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K-100E
Installation Manual
24 pgs815.94 Kb0
User Manual
8 pgs275.27 Kb0

Meiko K-100E Installation Manual

K SERIES
High Temperature Sanitizing Rack Conveyor Dishwashers (USA Version)
OWNER’S INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Models:
• K-80E, K-80ET, K-80S, K-80ST • K-90E, K-90ET, K-90S, K-90ST • K-100E, K-100ET, K-100S, K-100ST
Meiko • 917 Airpark Center Drive • Nashville, TN 37217 • Phone: (615) 399-6600 • (800) 55-MEIKO • Fax: (615) 399-6620
Rev. 6/07
TABLE OF CONTENTS
1. INTRODUCTION ................................. 3
1.1 Overview of Equipment ............................. 3
1.2 General Safety Information........................ 3
3.13 Connecting Chemical Containers
or Dispensers .......................................... 11
3.14 Fresh Water Supply Connection(s).......... 11
3.15 Steam System Connections .................... 12
3.16 Drain Connection ..................................... 12
2. TRANSPORT AND SHIPPING ............ 3
3. INSTALLATION .................................... 4
3.1 Overview of Installation ............................. 4
3.2 Requirements Before Installation .............. 4
3.3 Uncrating, Positioning and Leveling ............. 5
3.4 Tabling Attachment .................................... 6
3.5 Vent Cowl Collars (if so equipped) ............ 6
3.6 Booster Heater Placement ........................ 7
3.7 Accessing the Utility Connections ............. 7
3.8 Main Electrical Supply Connection ............ 8
3.9 Dispensing System Overview .................... 8
3.10 Installing an External Solid or Liquid
Detergent System ...................................... 9
3.11 Installing an External Liquid Rinse
Aid System ................................................ 9
3.12 Wiring External Chemical Dispensing
Systems ................................................... 10
3.17 Final Assembly ........................................ 13
4. OPERATION ....................................... 14
4.1 Location and Description of Controls....... 14
4.2 Startup ..................................................... 15
4.3 Loading.................................................... 16
4.4 Operation................................................. 17
4.5 Clearing Jams.......................................... 17
4.6 Shutdown ................................................ 17
5. CLEANING ......................................... 18
5.1 Daily Cleaning (or as required) ................ 18
5.2 Weekly Cleaning (or as required) ............ 18
5.3 Exterior Cleaning (as required) ................ 20
5.4 Deliming (as required) ............................. 20
6. TROUBLESHOOTING ........................ 21
AN ELECTRICAL WIRING DIAGRAM IS LOCATED INSIDE THE CONTROL BOX OF THIS MACHINE.
MEIKO K-SERIES RACK CONVEYOR DISHWASHERS HAVE BEEN DESIGNED EXCLUSIVELY
FOR THE WASHING OF DISHES, GLASSWARE, CUTLERY, KITCHEN UTENSILS AND TRAYS
IN A COMMERCIAL OR INSTITUTIONAL SETTING AND MUST NOT BE USED FOR ANY
OTHER PURPOSE WITHOUT THE WRITTEN PERMISSION OF MEIKO.
MEIKO ACCEPTS NO RESPONSIBILITY FOR DAMAGE TO THE APPLIANCE, SURROUNDING
EQUIPMENT OR ENVIRONMENT THAT IS CAUSED BY INAPPROPRIATE INSTALLATION OR
OPERATION, OR FROM ANY SERVICE THAT IS UNDERTAKEN BY NON-AUTHORIZED
PERSONNEL, OR FROM THE USE OF ANY PARTS EXCEPT THOSE THAT ARE APPROVED
BY THE MANUFACTURER. ANY SUCH INSTALLATION, USE OR SERVICE WILL IMMEDIATELY
VOID THE MANUFACTURER’S WARRANTY.
ANY MODIFICATIONS TO THE APPLIANCE THAT ARE PERFORMED WITHOUT THE WRITTEN
PERMISSION OF MEIKO WILL IMMEDIATELY VOID THE MANUFACTURER’S WARRANTY.
Meiko reserves the right to change any specifications without notice at any time.
Meiko • 917 Airpark Center Drive • Nashville, TN 37217 Phone: (615) 399-6600 • (800) 55-MEIKO • Fax: (615) 399-6620
www.meiko.us
Page 2
SECTION 1 - INTRODUCTION
1INTRODUCTION
1.1 Overview of Equipment
Meiko K-series rack conveyors are commer­cial dishwashers designed for cleaning dishes, glassware, trays, cutlery and kitchen utensils with a minimum of employee intervention or supervision.
