LVO RW1548 Service Manual

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

W A R R A N T Y

LVO Manufacturing Inc. warrants equipment manufactured by it to be free from defects in material and workmanship for a period of one (1) year from date of delivery except as noted below.

LVO will not be held responsible for damage or unsatisfactory performance due to negligence, accident, alteration, unauthorized repair, improper installation or startup (see owner's manual), improper application, or improper maintenance (see owner's manual).

Parts found, on factory inspection, to be defective in workmanship or materials during the warranty period will be replaced (parts and labor, not overtime), provided the Buyer returns the defective parts to LVO Manufacturing Inc. within 30 days, transportation prepaid. LVO Manufacturing Inc. will pay UPS 2nd Day Air shipping charges for parts (with the exception of excessively large or heavy items) covered on warranty if the machine is not operational.

LVO Manufacturing Inc. reserves the right to make changes in design and construction of its products without imposing any obligation upon itself toward products previously manufactured.

This warranty is in lieu of any other warranties, expressed or implied, made on the part of LVO Manufacturing Inc. who does not accept responsibility to any purchaser of it's products for any representation or warranty made by dealers or salespersons beyond those herein expressed including any implied warranties of merchantability or fitness for a particular purpose.

Warranty Procedure

1)Locate and record the 12 digit serial number located on the upper left-hand side of the pan washer.

2)Gather as much information about the problem as possible.

3)Call LVO Manufacturing Inc. at 1-800-346-5749 and request technical service.

Prior to performing any warranty work you must call the factory for a warranty authorization number (WA-____). This warranty authorization number must be on every invoice we receive for services rendered on the machine. Without this authorization number the invoice will not be paid. The warranty number must also be included with the defective part returned.

1

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Table of Contents
Warranty	1
Table of Contents	2
Specifications	3
Electrical Data Breakdown	4
Warnings and Cautions	5
Introduction	6
Installation Instructions	7
Start-Up Procedures	11
Sequence of Operation	13
Operation of Machine	14
Trouble Shooting - Electric Machine	17
Trouble Shooting - Gas Machine	18
Trouble Shooting - Steam Machine	18
Parts List	19
Preventive Maintenance	21A
Drawings:
General View	22
Floor Model with Ramp	23
Three View: - Gas Wash Heat - Pit Model	24
Three View - Electric Wash Heat - Floor Model	25
Three View - Steam Wash Heat - Floor Model	26
Concrete Pit Specifications	27
Stainless Steel Pit - General	28
Stainless Steel Pit Liner - Top View	29
Stainless Steel Pit Liner - Side View	30
Bun Pan Rack	31
Cake Pan Rack	32
Bowl/Utensil Rack	33
Rinse System	34
Floor Grate and Screen Location	35
Electric Wash Heat - Control Circuit Ladder Diagram	36
Gas or Steam Wash Heat - Control Circuit Ladder Diagram	37
Electric Wash Heat - Control Circuit Schematic with 700 cfm Fan	38
Gas Wash Heat - Control Circuit Schematic with 700 cfm Fan	39
Steam Wash Heat - Control Circuit Schematic with 700 cfm Fan	40
Trouble Shooting Flowchart	41

2

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

RW1548 SPECIFICATIONS

OVERALL DIMENSIONS

WIDTH = 57” (60” WITH SIDE SUPPORT ANGLES)

DEPTH = 65”

HEIGHT (OVERALL) = 92-1/2” (94-1/2” GAS)

HEIGHT (PIT MODEL) = 81-1/2” ABOVE FLOOR

HOT WATER SYSTEM

1” HOT WATER SUPPLY REQUIRED, UNION PROVIDED 140° F. WATER REQUIRED AT THE MACHINE

168 GPH AT 20 PSI (14 GAL./CYCLE x 12 CYCLES/HR.

RINSE BOOSTER: TWO 9kW HEATING ELEMENTS IN A 20 GAL. RINSE TANK

FULL LOAD AMPS
	208 VOLT	230 VOLT	460 VOLT
ELECTRIC	133.1	122.3	62.1
GAS/STEAM (INJECTED)	95.6	88.4	45.2
STEAM (RECIRCULATING)	45.6	43.2	22.6

GAS SYSTEM (GAS MACHINES ONLY)

