PrecisionTemp PT-200FT, PT-200RC, PT-56 Service Manual

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Warning:

If the information in this service pack is not followed exactly, a fire or explosion

ANSI Z21.10.3

Service Manual

PT-200FT, PT-200RC & PT-56

Gas Booster Heaters

CAN 1-43 – M85 NSF 5e- 2000

may result causing property damage, personal injury, or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.

IF YOU SMELL GAS:



Do not try to light any appliance.



Do not turn any electrical switch on or off



Do not use the phone in your building



Immediately call your gas supplier from a neighbor’s phone



If you cannot reach your gas supplier, contact the fire department.

Installation and service must be performed by a qualified installer, service agency or gas supplier.

Should overheating occur or the gas supply fails to shut off, turn off the manual gas control valve at the appliance.

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water.

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 1

IMPORTANT NOTICE TO REPAIR

Repair Technician must call PrecisionTemp

TECHNICIAN

PRIOR to starting WARRANTY repairs to

obtain a warranty authorization number.

No reimbursements

will be made without an authorization number

NO additional time reimbursements will be made

without prior authorization. All warranty parts

must be returned within 15 days of completing

repair (return label supplied). All warranty invoices

must be accompanied by a copy of the technician

worksheet detailing the customer complaint,

correction and product serial number. NO Facility

issues are covered by PrecisionTemp’s warranty.

CALL BEFORE SERVICING

M-F 9am-5:30pm ET

800-934-9690 or 513-641-4446

After Hours tech calls M-F 6-9pm ET and

Saturdays 9am-3pm ET 513-373-8357

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 2

T-200 & PT-56 Installation and Service Bulletin Contents

• Parts and Labor Warranty

• Warranty Policy Procedure

• Introduction

• PT-200FT Design and Sequence of Operation

• PT-200RC Design and Sequence of Operation

• PT-56 Design and Sequence of Operation

• Reference Component Illustrations

• Control Board Layout Illustration

• PT-200FT Troubleshooting Guide

• PT-200RC & PT-56 Troubleshooting Guide

• PT-200FT Electrical and Plumbing Schematics

• PT-200RC &PT-56 Electrical and Plumbing Schematics

• PT-200FT Service Codes

• PT-200RC & PT-56 Service Codes

• Service Bulletins and Charts

o SB-1 12 Volt Power Supply Change Procedure o SB-1A 24 Volt Power Supply Change Procedure o SB-2 Pressure Switch Adjustment o SB-3 Circuit Board Replacement o SB-5 Igniter Change and Spark Gap Adjustment o SB-6 Direct Spark Ignition (DSI) Board Change o SB-7 Automatic Calibration (AutoCal) Procedure o SB-8 Modulating Valve Replacement o SB-10 Changing Outlet Temperature Setting o SB-11 Fan Relay o SB-12 Combination Gas Valve Replacement o SB-13 Flow Meter Check and Replacement o SB-14 Burner Manifold Pressure Check and Adjustment o SB-15 T-Mid Thermistor Change Procedure o SB-16 T-Out/ T-In Thermistor Change Procedure o SB-17 Thermistor Reading Procedure o SB-18 PT-56 Tank Replacement o SB-19 PT-56 Pump Replacement o SB-20 PT-56 Testing Procedure

• Thermistor Calibration Chart

• Replacement Parts List

• Preventative Maintenance Schedule

• Installation Manual

• Factory Authorized Startup Procedure

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 3

MANUFACTURER’S LIMITED PARTS AND LABOR WARRANTY/GAS

BOOSTER HEATER

RAD Technologies, Inc, d/b/a PrecisionTemp, also called the ‘Company’ hereafter, warrants the products it manufactures to be free of defects in both material and workmanship, under normal use and service, when installed and maintained in accordance with PrecisionTemp written instructions, subject to the time periods, terms, and conditions stated below:

The warranty period is eighteen (18) months parts and twelve (12) months labor from the date of in-service or Factory Authorized Start-Up. For booster heaters that are wall mounted, the Company will extend the warranty by six (6) months for both parts (total 24 months) and labor (total 18months). The burner, heat exchanger and tank replacement are warranted for five (5) years (parts only), which will be pro-rated after the first year (call factory for details). Defective parts will be repaired or replaced at the manufacturer’s sole discretion.*

This warranty does not cover failure in any water components including tank, heat exchanger or pump due to freezing, chemical attack, sediment buildup, liming, or scaling due to hard water. Labor charges will be paid by the Company based on PrecisionTemp service labor rate schedule on work performed during regular business hours. Overtime premiums will not be paid by PrecisionTemp. The length of the warranty on any warranty replacement item will be the lesser of ninety (90) days or unexpired portion of the original warranty. Outside the Unites States and Canada, the Company liability is limited to the replacement of the warranted part as specified by the time periods and conditions above.

The Company limits warranty travel time to a maximum total of two (2) hours and one hundred (100) miles. The Company will not pay travel time or mileage that exceeds this without prior authorization. All warranty service must be completed by the Company or its authorized agencies. The Company does not authorize any other person or company to perform warranty service on the Product.

IN ALL EVENTS, NO WARRANTY OF ANY KIND, EXPRESSED OR IMPLIED, SHALL EXTEND BEYOND THE RESPECTIVE TIME PERIODS OR TERMS DESCRIBED ABOVE. IN NO EVENT WILL PRECISIONTEMP BE LIABLE FOR INCIDENTAL, SPECIAL, OR CONSEQUENTIAL DAMAGES SUCH AS LOSS OF USE OR INJURY TO OTHER PROPERTY, LABOR COSTS, OR LOST PROFITS RESULTING FROM USE OR INABILITY TO USE PRODUCT.

IN ORDER TO ACTIVATE THE TERMS OF THIS WARRANTY, THE PURCHASER MUST CONTACT PRECISIONTEMP AND PERFORM A FACTORY AUTHORIZED START-UP. *Accessory components supplied by PrecisionTemp, carry a one-year parts only warranty. Accessory components include, but are not limited to: temperature gauge, expansion tank, ball valve, drain valve, pressure reducing valve, and relief valve. Labor to replace these components is not covered by this warranty.

LIMITED WARRANTY PROVISIONS

This warranty is intended to provide you with protection against abnormal failure due to faulty materials or workmanship. It does not cover adjustment or replacements due to normal wear. This warranty shall not cover:

1. The cost of labor for stopping leaks that may be corrected by tightening.

2. Damage resulting from untreated hard water conditions resulting in liming or scaling, clogging of valves preventing proper operation, objects such as dirt, sand, chemical buildup or debris, or broken parts caused by solder or other debris passing through this unit.

3. Transportation, installation or removal costs are not covered by this warranty. This warranty does not cover any failures or operating problems due to abuse, accident, alteration of equipment, improper installation, negligence, application of improper voltage, or recalibration of thermostats or limit switches.

4. Damage caused by over-voltage or use with utility service other than designated on the machine’s rating plate or improper connection to utility service. Failure to comply with local building codes, inadequate wiring or plumbing.

5. Damage caused by excessive water pressure.

6. Regular maintenance is owner’s responsibility.

7. Any additional time required to gain access to service the equipment. Additional charges will be billed to the customer.

8. Incidental, special, or consequential damages such as loss of use or injury to other property, labor cost, or lost profits resulting from use or inability to use product.

This warranty is void if defect is due to damage from shipment handling, fire, water, accident, abuse, misuse, acts of God, attempted repairs or improper installation by unauthorized persons, if serial numbers or identifying marks have been removed or altered, or if equipment is used for purposes other than that for which it is intended. 7/2008

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 4

Manufacture’s Limited Parts and Labor Warranty

Limited Warranty Provisions

This warranty is intended to provide you with adequate protection against abnormal failure due to faulty materials or workmanship, but it does not cover adjustment or replacements due to normal wear.

