergent the notch should be closed slightly in increments until the correct level is reached.
CAM 7: Cam 7 is an adjustable cam and controls the rinse aid pump.
FUNCTION: The rinse aid pump cam works off the normally closed contacts of cam 7. This requires the switch arm to be held open by the cam and allowed to drop into the notch to operate the pump. The time that the rinse aid pump will remain energized must be determined in the field to suit the chemical used and water conditions.
SETTINGS: The left side of cam 7 must be set to drop in past the starting point of the fill cam and after the drain solenoid has closed. The adjustment for rinse aid volume must be made with the right side of the cam. To increase the volume the notch should be increased or to decrease the amount of detergent the notch should be closed slightly in increments until the correct level is reached.
5
TIMING SEQUENCE
2 SECONDS INTO CYCLE
*Wash pump starts, runs for 40 seconds, then shuts down. Controlled by C2 cam.
4 SECONDS INTO CYCLE
*Detergent feed pump is energized. The length of time will be field determined. Time will depend on the detergent used and water conditions. controlled by C6 cam.
10 SECONDS INTO CYCLE
* Detergent feed pump shuts down. Controlled by C6 cam.
42 SECONDS INTO CYCLE
*Wash pump shuts down. Controlled by C2 cam.
*Drain solenoid is energized (opens). wash water drains from the unit. Controlled by C3 cam.
51 SECONDS INTO CYCLE
* Fill solenoid valve is energized (opened) starting to fill unit. Controlled by C4 cam.
53 SECONDS INTO CYCLE
* Drain solenoid valve is de-energized (closed). Controlled by C3 cam.
54 SECONDS INTO CYCLE
*Sanitizer pump is energized, injecting sanitizer into wash tank. Controlled by C5 cam.
*Rinse aid pump is energized, injecting rinse aid into wash tank. Controlled by C7 cam.
58 SECONDS INTO CYCLE
* Sanitizer pump is de-energized. The length of time that the sanitizer pump is activated will be determined in the field. Timing will depend on the chemical used and water conditions. Controlled by C5 cam.
60 SECONDS INTO CYCLE
* Rinse aid pump is de-energized. The length of time that the rinse aid pump is activated will be determined in the field. Timing will depend on the chemical used and water conditions. Controlled by C7 cam.
62 SECONDS INTO CYCLE
*Wash pump is energized for the rinse cycle.
*Fill solenoid valve is de-energized.
87 SECONDS INTO CYCLE
*Wash pump is de-energized.
*End of cycle.
6
TROUBLESHOOTING SECTION
WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reap ply power to test. When replacing electrical parts, disconnect power at source circuit breaker.
Symptom |
Possible Cause |
Action |
|
Dishmachine will not run, no voltage at |
Service disconnect switch off or faulty. |
Turn disconnect on. |
|
wash relay terminals L1 and T1. |
|
|
|
|
Branch circuit breaker tripped/fuse blown. |
Reset or replace. |
|
|
|
|
|
|
Loose or broken connection to dishmachine. |
Tighten or replace connections. |
|
|
|
|
|
Machine will not run in "ON" position unless |
Door switch shorted out. |
With the door open, check for voltage |
|
cam timer is moved off the "home" position. |
|
between ORANGE/WHITE door switch and |
|
|
|
neutral. If 120V, replace the door switch. |
|
|
|
|
|
|
Faulty control relay. |
With the door open, check for voltage |
|
|
|
between connections #9 & #3 on control |
|
|
|
relay. If 120V, replace control relay. |
|
|
|
|
|
|
Faulty "cycle reset" microswitch in cam |
Replace microswitch. |
|
|
timer. |
|
|
Machine will not cycle in "ON" position, |
Faulty cycle reset cam microswitch. |
With the switch in the Normal position, |
|
works in Delime mode. |
|
rotate the cams manually off the home |
|
|
|
position. Check the voltage between the |
|
|
|
ORANGE and BLACK/WHITE wires on the |
|
|
|
cycle reset switch. |
|
|
|
If it is 120V, then the switch is open and |
|
|
|
||
|
|
should be replaced. |
|
|
|
|
|
|
Faulty cam timer motor |
If cam timer is not rotating, check the |
|
|
|
voltage to the motor. If voltage is present |
|
|
|
when the door is closed, replace the motor. |
|
|
|
|
|
|
Faulty control relay. |
Check the voltage across contacts #9 and |
|
|
|
#6. If 120V when the door is closed, replace |
|
|
|
the relay. |
|
|
Faulty NORMAL/DELIME switch. |