½” GAS SUPPLY CONNECTION

NATURAL: 7” W.C. MINIMUM INLET, 6” W.C. MAIN MANIFOLD = 66,000 BTU PROPANE: 11” W.C. MINIMUM INLET, 10” W.C. MAIN MANIFOLD = 66,000 BTU 4” STAINLESS STEEL CHIMNEY

STEAM SYSTEM (STEAM MODELS ONLY

¾” STEAM LINE, 10-15 PSI - 37 LBS. / HR. AVERAGE – INJECTED

76 LBS. / HR. AVERAGE – RECIRCULATING

WASH SYSTEM

10 HP & 5 HP PUMPS IN SERIES RECIRCULATE APPROXIMATELY 240 GPM @ 60 PSI.

HEAT: >ELECTRIC – ONE 9 kW AND ONE 4.5 kW HEATING ELEMENT

>GAS – THREE 22,000 BTU RATED INFRARED BURNERS = 66,000 BTU >STEAM – DIRECT INJECTION, 10-15 PSI, 37 LBS / HR AVERAGE

RECIRCULATED, 10-15 PSI, 76 LBS / HR AVERAGE

65 GALLON WASH TANK

1-1/2” COPPER DRAIN

8” STEAM EXHAUST VENT COMPANION FLANGE

3

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Electrical Data for MODELS RW1548 - Electric

Voltage	208	230	460
Phase	3	3	3
Pump Motor (5HP + 10HP)	43.6	41.2	20.6
Control Circuit	2.0	2.0	2.0
Wash Heaters (one 9kW + one 4.5kW)	39.5	35.9	18.9
Rinse Heaters (two 9kW)	50.0	45.2	22.6
Total	133.1	122.3	62.1
Exhaust Fan (Opt.)	2.0	2.0	2.0

Electrical Data for MODELS RW1548 - Gas

Voltage	208	230	460
Phase	3	3	3
Pump Motor (5HP + 10HP)	43.6	41.2	20.6
Control Circuit	2.0	2.0	2.0
Rinse Heater (two 9kW)	50.0	45.2	22.6
Total	95.6	88.4	45.2
Exhaust Fan (Opt.)	2.0	2.0	2.0

Electrical Data for MODELS RW1548 - Steam

Voltage	208	230	460
Phase	3	3	3
Pump Motor (5HP + 10HP)	43.6	41.2	20.6
Control Circuit	2.0	2.0	2.0
Total	45.6	43.2	22.6
Exhaust Fan (Opt.)	2.0	2.0	2.0

Electrical Supply to the machine should exceed the figures by the amount required by local codes.

Note: Changing the voltage of the machine in the field requires different heating elements. Contact the factory if this situation arises.

4

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

General Warnings and Cautions

1.Service work on the machine should be done by either a factory representative or qualified local service company. Contact the factory if the machine is under warranty.

2.Failure to follow the cleaning guidelines described in this manual will damage the machine and will void the warranty.

Gas Model Warnings and Cautions:

1. Installation must conform with local codes and the National Fuel Gas Code, ANSI Z223.1.

In Canada: Installation must be in accordance with CGA Standard CAN/CGA-B149.1, Natural Gas Installation Code or CAN/CGA-B149.2, Propane Installation Code.

FOR YOUR SAFETY: DO NOT STORE OR USE GASOLINE OR OTHER FLAMMABLE VAPORS OR LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER APPLIANCE.

WARNING: IF YOU SMELL GAS, SHUT OFF THE GAS SUPPLY TO THE APPLIANCE, EXTINGUISH ANY OPEN FLAME, AND TEST ALL JOINTS WITH A SOAP SOLUTION. IF ODOR PERSISTS, CALL YOUR GAS SUPPLIER IMMEDIATELY.

AVERTISSEMENT: SI UNE ODEUR DE GAZ EST DÉCELÉE, COUPER L’ALIMENTATION EN GAZ DE L’APPAREIL, ÉTEINDRE TOUTES LES FLAMMES ET VÉRIFIER TOUS LES RACCORDS À L’AIDE D’UNE SOLUTION SAVONNEUSE. SI L’ODEUR PERSISTE, AVERTIR IMMÉDIATEMENT LE FOURNISSEUR DE GAZ.

2.Instructions should also be posted in a prominent location describing what to do in the event that the smell of gas is detected in the vicinity of the machine. (This information can be obtained from your local gas supplier).

3.Do not obstruct the flow of ventilation and combustion air to the machine.

