Nova DM400 Reference Manual

SPRITE WAREWASH

DISPENSING SYSTEM

Reference Manual

DM-400 Series

P/N 20-06270-00 Rev . N

P/N 20-06270-00 Rev. N

Table of Contents

1 Description of Features

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 Mechanical Installation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Wall Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Probe Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Rinse Injection Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Detergent Bulkhead Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Rinse and Detergent Supply and Discharge Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Solenoid Water Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3 Electrical Installation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Probe Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Main Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

115 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

208/240 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

230 VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Detergent Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Detergent Signal Wiring – Probe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Detergent Signal Wiring – Probeless Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Rinse Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

4 Description of Controls

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Key Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

5 User Mode Operation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Display Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

User Mode Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Guide to Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Visual Alarm Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Rack Counter (Menu 11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Detergent Prime (Menu 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Rinse Prime (Menu 13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

De-Lime (Menu 14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Live Conductivity Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Alarms (Probe Mode Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Low Detergent Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Detergent Overfeed Stop Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Manual Initial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Password Access to Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

P/N 20-06270-00 Rev. N iii

6 Program Mode Operation

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Program Mode Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Configuration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Detergent Control (Menu 21) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Machine Type (Menu 22). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Detergent Type (Menu 23.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Pulse Feed – Capsule Detergent Only (Menu 23.2) . . . . . . . . . . . . . . . . . . . . . . 6-4

Alarm Volume (Menu 24). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Rack Time in Rinse (Menu 25) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Initial Charge - Probeless Only (Menu 26). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Manual Initial Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Automatic Initial Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Change Installer Password (Menu 27). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Demo Mode (Menu 28). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Adjustments—Probe Mode (Menu 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Detergent Tank Reading (Menu 31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Detergent Set Point (Menu 32.1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Live Conductivity Display (Menu 32.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Rinse Pump Speed (Menu 33) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Low Detergent Alarm Delay (Menu 34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Rinse Feed Option (Menu 35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Rinse Delay Time (Menu 36) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Adjustments—Probeless Mode (Menu 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Detergent Initial Charge (Menu 41) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Detergent Dose (Menu 42) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Detergent Dose Interval (Menu 43). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Rinse Pump Speed (Menu 44) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Rinse Feed Option (Menu 45) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Rinse Delay Time (Menu 46) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

7 Troubleshooting

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Alarms and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Dead Unit (No Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

No Detergent Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Excess Detergent Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

No Rinse Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

8 Maintenance and Service

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Pump Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Service Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

9 Specifications

Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Index

iv P/N 20-06270-00 Rev. N

Description of Features

Overview

This chapter describes the features of the Sprite Warewash Dispensing System.

Advanced Design

The SPRITE uses miniaturized electronics to provide powerful features in a small package. A digital readout allows simple, three-button programming of all options.

Reliability

The gasket-enclosed SPRITE Warewash Dispenser is highly water resistant and the electronics are further protected within the enclosure. The readout gives confirmation of detergent and rinse feeds.

Versatility

The SPRITE can be configured as a conductivity probe controlled unit or as a probeless, time-based dispenser. It can accept a 100-115VAC nominal to 200-249VAC nominal (+/- 10% fluctuation) main power input at 50 or 60 Hz. Rinse and Detergent control signals are universal “machine interface” types that are capable of accepting any voltage from 24 to 240 VAC nominal (+/- 10% fluctuation) or 24 VDC (+/- 20% fluctuation). SPRITE can control either capsule or liquid detergents.

Cost Savings

A special Rinse Saver Feature prevents rinse additive waste during fills of the washer. Digital electronics ensure accurate detergent control and minimize overuse.

Intelligence

The SPRITE includes a rack counter as a “standard” feature. A unique “De-Lime” mode allows for safe washer cleaning without detergent waste.

Choice of Options

A full range of programmable options are included, such as rinse delay, variable alarm volume, and manual prime for both rinse and detergent.

Easy Service/Repair

The SPRITE features convenient front access for all servicing. No internal access to the cabinet is required for installation and routine maintenance. In the unlikely event that repairs are required, spare parts are available in modular form for fast and convenient service.

P/N 20-06270-00 Rev. N 1-1

1-2 P/N 20-06270-00 Rev. N

Mechanical Installation

Overview

This chapter describes the hardware installation of the Sprite. In this chapter, you will:

• Wall-mount the Sprite

• Mount and Install Probe (if applicable)

• Mount and Install Rinse Injection Fitting

• Mount and Install Detergent Bulkhead Fitting

• Install Rinse and Detergent Supply and Discharge Tubes

• Install Solenoid (if applicable)

Figure 2-1 System Diagram

P/N 20-06270-00 Rev. N 2-1

Wall Mounting

Warning

Choose an installation location that is:

The Sprite dispensing system is intended to be installed by experienced installers, in accordance with all applicable electrical and plumbing codes. All dish machine and dispenser power must be disconnected during installation and/or any time the dispenser cabinet is opened.

Mounting Bracket

• Close to the product containers.

• At a reasonable height for easy maintenance access.

• Away from any direct sources of steam, water spray, and high tem-

peratures.

