Power Soak PS-201 Service Manual
SERVICE MANUAL
PS-200 & PS-201
Table of Contents
Explanation of Warning Messages ......................................................................................... 1
Danger ............................................................................................................................................ 1
Warning ......................................................................................................................................... 1
Personal Injury Hazard ........................................................................................................... 1
Chemical Hazard ........................................................................................................................ 1
Preventive Maintenance ............................................................................................................ 2
Daily ................................................................................................................................................ 2
Monthly ......................................................................................................................................... 2
Troubleshooting ............................................................................................................................ 3
Hazard to Untrained or Unauthorized Personnel. ...................................................... 3
Pump leaks ................................................................................................................................... 3
Intermittent running ............................................................................................................... 3
Pump does not work ................................................................................................................ 4
Pump works- Heater does not work ................................................................................. 4
Water too hot or not hot enough ........................................................................................ 4
No Power ...................................................................................................................................... 5
Error Codes .................................................................................................................................. 5
Component Operation and Checks ........................................................................................ 7
Liquid Level Sensors ................................................................................................................ 7
Thermistor ................................................................................................................................... 7
Heater Thermodisc (Hi-Limit or Cutoff Switch) .......................................................... 8
Transformer ................................................................................................................................ 8
Triac (Thyristor or Solid-State Relay) .............................................................................. 9
Contactor ...................................................................................................................................... 9
Heater Element .......................................................................................................................... 9
Parts List ........................................................................................................................................ 10
Motor – Impeller – Pump Assembly ............................................................................... 10
Motor – Impeller- Pump Assembly ................................................................................. 11
Motor – Impeller- Pump Assembly ................................................................................. 11
Heater .......................................................................................................................................... 13
Control Panel ........................................................................................................................... 14
Miscellaneous .......................................................................................................................... 14
Optional Chemical Dispenser ............................................................................................ 15
Electrical Schematic .................................................................................................................. 16
208-240 volt 60 Hz 1 phase ............................................................................................... 16
208-230 volt 60 Hz 3 phase ............................................................................................... 17
460 volt 60 Hz 3 phase ........................................................................................................ 18
Electrical Schematic (European) ......................................................................................... 19
400 volt 50 Hz 3 phase ........................................................................................................ 19
230 volt 50 Hz 3 phase ........................................................................................................ 20
Motor and Pump Assembly.................................................................................................... 21
Exploded View ......................................................................................................................... 21
Motor and Pump Assembly & Disassembly Procedures ........................................... 22
DISASSEMBLY PROCEDURE: ............................................................................................ 22
INSPECTION OF THE COMPONENTS: ........................................................................... 22
ASSEMBLY PROCEDURE: .................................................................................................... 22
Appendix A.................................................................................................................................... 24
Explanation of Warning Messages
Read, understand and follow all DANGER, WARNING, and CAUTION messages located in
this guide and on the equipment.
Danger
Personal Injury and Property Damage hazard.
May result in serious injury of death.
May cause extensive equipment damage.
Warning
Property Damage Hazard.
May result in property or equipment damage.
Personal Injury Hazard
Hazard from sharp objects.
May result in serious injury or death.
Chemical Hazard
May result in serious injury or death. Instructions,
labels and Material Safety Data Sheets (MSDSs) should
be supplied with all detergents and sanitizing
chemicals. The manufacturers, importers and
distributors of your cleaning chemicals are responsible
for providing this information.
1
Preventive Maintenance
Power Soak machines require minimal, routine preventive maintenance. As such, the
following should be done on a routine basis to ensure that your system remains reliable:
Daily
Clean the liquid level sensors. These sensors are located on the side walls of the wash and
sanitizer tanks. They are the white plastic discs with metal centers. Clean the sensor
faces thoroughly. If cleaned regularly, a washcloth and soapy water are all that is
required.
If the liquid level sensors are not cleaned regularly, the
machine may fail to operate. Dirty sensors may create a
situation that will allow the machine to run without water,
which can cause serious damage to the unit.
Monthly
IMPORTANT: Turn off the power to the unit at the main
breaker prior to performing the following task!
After shutting off the power at the system’s dedicated breaker, clean the pump motor fan
shroud with a stiff bristle brush and a vacuum. If a brush and vacuum are unavailable,
clean the shroud with a damp, soapy rag. The motor shroud is the “vented” cover located at
the end of the motor (closest to the control panel). This will prevent grease and dust from
accumulating in the cover’s openings, which can obstruct the airflow that cools the motor.
De-lime the wash sink. Simply add a de-liming agent to a sink of warm, fresh water and
run the system overnight.