4.Gas model pan washers are equipped with an electronic ignition which automatically lights the burners when the power switch is turned to the "ON" position and there is enough water in the machine. To shut the burners off, the power switch should be turned to the "OFF" position.

5

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Introduction

This manual should be read and understood by everyone involved with the installation and operation of the rack washer. Keep this manual in a safe place for future reference. Extra copies or replacement copies can be purchased from the manufacturer.

Service work on the machine should be done by either a factory representative or qualified local service company. Contact the factory if the machine is under warranty.

The LVO rack washer is designed for use in bakeries, restaurants, schools, hospitals, and hotels, to clean racks, pots, pans, bowls, and utensils. LVO rack washers are constructed of 14 gauge stainless steel (cabinets) and 12 gauge stainless steel (framework). The interior piping, rinse system, wash arms, and screens are stainless steel. The control panel is assembled with UL approved components and is housed in a stainless steel control box. Because of its sturdy construction, it will deliver years of powerful, thorough cleaning.

The machine is equipped with heating element(s) in the rinse tank to boost the rinse water to a sanitizing 180 F at the inlet to the machine. A rinse tank heated with recirculated steam is an option available on some models.

The wash tank on electric models incorporates heating element(s) for heating the wash water. The gas models use a series of 22,000 BTU infrared burners. Steam models use a direct injection system or a recirculated steam heating coil.

The pump recirculates wash water at approximately 55 pounds per square inch of pressure.

Each machine is equipped with two safety switches. The first is a low water cut-off, which shuts the machine off when the water level in the wash tank falls below the required level. The other safety device is a door switch which prevents the machine from operating when the door is not completely closed. An electrical schematic for your machine is posted inside the control box cover.

Detergent Feeders

This machine must be operated with an automatic detergent feeder, including a visual means to verify that detergent is delivered or a visual or audible alarm to signal that detergent is not available for delivery. Power for the feeder can be provided by the pump supply connection in the control panel. See feeder equipment manual for additional information.

6

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Installation Instructions

Step 1 READ: Read and understand these instructions thoroughly before attempting any part of the installation procedure.

WARNING: Not following these instructions may void warranty, cause damage to the equipment and/or cause injury to anyone involved in the installation or operation of this machine.

A copy of the installation instructions and start-up procedure is printed on the yellow sheet attached to the side of the machine. EVERYONE involved with the installation must be familiar with all aspects of the installation procedure.

Step 2 POSITIONING: The factory recommends leaving as much room as possible around the machine for future service work. No less than 16" should be allowed along the sides of the machine (36" for side with control box) and no less than 12" between the rear of the

machine and the wall. Extra room around the machine will facilitate cleaning the washer area.

Note: Gas models should be installed in a location free of drafts.

Step 3 UNCRATING: Leave the machine fully crated until the washer is placed in the location where it is to be installed. Inside you will find the accessories for the machine. Among these will be the fan and the legs (if ordered). The legs are adjustable by turning the small end one way or the other. Legs are not required for pit models.

When a pit is used it can be installed prior to receiving the machine. There are two types of pits to choose from: concrete (see page 27) or stainless steel (see pages 28 - 30). Concrete pits are the most common. They are usually installed by a general contractor. Note that the drain system will also be installed at this time. Generally concrete pits are painted to make them water proof.

A stainless steel pit is available for installations in buildings with basements. The stainless pit can also be used as a liner with concrete poured around it. The stainless steel pit is equipped with a coupler to allow the plumber to connect the drain (see pages 28 - 30).

Prior to receiving the rack washer, the service lines can be stubbed in close to where the rack washer will be installed (see page 22). This will speed up the completion of the installation once the machine is in place.

7

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

There are many methods for setting the machine in the pit. Often the machine is slid into the pit from the front. Hydraulic jacks, pry bars and pallet jacks or a forklift are usually necessary to accomplish the task. Keep in mind that the heaviest part of the machine is the backside where the pumps are located.

Once the machine is in the pit, the front floor grate should be set in place. The machine should then be moved ahead to eliminate any gaps between the machine and the floor grate yet leaving enough a space that the floor grate can be removed for periodic hosing down of the pit floor.

Step 4 DRAIN: Provisions for the drain should be made next. The rack washer has a copper drain located as shown on pages 24 - 26 of this manual (see page 3 for drain size). The drain should be plumbed according to local code. Local ordinance may require a grease trap, vent, and/or a floor sink. If required these should be installed before the machine is installed. It is strongly recommended that unions be used to allow the machine to be easily moved. Failure to do so may void the warranty.