• Close enough to the dish machine electrical control panel to allow

Back of Unit

dispenser wiring without use of an external junction box (not provided) wherever possible.

1. Using mounting bracket as a template, mark holes to drill into mounting surface. For sheet metal mounting with screws and nuts, drill 1/4" (6

Hang unit from this lip on to Mounting Bracket

mm) holes. For wall anchors, drill holes as appropriate for anchors used.

2. Attach mounting bracket to mounting surface with hardware provided.

Figure 2-2 Mounting

3. Hang unit on bracket. Optional: Drill hole and attach lower mounting hole to mounting surface.

Probe Mounting

(Probe Operation Only)

Bracket

The probe senses the detergent concentration. Correct probe placement is critical for accurate detergent concentration control. Always use the new probe provided with the dispenser.

When choosing a mounting location, make sure that the probe will be completely immersed in the wash tank solution, in an area that has a good flow of solution, and close to the product entry point.

Figure 2-3 Probe Mounting

Many dish machines will have knockouts provided for probe installation and/or will have existing probes. Previously punched probe holes may be suitable, but always confirm that the probe will be immersed in the wash tank solution before installing. The following steps describe probe installation.

If a probe hole is present, skip to Step 2.

1. Drill a 3/8" hole in the center of the probe location. Use a Greenlee (or similar) 7/8" hole punch to cut the final hole.

2. Remove the probe retaining nut.

3. From inside the dish machine tank wall, insert probe (with rubber gasket) into hole.

4. From outside the dish machine tank wall, install second rubber gasket, plastic washer and probe retaining nut. Tighten finger-tight only.

Warning

Do not over-tighten the retaining nut!

2-2 P/N 20-06270-00 Rev. N

Rinse Injection Fitting

Install the rinse injection fitting at least 6" below the dish machine rinse plumbing vacuum breaker to conform to plumbing codes. The injection fitting threads into 1/8" NPT female threads. If the dish machine rinse plumbing is thin-wall pipe, use a saddle clamp

Threads into rinse plumbing

Compression Fitting (tube from pump)

with a 1/8" NPT threaded hole. If an optional pressure switch will be used, thread the injection fitting into one side of the pressure switch water source fitting pipe tee. If the machine already has a tapped hole to accommodate the fitting, skip to Step 3.

Figure 2-4 Rinse Injection Fitting

Choose a location for the rinse injection fitting that is at least 6" downstream from the solenoid valve and vacuum breaker. On continuous rack, flight, or conveyor machines, be sure this location is downstream from any rinse makeup water.

1. Drill a 7/32" hole in the rinse plumbing injection location.

2. Tap the hole drilled in Step 1 with a 1/8" NPT tap.

3. Install the injection fitting. Use thread sealant to ensure a leak-free assembly.

Detergent Bulkhead Fitting

(Liquid Detergent Only)

Caution

Follow the instructions provided with your solid, powder, or slurry feed system for solenoid equipped units instead of using the following section.

Correct placement of the detergent bulkhead fitting is critical for accurate detergent concentration control (in probe mode only). When choosing a mounting locating, make sure that the detergent bulkhead fitting is:

• Above the water line in the tank.

• Close to the probe location (when possible).

• Discharging detergent directly into the wash tank and not on top of any shelf areas or other

obstacles that could prevent detergent from falling directly into the wash tank.

Previously punched holes may be suitable, but always confirm that the fitting is correctly placed.

If a hole is present, skip to Step 2.

1. Drill a 3/8" hole in the center of the detergent inlet location. Use a Greenlee (or similar) 7/8" hole punch to cut the final hole.

2. Remove the detergent bulkhead fitting retaining nut.

3. From inside the machine, insert detergent bulkhead fitting (with rubber gasket) into hole.

4. From outside the machine, install second rubber gasket, plastic washer and plastic retaining nut. Tighten finger-tight only.

Figure 2-5 Detergent Bulkhead Fitting

CAUTION: Do not over-tighten the retaining nut.

P/N 20-06270-00 Rev. N 2-3

Rinse and Detergent Supply and Discharge Tubes

Note

prite DM 411

Figure 2-6 Dispensing System

1. Route pump supply tubes from supply containers to the inlet sides (left) of each respective pump. Slip the tube through the compression nut into fitting and tighten.

2. Route pump discharge tubes to the outlet sides (right) of each respective pump. Slip the tube through compression nut into fitting and tighten.

3. Route other end of rinse pump discharge tube to rinse injection fitting installed in “Rinse Injection Fitting” on page 2-3. Slip the tube through compression nut into fitting and tighten.

4. Route other end of detergent pump discharge tube to the detergent bulkhead fitting (installed in

“Detergent Bulkhead Fitting” on page 2-3

Supply and discharge tubes are not included with the standard unit.

from water source

pump discharge tube connection

pump supply tube connection

to detergent feed bowl

). Slip tube through compression nut into fitting and tighten.

Sprite DM 420

Solenoid Water Feed

(Solenoid Equipped Units Only)

If you are using a solid, powder or slurry feed system, you will need a water source for the dispenser solenoid valve. This water supply may be hot or cold but, for safety reasons, should not come from th e boosted temperature rinse water line on high temperature dish machines.