In the NORMAL position, check the voltage |
|
|
|
between WHITE/BLACK & WHITE/RED |
|
|
|
wires to switch. If 120V, replace the switch. |
|
|
|
|
|
Machine will not run. Wash pump motor will |
Open door switch. |
With door closed, measure voltage between |
|
run if wash relay is depressed manually |
|
BLUE and WHITE/BLACK wires on |
|
(nothing else works). |
|
terminals #6 & #9 of the relay. If 120V, |
|
|
|
replace the relay. |
|
|
Faulty control relay. |
Measure between the BLACK wires on |
|
|
|
terminals #6 & #9 of the relay. If 120V, |
|
|
|
replace the relay. |
|
|
|
Measure between the WHITE/ BLACK wire |
|
|
|
on terminal 4 and the ORANGE/WHITE wire |
|
|
|
on terminal 7 of the relay. If 120V, replace |
|
|
|
relay. |
|
|
|
|
|
Machine will not run in "ON" position or in |
Faulty door switch. |
With door closed, check for voltage between |
|
Delime mode. |
|
WHITE/BLACK and ORANGE/WHITE wires |
|
|
|
to the door switch. If 120V, replace open |
|
|
|
switch. |
|
7
TROUBLESHOOTING SECTION
WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reap ply power to test. When replacing electrical parts, disconnect power at source circuit breaker.
|
Symptom |
Possible Cause |
Action |
|
|
Machine will not run in "ON" position or in |
Faulty OFF/ON/FILL switch. |
With switch ON, check voltage between |
|
|
Delime mode. |
|
BLACK and WHITE/BLACK wires on switch. |
|
|
|
|
Replace the switch if 120V. |
|
|
|
Faulty NORMAL/DELIME switch. |
In the NORMAL position, check the voltage |
|
|
|
|
between WHITE/BLACK & WHITE/RED |
|
|
|
|
wires to switch. If 120V, replace the switch. |
|
|
|
|
|
|
|
Machine cycles continuously. |
Cycle reset switch loose. |
Reposition switch assembly, bend metal |
|
|
|
|
lever if necessary. |
|
|
|
Faulty cycle reset switch. |
Measure between BLACK/YELLOW & |
|
|
|
|
ORANGE wires on "cycle reset" switch while |
|
|
|
|
timer is rotating. As the switch lever drops |
|
|
|
|
into home position you should measure |
|
|
|
|
120V. If not, adjust or replace the switch. |
|
|
|
|
|
|
|
Machine will not fill, other functions work. |
Y-strainer plugged. |
Clean strainer. |
|
|
|
Water valve(s) turned off. |
Turn on water valves. |
|
|
|
Faulty solenoid valve diaphragm. |
Replace diaphragm, clean foreign material |
|
|
|
|
out of valve body and orifices. |
|
|
|
|
|
|
|
|
Faulty solenoid coil. |
If coil has voltage but no continuity, replace |
|
|
|
|
coil (continuity is measured across coil |
|
|
|
|
connectors with wires removed). |
|
|
|
|
|
|
|
|
Faulty fill microswitch. Will not fill during |
During fill, measure between the ORANGE |
|
|
|
cycle only. |
and WHITE/GREEN wires. If 120V, adjust |
|
|
|
|
or replace switch). |
|
|
|
Faulty OFF/ON/FILL switch. |
Depress switch, measure between BLACK |
|
|
|
|
and WHITE/GREEN wire. If 120V, replace |
|
|
|
|
switch. |
|
|
Machine fills continuously even with no |
Solenoid valve dirty or faulty. |
Clean valve, replace plunger and/or |
|
|
power applied to machine. |
|
diaphragm. |
|
|
Machine fills continuously, only when the |
Faulty fill microswitch. |
Repair/replace switch. |
|
|
power is on. |
|
|
|
|
Cam timer stalled in fill position. |
If cam timer is not rotating, check the |
|
|
|
|
|
voltage to the timer motor. If 120V when |
|
|
|
|
door is closed, replace the timer motor. |
|
|
|
|
|
|
|
|
Shorted OFF/ON/FILL switch. |
Check voltage between BLACK and |
|
|
|
|
WHITE/GREEN connections of the switch in |
|
|
|
|
the "ON" position. If you do not read 120V, |
|
|
|
|
replace switch. |
|
|
Wash motor does not run, other functions |
Loose wire connection to microswitch, relay, |
Tighten wires. |
|
|
work, motor runs only when the wash relay |
or contactor. |
|
|
|
is manually pushed down. |
Faulty wash cam microswitch. |
During wash cycle, check voltage between |
|
|
|
|
ORANGE and BLACK/ ORANGE wires on |
|
|
|
|
the microswitch. If 120V, replace the switch. |
|
|
|
|
|
|
|
|
Faulty delime switch. |
During wash cycle, check the voltage |
|
|
|
|
between the two BLACK/ ORANGE wires |
|
|
|
|
(not jumpers). If 120V, replace the delime |
|
|
|
|
switch. |
|
8
TROUBLESHOOTING SECTION
WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reap ply power to test. When replacing electrical parts, disconnect power at source circuit breaker.