Models that set in a pit do not require a drain connection because the wash tank drains directly into the pit.

Step 5 WATER SUPPLY HOOK-UP: The factory recommends 140° F (120° F minimum) hot water at the machine (see page 3 for water line size). This may require a dedicated water heater for the rack washer. If hard water is present the manufacturer recommends installing a water softener or calcium filter. Hard water deposits will shorten the life of many of the components on the rack washer, resulting in higher maintenance costs. Please note that a union is installed at the point of hook-up (see pages 24 - 26). This will allow the machine to be moved for service and cleaning. The customer must furnish a shut-off valve on the supply side of the union. This shut-off should be easily accessible to the operator of the machine.

Step 6 STEAM VENT: The machine is equipped with a collar for 8" duct work as shown on pages 24 - 26. This duct should be directly vented to the outside of the building. DO NOT vent into a wall, attic, or any other concealed space of the building and avoid horizontal runs of duct.

The factory recommends 8" plastic pipe or stainless steel duct for the vent. If stainless steel is used the duct work should be installed with reverse joints so that the condensate inside the vent can drain back into the machine without leaking. All seams should also be sealed with silicon.

Generally the machine is ordered with a 700 cfm, 1/2 Hp squirrel cage fan. The 700 cfm fan and adapter (provided) should be mounted and siliconed directly to a flange on the top of the machine before the duct work is installed. The ductwork attaches directly to the exhaust of the fan. Wire is provided to wire the fan directly into the control panel. A dedicated breaker and

8

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

contactor for the 700 cfm fan are provided. The 700 cfm fan is controlled by a timer and runs for a short time at the end of each cycle.

Note: Consult the factory before connecting any fan not supplied with the machine.

Step 7 ELECTRICAL CONNECTION: The electrical connection to the machine should be made by a qualified electrician. All steps should be taken to insure that the supply voltage to the machine is the same as the rated voltage of the machine. Also check that sufficient amperage is supplied to the machine (see page 3 or page 4 for ratings).

A main power shut-off, supplied by the customer, must be installed near the machine in a place easily accessible by anyone operating or servicing the machine. The line from the main shut-off to the machine should be watertight flex conduit. The factory strongly recommends that a few extra feet be used to allow the machine to be moved if necessary. The wire used to supply the machine must be heavy enough to carry the amperage load of the machine.

The first connection should be the main ground to the grounding lug on the control panel. Next the hook-up can be made to the main power block. On 230 VAC machines the wild leg must be connected to the center terminal.

Once the hook-up is complete the circuit breakers in the control box of the washer must be checked to make sure they are in the "OFF" position. The main switch on the wall can then be turned on to power the machine.

Step 8 GAS CONNECTION (Gas models only): A certified gas technician is required for the hook-up and final adjustments of the burners. This is necessary to insure proper inlet and manifold pressure for the gas machines (see page 3 for gas pressure settings).

Verify the type of gas supply to be used, either natural or LP, and make sure the marking on the gas data plate agrees with that of the supply. The gas line hook-up must be made with a union at the location shown on page 24 (see page 3 for gas line size). This line must have a shut-off valve (supplied by the customer) installed near the machine and accessible by anyone operating or servicing the machine.

A stainless steel gas chimney runs up the backside of the machine (see page 3 for size of chimney). A draft diverter is included with the machine (shipped inside the machine with the other accessories). The draft diverter must be installed on top of the factory installed chimney. The Type B gas flue can then be continued to the outside of the building per local codes.

The initial start-up of the burners should not be done until the following start-up procedures for the machine have been completed.

9

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Step 9 STEAM HOOKUP (Steam models only): A steam line is required to supply the steam injector or recirculated steam heat exchanger coil (see page 3 for size of steam line). A strainer is already built into the machine but a union will be required in the supply line (supplied by the customer). The Specification sheet on page 3 lists the rated pressure and average steam consumption rate for the machine.

10

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Start-Up Procedures

Warning: These instructions must be followed or damage to the machine will result.

Step 1: Close the drain valve (see location on page 24 - 26). On machines equipped with Auto Fill and Auto Drain, the drain valve will automatically close when the Auto Fill button is pushed.

Step 2: Open the main water supply valve (if the machine is equipped with the Auto Fill option skip to Step 3), then open the fill valve (see location on pages 24 - 26). Fill the machine to the top of the scrap trays. The machine is equipped with a low water protection device and will not run without sufficient water in the wash tank.