The dispenser solenoid valve fittings are 1/4" (6mm) compression. Typically, a saddle clamp is used for the solenoid valve water sou rce. If the plumbing is steel or brass, d rill a 7/32" hole and tap for 1/8" NPT threads.

Caution

1. Install petcock valve to water source plumbing. Connect 1/4" copper or plastic tube to the valve.

2. Route tube to dispenser solenoid valve. Slide tube into water inlet side compression fitting and tighten.

3. Connect another 1/4" tube to the outlet side of the dispenser solenoid valve and route to the water inlet connection for the feed system.

4. Confirm that all compression fittings are tight.

5. Be sure to turn on water source valve prior to adjusting dispenser settings.

If the water source is hot, use only copper tubing; DO NOT use poly tubing.

2-4 P/N 20-06270-00 Rev. N

Electrical Installation

Overview

This chapter describes the electrical connections of the Sprite. In this chapter, you will connect:

• Probe Wiring

• Electrical Connections

• Main Power Wiring

• Detergent Signal Wiring (Probe and Probeless modes)

• Rinse Signal Wiring

All electrical connections (except the probe) must be in either the dish machine control circuit panel or an external junction box.

The dispenser is pre-wired with a multi-conductor electrical cable that must be run through a conduit to the location where hard-wired connections are

Note

made on the dish machine.

Use a 1/2" (13 mm) ID water tight conduit meeting all local and national codes. A conduit fitting is present on the bottom of the dispenser where the power cable exits.

The probe wire is also pre-wired and should be routed to the probe location and cut to length if a probe is used.

P/N 20-06270-00 Rev. N 3-1

Probe Wiring

1. Route the probe wire to the probe location and cut to fit. If you need to extend the probe wire, use high quality , corrosion resistant (waterproof is best) butt splices with a good quality crimping tool.

2. Strip wire ends and crimp on the ring lugs provided.

3. Connect the ring lugs to the probe with nuts and star washers provided. Be sure that connections are tight and secure.

Electrical Connections

Table 3-1 90-130 VAC Main Power

Wire Colors Circuit Voltage Function

Gray/Violet 90-130 VAC 50/60 Hz Main AC Power

Black 90-130 VAC 50/60 Hz Main AC Power

Brown No Connection - Insulate! Warning - Live!

Yellow 24-249 VAC, +24 VDC Detergent Signal

Yellow/White 24-249 VAC, -24 VDC Detergent Signal

Violet 24-249 VAC, +24 VDC Rinse Signal

White/Violet 24-249 VAC, -24 VDC Rinse Signal

Table 3-2 200-249 VAC Main Power

Wire Colors Circuit Voltage Function

Gray/Violet 200-249 VAC 50/60 Hz Main AC Power

Brown 200-249 VAC 50/60 Hz Main AC Power

Black No Connection - Insulate! Warning - Live!

Yellow 24-249 VAC, +24 VDC Detergent Signal

Yellow/White 24-249 VAC, -24 VDC Detergent Signal

Violet 24-249 VAC, +24 VDC Rinse Signal

White/Violet 24-249 VAC, -24 VDC Rinse Signal

Table 3-3 230 VAC Main Power

Wire Colors Circuit Voltage Function

Lt. Blue 200-249 VAC 50/60 Hz Main AC Power

Brown 200-249 VAC 50/60 Hz Main AC Power

Yellow 24-249 VAC, +24 VDC Detergent Signal

Yellow/White 24-249 VAC, -24 VDC Detergent Signal

Violet 24-249 VAC, +24 VDC Rinse Signal

White/Violet 24-249 VAC, -24 VDC Rinse Signal

3-2 P/N 20-06270-00 Rev. N

Main Power Wiring

115 VAC

Connect the gray with violet stripe wire to the neutral source. Connect the black wire to the 115 line. Cap off and insulate the brown wire (Wire nut provided).

208/240 VAC

Connect the gray with violet stripe wire to one side of the voltage source. Connect the brown wire to the other line of the voltage source. Cap off and insulate the black wire (Wire nut provided).

230 VAC

Connect the light blue wire to one side of the voltage source (Neutral, if available). Connect the brown wire to the other side of the voltage source.

Detergent Signal Wiring

(+) Yellow

(-) White/Yellow

Detergent Signal

Figure 3-1 Detergent Signal Wiring Diagram—Probe or Probeless Mode

The detergent signal input is an optically isolated signal input that draws no more than 20 mA. It is a universal voltage input that accepts any voltage between 24 and 240 VAC nominal (+/- 10% fluctuation), or 24 VDC nominal (+/- 20% fluctuation).

Detergent Signal Wiring – Probe Mode

Typical wiring locations are dispenser detergent power source or the wash motor contacts in the dish machine control panel. This power source is on when the dishwasher is running the wash pump.

• Connect yellow (DC +) and white/yellow (DC -) colored wires to detergent power source.

24-240V 50/60Hz or 24V DC

P/N 20-06270-00 Rev. N 3-3

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