Ask your chemical sales representative to recommend a specific de-liming agent.
Note: The motor bearings do not need to be greased because they are permanently sealed.
If you have any questions regarding the preventive maintenance procedures, please contact
the factory at 800-444-9624.
2
Troubleshooting
Hazard to Untrained or Unauthorized Personnel.
The following procedures are provided for use by an authorized service
agency. No facility owner, manager, employee or other unauthorized
person should attempt to perform any of these procedures. To obtain
the name of a recommended service agent in your area, please call the
Power Soak Service Department. 800-444-9624.
When performing trouble shooting procedures, the authorized service
agency will need to open the electrical enclosure on the Power Soak
machine.
The control panel must be properly closed before reconnecting the
power to the machine.
Pump leaks
Look for Correction
1 Defective ADAPTER O-RING Replace
2 Defective PUMP SEAL Replace
Intermittent running
See “Pump does not work” below
3
Pump does not work
Look for Correction
1 Slow flashing Green Light Clean Liquid Level Sensors.
Fill sink with water to proper level.
Tighten the External Wiring Harness on
back of Control Panel.
2 Solid Blue Light Clean Liquid Level Sensors.
Drain sink and refill with proper water level.
3 Error LED on UPM Record the pattern – See “Error Codes”
4 Red, Green, Blue lights blinking together Low power to UPM – See “No Power”
5 No indicator lights at all Water too hot – reduce temperatures to
115° with ice or cold water
See “No Power”
Pump works- Heater does not work
Look for Correction
1 Water temperature < 110°F Check Heater and replace as necessary.
Check Triac(s) and replace as necessary.
2 Water temperature between 110°F and
120°F
3 Water temperature > 120°F Check Thermistor and replace as necessary.
Normal operating temperature.
Too much soap can cause excessive heat
buildup
Water too hot or not hot enough
Look for Correction
1 Water temperature < 110°F Check Heater and replace as necessary.
Check Triac(s) and replace as necessary.
2 Water temperature between 110°F and
120°F
3 Water temperature > 120°F Check thermistor and replace as necessary.
Normal operating temperature.
Too much soap can cause excessive heat
buildup.
4
No Power
Look for Correction
1 Incoming voltage between L1 and L2 (L1L2)
(Also L1-L3, L2-L3 if 3 phase)
2 Less than 10 volts to UPM
(leave UPM plugged in during check)
Check Heater and replace as necessary.
Water too hot, above 135°F – empty sink
and refill with 115°F water.
Tighten the External Wiring Harness on
back of Control Panel.
Check transformer and replace as necessary.
Check thermal cutoff for heater and replace
as necessary.
Check thermal cutoff for motor and replace
as necessary.
Error Codes
~ Represents a “long” flash
* Represents a “short” flash
Look for Correction
1 ~ ~ ~ * Liquid Level Error This error appears when the upper liquid
level sensor sends a signal to the UPM (W-H
light is illuminated) and the low liquid level
sensor is not sending a signal to the UPM
(W-L is not illuminated). The low level
sensor may not be functioning due to a
coating of debris or a broken/disconnected
wire that is preventing the signal to the
UPM. A continuous signal from the upper
level sensor can be caused by debris coating
the face of the sensor or faulty wiring that
has the sensor connection grounded to the
wash tank when there is no fluid in the tank.
The liquid level lights on the UPM can be
used to help determine the problem.
5
2 ~ ~ ~ * * Temperature Sensor Error When the UPM receives a signal from the
thermistor that is outside the range of the
UPM programming, the temperature sensor
error will actuate
error if it reads a resistance greater than
430 k and less than 15 k. Check and replace
Thermistor as necessary.
3 ~ ~ ~ * * * Over Current Error If any of the high voltage components begin
drawing excessive current, the current
sensor will send a signal to the UPM to start
the Over Current Error and deactivate the
contactor which turns the power off to the
machine. Check and replace the
transformer, motor and/or heater as
necessary.
4 ~ ~ ~ * * * * Over Temperature Error If the fluid temperature in the wash tank
exceeds 135°F it will activate this error
message and stop the machine. This error
code cannot be reset until the fluid is
drained below the low level sensor in the
wash tank.
5 ~ ~ ~ * * * * * Current Sensor Error The UPM must receive a signal from the
current sensor to verify that it is connected
and working. If it does not receive the
signal, the UPM program will stop the
machine and give this error code.
6 ~ ~ ~ * * * * * * Membrane Error In the event that one of the control panel
buttons sends a constant signal to the UPM,
the program will recognize that the
membrane is defective and display this
error code (see Section 6.9 Push Button
Membrane).
.
The UPM will signal an
6
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