Step 3: With the circuit breakers in the control panel of the machine in the "OFF" position and the main power supply to the machine connected, the ON-OFF switch on the button panel can be turned to the "ON" position. This should light the amber power light. If not, check this bulb and the other two bulbs to make certain they are tight.

Machines equipped with the Auto Fill option can now be filled by pressing the Auto Fill button. (If the building pressure is quite high, some water may run out the overflow at the end of the fill cycle).

Note: The machine has a door safety switch and will not operate with the door partially open.

Step 4: With the machine full of water and with the door closed, press the start button and let the machine go through a complete cycle. The timers in the control panel will go through their sequence, lighting the wash and rinse lights on the front of the machine. The cycle is complete when the clear and red light go off and the amber light stays on. The pump will not run at this time because the pump circuit breaker in the control panel is in the "OFF" position.

Step 5: Repeat Step 4 at least one more time or until water can be heard spraying out of the rinse nozzles. This ensures that the rinse tank is full of water before the heating element is energized.

Step 6: All circuit breakers in the control panel can now be switched to the "ON" position. This will energize the heating system in the wash and rinse tanks.

Step 7: Check the pump for proper rotation by pressing the start button and observing the wash pressure gauge on the front of the machine for 5 to 10 seconds. Then press the stop button. The wash pressure should be 45 - 60 psi. If the pressure is erratic and only rises to about 25 psi, the pump is running backwards. The pump will also have a noticeable growl when running backwards. The outside two wires that feed the power block in the control panel should be reversed. Run the pump again to confirm that it is operating correctly.

11

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Step 8: With the power on, the wash and rinse heating systems should be checked. The rinse tank should take 5 to 10 minutes to reach 195 F and the wash should take approximately 60 minutes to reach 150 F. The times will vary depending on the temperature of the incoming water. Note: The rinse manifold gauge measures the temperature of the rinse water just before it enters the machine. Therefore this temperature reading is only accurate while the machine is rinsing.

If the machine is not reaching temperature check to make sure that all the breakers in the control panel are in the "ON" position. If the wash tank is gas heated make certain that main gas valve and the gas valve in the control panel are open. During initial start-up gas machines may have to be turned on and off several times to bleed the air out of the gas lines. Wait about a minute after turning the machine off before turning it back on. If the machine still does not appear to be heating up properly call LVO Manufacturing at 1-800-346-5749.

Step 9: Adjust the pressure regulator (see location on pages 24 - 26). The pressure should be set at 20 psi on the rinse gauge while the machine is rinsing. Variations in building water pressure may require the pressure to be increased or decreased from its factory setting.

Step 10: If the machine is equipped with the 700 cfm fan option (see page 8 for a description of the fan option) check to make sure that it is rotating in the correct direction. If the fan is blowing into the machine rather than out the vent the two outside wires on the three phase fan connection in the control panel need to be swapped. Recheck to confirm proper rotation.

Step 11: Replace all covers and peel off the plastic protective coating and tape etc. from the machine which may have been used to prepare the machine for shipping.

12

LVO Manufacturing Inc.

808 N. 2nd Avenue E., P.O. Box 188

Rock Rapids, IA 51246

www.lvomfg.com

[phone]
1-800-346-5749	Fax	[phone]

__________________________________________________________________________________________________________________________________________________________________

Sequence of Operation

-Power switch "ON".

-LOGO logic control is energized.

-Fill button (optional) energizes fill solenoid.

-Low water safety switch closes terminals 1 and 4 in the control panel if there is sufficient water in the wash tank.

-Amber indicator light comes on.

-Wash and rinse temp controls are energized.

-Temp controls energize wash and rinse heating systems. -Door safety switch is energized.

-Stop and Start buttons are energized.

-Start button is pushed energizing the internal timing functions of the logic control. -Red indicator light is energized

-Wash timer (Light, Medium, or Heavy) starts, energizing the pump contactor for set amount of time.

-Wash time runs out energizing the rest timer.

-After set amount of rest time, the rinse timer starts, energizing the rinse solenoid valve and clear indicator light.

-If the machine is equipped with the exhaust fan option, the fan timer runs for the set time when the rinse times out.

-After the rinse timer (or optional fan timer) has timed out, all timers are reset, and the red/clear indicator lights are de-energized.

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