|
|
|
|
|
|
|
|
Symptom |
Possible Cause |
Action |
|
|
|
Wash motor does not run, other functions |
Faulty control relay. |
Check the voltage across relay contacts #7 |
|
|
|
work, motor runs only when the wash relay |
|
& #4. If 120V during the wash cycle, replace |
|
|
|
is manually pushed down. |
|
the relay. |
|
|
|
|
|
|
|
|
|
|
Faulty wash relay. |
Check voltage at relay coil between |
|
|
|
|
|
ORANGE/BLACK and WHITE wires. If you |
|
|
|
|
|
read 120V, coil is faulty. Replace the relay. |
|
|
|
|
|
|
|
|
|
Wash motor does not run even when the |
Loose wire connections to motor, delime |
Tighten wires. |
|
|
|
wash relay is manually depressed; other |
switch, or from contactors. |
|
|
|
|
functions work. |
|
|
|
|
|
Mechanical binding in pump. |
If motor has correct incoming voltage, and |
|
|
|
|
|
|
its overload is tripping, repair or replace the |
|
|
|
|
|
pump. |
|
|
|
|
Mechanical binding in pump. |
On end of motor, opposite pump, remove |
|
|
|
|
|
endcap. With large slot type screwdriver, fit |
|
|
|
|
|
|
|
|
|
|
Faulty wash motor. |
If the motor has the correct incoming |
|
|
|
|
|
voltage and the pump is okay, replace the |
|
|
|
|
|
motor. |
|
|
|
|
Faulty wash relay. |
With the wash relay pushed in, check the |
|
|
|
|
|
voltage between T1 and L1 of the relay. If |
|
|
|
|
|
120V, replace the relays. |
|
|
|
|
|
|
|
|
|
|
High or low voltage problem. |
Check voltage at motor and at power |
|
|
|
|
|
terminal block. Compare to electrical |
|
|
|
|
|
specifications. |
|
|
|
Wash motor runs continuously. |
The NORMAL/DELIME switch is in the |
Place the switch in the Normal position. |
|
|
|
|
Delime position. |
|
|
|
|
|
Wash relay contacts are welded closed. |
Turn machine off. If wash relay doesn't |
|
|
|
|
|
release, replace contactor. |
|
|
|
|
Cam timer stalled in wash or rinse cycle. |
If cam timer is not rotating, check the |
|
|
|
|
|
voltage to the timer motor. If no voltage |
|
|
|
|
|
when the door is closed, check wires and/or |
|
|
|
|
|
replace motor. |
|
|
|
|
|
|
|
|
|
|
Wash motor microswitch faulty. |
Tighten connections, make sure switch |
|
|
|
|
|
makes contact, replace if necessary. |
|
|
|
Machine runs with door open. |
Door switch shorted. |
With machine off, open doors, and with both |
|
|
|
|
|
wiresto door switch unplugged, measure |
|
|
|
|
|
continuity between wires on switch. If there |
|
|
|
|
|
is continuity, replace the switch. |
|
|
|
|
|
|
|
|
|
|
Faulty wash relay (wash relay contacts |
Turn machine off, if wash relay doesn't |
|
|
|
|
welded closed). |
release, replace contactor. |
|
|
|
|
Faulty control relay. |
With power off, remove WHITE/RED & |
|
|
|
|
|
BLACK/YELLOW wires from control relay |
|
|
|
|
|
terminals #9 & #6. If there is continuity, |
|
|
|
|
|
replace relay. |
|
|
|
Low pumped water pressure. |
Water level is too low. |
Increase fill time on cam timer, or decrease |
|
|
|
|
|
drain timer, or increase incoming water |
|
|
|
|
|
pressure. |
|
|
|
|
Sump strainer clogged. |
Clean strainer. |
|
|
|
|
Wash arms clogged. |
Clean arms and jets. |
|
9
Loading...