This warranty shall not cover:

1. The cost of labor for stopping leaks that may be corrected by tightening.

2. Damage resulting from untreated hard water conditions resulting in liming or

scaling, clogging of valves preventing proper operation, objects such as dirt, sand, chemical buildup or debris, or broken parts caused by solder or other debris passing through this unit.

3. Transportation, installation or removal costs are not covered by this warranty.

This warranty does not cover any failures or operating problems due to abuse, accident, alteration of equipment, improper installation, negligence, application of improper voltage, or recalibration of thermostats or limit switches.

4. Damage caused by over-voltage or use with utility service other than designated

on the machine’s rating plate or improper connection to utility service. Failure to comply with local building codes, inadequate wiring or plumbing.

5. Damage caused by excessive water pressure.

6. Regular maintenance is owner’s responsibility.

7. Any additional time required to gain access to service the equipment. Additional

charges will be billed to the customer.

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 5

PrecisionTemp Warranty Procedure

The following procedure must be followed to implement the PrecisionTemp “Manufacturer’s Limited Warranty”. Please refer to the “Manufacturer’s Limited Warranty” for full terms.

To Make a Warranty Claim

1) Contact PrecisionTemp prior to going to the service site. When the technician arrives at the service location, he must call PrecisionTemp @ 513-641-4446 or 800-934-9690.

NO work should be performed prior to calling PrecisionTemp for a work authorization number. This work will be considered unbillable time and could void

the warranty.

If it is known in advance that warranty work must be performed on PrecisionTemp equipment outside of PrecisionTemp’s normal business hours (9:00 AM – 5:00 PM Eastern time), call one of the above numbers in advance for the phone number of a PrecisionTemp technician to assist you after-hours.

2) If it is known in advance that a part is needed for the service, the service call must not be made until part is on-site.

3) The equipment serial number, work authorization number and installation location MUST be on all paper work..

4) Parts replaced under warranty must be returned to PrecisionTemp within 15

(fifteen) days of claim.

5) Hourly rate and travel expense must be approved in advance of work being performed.

Under no circumstances will PrecisionTemp pay overtime fees.

6) All warranty invoices must be accompanied by copies of the technician’s work sheet detailing the service performed and hours worked.

7) Accessory components supplied but not installed by our factory carry a one-year parts only warranty. Labor to replace these components is not included. The length of the warranty on any replacement item will be the lesser of (90) days or unexpired portion of the original Warranty.

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 6

PrecisionTemp will cover warranty work preformed only on PrecisionTemp products for defects in material or workmanship, not problems related to the facility, installation or related equipment issues such as:

• Improper water pressure.

• Tripped circuit breaker.

• Improper installation including blocked access to heater access panel.

• Improper primary hot water temperature or water pressure issue.

• Cold water bypass or negative air pressure in facility.

• Improper power hookup or power turned off.

• Undersized gas line or low gas pressure.

• Water flow problems caused by the ware washer such as liming or

defective solenoid valves.

• Excessively long recirculation loops or undersized plumbing components.

• Any problem that is a result of any of the above situations that occur due

to misrepresentation of the facilities to PrecisionTemp, consultants or installers prior to or after equipment installation.

Warranty coverage is based on PrecisionTemp’s warranty policy. PrecisionTemp may, at times, arrange service as a courtesy to the customer. This does not imply that PrecisionTemp guarantees the performance of this service or is responsible for the charges. PrecisionTemp will not pay for additional time required to gain access to its equipment or for the technician not being given access to equipment in a reasonable time-frame. PrecisionTemp reserves the right to accept or deny warranty claims based on the above policy.

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 7

PrecisionTemp Parts Warranty Policy:

All replacement parts are covered for a period of 90 days from the time of installation. Parts replaced under the terms of basic product warranty are covered through the product warranty period or 90 days whichever is greater. Parts replaced on units not covered by basic product warranty have a parts only warranty with NO labor coverage for a period of 90 days from the date of installation.