A single on/off switch sets the machine into automatic operation. When a rack is pushed into the opening of the machine, the pawl bar drive is activated. Mechanical actuating levers inside the machine are activated by the movement of the rack, automatically activating the prewash (if so equipped), wash and rinse zones.
During idle periods, the wash and rinse are deactivated automatically to conserve water, energy and chemicals, while steam coil or electric tank heaters maintain the water temperature for quick recovery.
Other features of the unit that affect operation include:
Side-drive system - Racks are advanced through the machine using pawl bars at the sides of the rack rails. This provides an unobstructed wash pattern.
IMPORTANT
Meiko K-Series rack conveyor dishwashers have been designed exclusively for the washing of dishes, glassware, trays, cutlery and kitchen utensils in a commercial or institutional setting and must not be used for any other purpose.
1.2 General Safety Information
The following symbols and headings are used throughout this manual to indicate possible hazards to persons or to the equipment. The symbols and headings are shown in order of importance. The descriptive text following these headings is italicized for easy recognition.
WARNING! Possible hazard to per-
sons, such as from elec­trical shock, crushing, or hot surfaces.
CAUTION Possible hazard to the
dishwasher or to other equipment.
IMPORTANT Vital information or tips for
the installer or operator.
NOTE Information or tips for the
installer or operator.
Wash arm manifolds - Wash arms are pre­assembled into easily-removed manifolds for faster cleaning. The nozzles are slotted and concave to minimize clogging. Wash arm end caps are captivated to prevent their loss during cleaning.
External drain handle(s) - Pulling on the external handle(s) empties the machine quickly and safely.
Front-sloping wash tanks - For faster draining and easier cleaning.
For efficient and SAFE operation, be sure to follow the installation and operating instructions provided in this manual. In particular, all safety symbols and notices on the equipment and in the supplied documentation must be followed.
2TRANSPORT AND SHIPPING
IMPORTANT
• Observe any notices on the crating material that pertain to shipping.
• Use care when transporting the equipment.
• As you unpack the equipment, check that all components shown on the shipping invoice are present and intact. Be sure to check for shipping damage. If shipping damage is present, call Meiko Customer Service at 1-800-868-3840, providing full details on the customer, serial number and extent of damage present. Meiko will file a freight claim based on this information.
WARNING!
In NO EVENT should a damaged appliance be installed or operated!
Page 3
SECTION 3 - INSTALLATION
3INSTALLATION
3.1 Overview of Installation
The owner should contract with qualified personnel to move the appliance to the installation location, unpack it, and prepare it for final utility connections. In most cases, local codes prevent the final utility connections from being made by any party other than a licensed electrician, plumber and/or steam fitter.
IMPORTANT
It is the responsibility of the owner to ensure that all aspects of the installation comply with all applicable local and national codes.
IMPORTANT
The appliance’s warranty is not valid until a Meiko Authorized Service Agent performs a Performance and Installation Inspection.
Installation of the dishwasher involves the following steps:
• Verifying that the utility connections are present, are appropriate for the appliance, and comply with all applicable local and national codes.
• Unwrapping the appliance (leaving the shipping skid in place for easier move­ment) and checking for shipping damage.
• Moving the appliance to the installation loca­tion, removing the skid, and leveling the feet.
• Connecting the machine to tabling.
• Connecting the machine to a ventilation system (if so equipped).
• Connecting the machine to an external booster heater (if so equipped).
• Connecting the electrical supply.
• Installing the chemical dispensing system (if so equipped), following the manu­facturer’s instructions AND the instructions in Section 3 of this Manual.
• Connecting the fresh water supply.
• Connecting the steam supply line (for machines with steam heating).
• Connecting the steam condensate return line, and routing it to a floor drain (for machines with steam heating).
• Connecting the drain line, and routing it to a floor drain.
Page 4
• Contacting your Meiko Authorized Service Agent to perform a Performance and Installation Inspection for the machine. This step also validates the machine’s warranty.
3.2 Requirements Before Installation
Before the installer can uncrate and move the appliance to the installation location, the following conditions MUST be met:
• INSTALLATION AREA REQUIREMENTS
- The area MUST be frost-free. Freezing
temperatures (32°F/0°C or lower) inhibit proper operation and can damage internal components.
- The area MUST have a firm floor
surface. It is possible to compensate for uneven flooring by adjusting the feet.
- The area should be away from
appliances, furniture or surfaces that can be damaged by steam. If this is not possible, these items should be protected from the steam that is released during normal operation of the dishwasher.
• UTILTITY CONNECTION REQUIREMENTS
- Connections must be present and
ready for hookup to the appliance. All utility supplies must comply with the electrical information labels, with the information on the data plate, and with all applicable local and national codes.