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 8

Service Time Replacement Guide for PT-200

Part

Number Component Description

Diagnostic

Time Replace

1019 Ignition Probe 0.3 0.2 0.1

1092 Modulating Valve 0.50 0.5 0.2

1119 3 Amp Circuit Breaker 0.20 0.2 ▬

1436 T-In Assy 0.20 0.2 0.1

1437 T-Out Assy 0.2 0.2 0.1

1463 Solenoid Valve NG Robertshaw 0.50 0.5 0.1

1496 Wire Harness 12v DC to Board 0.20 0.2 ▬

1613 24v DC Power Supply 0.30 0.3

1615 Relay 12v DC Control 0.30 0.2 ▬

1616 Pressure Switch 0.30 0.2 0.2

Parts

1634 Pressure Reducing Valve ▬

Only ▬

1749 ECO 0.2 0.2 0.1

Parts

1752 Pressure Relief Valve ▬

Only ▬

1765 Ignition Wiring Harness 0.3 0.3 0.1

Test

▬

1826 Power Wire Harness /Cont Bd. 0.20 0.2 ▬

1854 T-Mid Assy 0.2 0.2 0.1

1875 Blower Assy 0.30 0.5 ▬

1896 Dual Temp Dig.Display 0.20 0.3 ▬

1897 12v DC Power Supply 0.2 0.3 ▬

1994 Heat Exchanger w/ass't parts ▬ ▬ ▬

2004 Switch on/off 0.20 0.1 ▬

2066 T-In Assy, temp display 0.2 0.2 ▬

2067 T-Out Assy, temp display 0.2 0.2 ▬

2354 Flowmeter Assy 0.30 0.3 ▬

2412 DSI Board 0.3 0.2 0.1

2416 Flow Meter Gaskets 0.20 0.3 ▬

1841 200 Control Bd. & Microprocessor 0.50 0.2 ▬

ACAL Automatic Calibration ▬ 0.5 ▬

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 9

SERVICE

INTRODUCTION

flow through design where the booster is located close to

ues, use

Check the software version label on the microprocessor with the list

Which type of booster heater do I have?

PrecisionTemp manufactures two booster heater models.

1. The PT-56 is used for all single rack door-type dishmachines. This unit is ETL certified for ventless operation (check local codes as some states do not allow ventless gas appliances) and has an internal tank and pump.

2. The PT-200 is used for all conveyor and flight type dishmachines. This unit requires a flue be fitted. This flue can exit into the pant leg duct or exhaust / condensate hood over the dishmachine (check local codes). There are three types of PT-200:

a. PT-200FT-199,000BTU

the dishmachine, typically under the dish table. Rinse flow rate 4-5+gpm. NOTE: The NSF-5 Code requires that booster heaters be located within five pipe feet of the dishmachine to maintain proper rinse temperature. If this cannot be accomplished, the pipe must be insulated or a recirculation system be installed.

b. PT-200OR-125,000BTU same as the PT-200FT, it is used for newer low flow

water conserving dishmachines. Rinse flow rate 2-3gpm. For service iss the PT-200FT installation, operation, and service instructions

c. PT-200RC- recirculation design, where the booster heater is located far from the

dishmachine. An additional pump and storage tank are fitted to the water lines to the dishmachine, external to the booster heater.

3. Aside from the model number, you can verify which model you have by looking at the model number label located on the front panel of the booster heater.

IMPORTANT! Verify which software version you have before completing any service!

You can verify this by looking at the software version label on the green electronic board inside the electronic drawer. When using this service manual, ensure you are using the correct software version. below:

1. PT-200 RC & PT-56 Software versions: 9098-A, 9098-B, 9098-C, 9098-D, 9098-E, 9098-F, 9098-G, 9098-H, 9098-I, 9098-J, 9098-K, 9098-L, 9098-M, 9098-N, 9098O

2. PT-200FT Software versions: 9097-A, 9097-B, 9097-C, 9097-D, 9097-E, 9097-F, 9097-G, 9097-H, 9097-I, 9097-J, 9097-T

3. PT-200OR Software versions: 9099-A, 9099-B, 9099-C, 9099-D, 9099-T

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 11

Turbine Flowmeter # 3226 Pressure Switch # 2937 Illustration # 200-3226 Illustration # 200-2937

Ignition Board pedestal #3166 DSI Ignition Board #3158 Illustration # 200-3166 Illustration # 200-3158

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 19

PT-200FT (Flow Through) and PT-200OR

DC through the brown wire to the pressure differential

Design and Sequence of Operation

The PT-200 tankless gas booster heater is designed as an on-demand water heater that ignites the burner when the ware washer rinse solenoid opens and water flows through the booster.