- Electrical leads, water supply line(s),
drain line, and the steam supply and condensate return lines (if so equipped) must be present. The water supply must match the pressure and temperature specified on the data plate. The steam supply (if so equipped) must match the pressure and volume specified on the data plate.
- For units using an external booster
heater, the heater should be installed and ready for connection to the appliance.
- For units using a chemical dispensing
system, appropriate dispensers or containers should be installed and ready for connection to the appliance.
• GENERAL REQUIREMENTS Authorized personnel should be available
to perform the actual utility connections.
SECTION 3 - INSTALLATION
3.3 Uncrating, Positioning and Leveling
1. Remove all shipping and packaging ma­terial from the appliance, including sup­ports and wrappings. Leave the shipping skid in place at this time to allow for easier movement to the installation location.
2. Check for shipping damage as described in Section 2, “Transport and Shipping.” If damage is present, call Meiko Customer Service at 1-800-868-3840, providing full details on the customer, serial number and extent of damage present. Meiko will file a freight claim based on this information.
3. Move the appliance to the installation area and remove the skid. Meiko recommends using a pallet truck to lift the entire pallet and avoid damage to the machine. Use caution to avoid damaging the appliance or any of its components.
CAUTION
If the pallet is removed, the frame of the dishwasher can be damaged by improper lifting. The machine’s weight must always be distributed properly using cross-mem­bers to protect the frame.
4. If dish tables are already in place, it may be necessary to remove the end cowlings to install the machine. To remove the cowl­ings, refer to Figure 3-1.
Each cowling is held in place by hex head acorn nuts on the inside of the machine. For easy access to the acorn nuts, simply lift the front access door(s).
5. Using a spirit level, check that the appli­ance is level in both directions (front-to­back AND side-to-side). If necessary, level the appliance by rotating the bottom sec­tion of each foot.
CAUTION
The dishwasher MUST be level for proper operation.
6. If you removed the cowling(s) in Step 4, replace them onto the machine at this time. Be sure to check that the rubber gas­ket that fits between each cowling and the body of the machine is properly seated.
7. Run a fine bead of clear silicone sealant along the top edge of the seam between each cowling and the machine.
CAUTION
Do not attempt to slide the machine on its feet. This can bend the legs.
Figure 3-1: Removing
Cowling
Threaded studs:
Qty. 16 for
standard height
machine
Qty. 20 for high-
hood (“-T” model)
machine
Open door(s) to
access acorn
nuts and washers
the end cowlings
(if required)
Gasket
With cowlings
removed, set machine into
place between
tables
Gasket
Cowling
Replace cowlings
Page 5
SECTION 3 - INSTALLATION
3.4 Tabling Attachment
1. Position the table lip-in at both ends of the machine, as shown in Figure 3-2. Be sure to seat the lip-in against the inner plate of the sidewall of the dishwasher.
CAUTION
If the table lip-in is forced between the inner and outer plates, it will not seat properly. Always ensure that the lip-in is seated correctly as shown in Figure 3-2.
Figure 3-2: Tabling attachment
Outer
plate
CORRECT INCORRECT
Table lip-in
extends to
Inner plate
inside face of
inner plate.
Table lip-in
should not be
inserted
between inner
and outer plate.
3.5 Vent Cowl Collars (if so equipped)
For units that are not equipped with optional vent cowl collars, skip ahead to Section 3.6, “Booster Heater Placement.”
1. Check that the ventilation ducts (or “pant legs” are correctly positioned above the vent cowl collars on the machine.
2. Determine how the ducts will be attached. See Figure 3-3.
Figure 3-3: Vent cowl collar ducting
Baffle
2. Position the dishwasher and tables as follows:
• Check that the centerline at the open-
ing of each table is aligned with the centerline of the rack track of the dish­washer.
• Check that the surface height of each
table matches the height of the rack track of the dishwasher, to ensure a smooth transition. The standard table surface height is 34” (864mm).
• Check that the dishmachine is level.
The height of the dishmachine, and of most tables, can be adjusted by rotating the feet at the end of the legs.
CAUTION
After adjusting the height of the dishmachine, always check that it is level to ensure proper operation.
3. After the tables have been positioned correctly, secure them to the dishwasher using silicone sealant.
Page 6
DUCT SLEEVED
OUTSIDE COLLAR
(RECOMMENDED)
DUCT SLEEVED INSIDE COLLAR
• In most instances, the ducts can be sleeved over the outside of the vent cowl collars. This is the easiest installation and is recommended.
For this installation, the INSIDE DIMENSIONS of the ducting, when viewed from the front of the machine, should be 4” W x 16” D. The duct can overlap the outside of the vent cowl collar by up to 2” without interfering with the operation of the baffle.
SECTION 3 - INSTALLATION
• Where required by local codes, the ducts can be sleeved inside the edge of the vent cowl collars.
For this installation, the OUTSIDE DIMENSION of the ducting, when viewed from the front of the machine, should be 3-3/4”W x 15-3/4” D. The duct should overlap the inside of the vent cowl collar by a maximum of 1/2” to avoid interfering with the baffle.
3. Install the ducts to the vent cowl collars.
4. Secure the ducts to the collars using sili­cone sealant.
5. The baffles cannot be properly adjusted until the machine is turned on. Refer to Section 3.17, “Final Assembly.”
Figure 3-4: Accessing utility connections
3.6 Booster Heater Placement
For units that are not equipped with an exter­nal booster heater (for instance, when using a building’s boiler as a 180°F water supply), skip ahead Section 3.7, “Accessing the Util­ity Connections.”
The booster heater should be positioned at the unload end of the machine, close to the water inlet access panel. Meiko recommends a maximum pipe length from the booster to the machine’s water inlet of 48”. If a longer pipe run is necessary, Meiko recommends the use of pipe insulation to minimize heat loss.
3.7 Accessing the Utility Connections
The utility connections for the machine are shown in Figure 3-4.
UNLOAD END
(VIEWED FROM
FRONT)
Rinse aid
connection
Remove
access
panel
LOAD END (VIEWED FROM REAR)
Machines without
prewash: Dummy plug in
wall for direct detergent
injection
Machines with prewash:
Pre-plumbed raceway
for detergent tubing
Main electrical
supply strain
relief
Additional holes for
detergent pump and
accessory wiring
(covered with blind
plugs)
Remove
access
panel
Hot (180°F) water
connection
Warm (110-140°F)
water connection (if
machine is equipped
with prewash)
UNLOAD END
(VIEWED FROM REAR-
STEAM HEATED
MACHINES ONLY)
Steam supply line (outboard)
Steam condensate return (inboard)
Page 7
SECTION 3 - INSTALLATION
3.8 Main Electrical Supply Connection
WARNING!
Check that the circuit breaker/fused disconnect is in the OFF position and that the unit is switched off before making the electrical utility connections.
IMPORTANT
In some cases, local codes dictate that electrical supply connections be made only by a certified professional.
1. Check that the incoming power leads are of sufficient rating for the appliance’s current draw. Amperage and minimum supply wire specifications are shown on the serial plate and on the electrical infor­mation label on the control box.
2. Remove the top cover panel from the electrical control box by removing the four screws that hold it in place.
3. Locate the strain relief for the electrical supply wiring on the back of the control box (Figure 3-4). Thread the incoming supply leads through the strain relief and to the main electrical supply terminal block.
4. Refer to Figure 3-5 and the electrical wiring diagram. Connect the power supply and ground leads as indicated.
5. Adjust the strain relief to fasten the wiring in place. You should leave enough slack in the wiring to prevent stress on the terminal connections.
Figure 3-5: Main electrical supply
connections
L1, L2 and L3 = “hot” (line)
GND = ground
3.9 Dispensing System Overview
K-Series rack conveyor dishwashers are designed for use with a liquid rinse additive, and either solid or liquid detergents. Detergent and rinse additive injection is supplied by external dispensing systems (supplied by others).
The machine is equipped with:
• A location for detergent injection at the load end of the machine (see Figure 3-6).
- Machines equipped with a prewash
section (K-66, K-76, K-80, K-86, K-90, K100) have a pre-plumbed tubing raceway exiting the machine at this location. The raceway is routed to deliver detergent into the wash tank. Solid or liquid detergent lines can be routed down the raceway and into the tank.
- Machines that are NOT equipped with
a prewash section (K-44, K-54, K-64), have a dummy plug at this location. Removal of the plug allows the detergent line to be installed for direct chemical injection into the wash tank at this location.
• A dummy plug in the floor of the wash tank that permits the installation of a detergent concentration probe.
• A final rinse plenum chamber with a fitting for a liquid rinse aid line (see Figure 3-7). A threaded pipe connection just below the plenum allows the installation of a final rinse pressure switch.
A dispensing system terminal block inside the control box of the machine provides contacts for two line voltage relays. These relays, when closed, provide a “window” for external pump systems to activate.
Page 8
• A relay labeled “DDC” (Detergent Dispenser Connection) closes whenever the wash pump is in operation. This relay should be used for the detergent dispenser.
• A relay labeled “CVS” (Conveyor Voltage Signal) closes whenever the conveyor drive motor is in operation. This relay should be used for the rinse aid dispenser.
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