The PT-200FT is designed to be installed close to the dish machine. The National Sanitation Foundation stipulates that if a booster heater that is located further than five feet from the dishmachine, then it requires a recirculation system be fitted. This system recirculates the water between the outlet of the booster and the inlet to the dishmachine to prevent temperature loss below the required 180°F. For further information, see the page titled “PT-200RC (Recirculation) Design and Sequence of Operation”.

The sequence of operation is as follows:

• Power is on, the power switch glows, and green LED on the control board flashes. The digital temperature readout is not displaying.

• The rinse solenoid of the warewasher opens and water flows through booster heater.

Note: The next steps take place in 3-5 seconds.

• The flow meter senses the water flow & sends a flow signal to the green control board.

• The green control board sends 12v

switch and on to the black solid-state relay that powers the power vent blower.

• The relay closes the 110v AC contacts to start the blower.

• Fluing is proofed by the clear vacuum tube that runs from the blower to the pressure

differential switch.

• The pressure differential switch contacts close, sending 12v DC to the spark ignition module via the grey wire.

• The ignition module simultaneously affects a spark through the heavy yellow wire to the spark ignition probe over the burner and sends 12v DC to the combination gas valve via the blue wire. Ignition attempts lasts up to 5.5 seconds. The digital temperature read-out displays the outlet temperature.

• Ignition of the burner’s center element is effected and the flame is proofed and monitored through the same yellow wire by the spark ignition module.

• The green control board sends DC voltage to the modulating gas valve for one second to effect flame cross-over to all burners.

• The micro-processor on the green control board monitors water flow with the flow meter and temperature with the three thermisters twice per second and varies voltage 0 – 22v DC to the gas modulating valve, varying gas flow to burner in order to maintain constant temperature output.

• Burner remains lit as long as the rinse solenoid is open, but if flame is extinguished for any reason, the gas valve will shut off in less than 1 second. Re-ignition will be attempted.

• When warewasher rinse solenoid closes and booster heater no longer senses flow, the booster heater reverts to standby mode and digital temperature readout turns off.

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 20

PT-200RC (Recirculating)

water in the line and prevents temperature loss.

DC through the brown wire to the pressure differential

DC to the

Burner remains lit as long as the water in the tank is below set temperature, but if flame is

Design and Sequence of Operation

The PT-200RC gas booster heater is designed for use when a PT-200FT (Flow through) cannot be used. It is for use when the booster must be remotely located from the dishmachine. The National Sanitation Foundation requires any booster that is not located within 5 feet of the dishmachine must have a recirculation system installed. The PT-200RC system includes the booster heater, circulation pump, expansion tank, and holding tank.

The PT-200RC is an on-demand water heater. During operation, any time the T-mid thermister senses the water temperature drop below the factory set temperature, the burner ignites and heats the dish machine rinse water. This water is circulated by the pump through a recirculation line from the outlet of the booster, to the recirculation tank mounted near the dishmachine, then back to the booster. This provides constant hot

The sequence of operation is as follows:

• Power is on and the power switch glows and green LED flashes. The pump is circulating water from the booster to the tank and on to the dish machine and back to the booster.

Note: The next steps take place in 3-5 seconds.

• The T-mid thermister on the booster sense low water temperature and sends a flow signal to the control board.

• The green control board sends 12v switch and on to the black solid-state relay that powers the power vent blower.

• The relay closes the 110v AC contacts to start the blower.

• Fluing is proofed by the clear vacuum tube that runs from the blower to the pressure

differential switch.

• The pressure differential switch contacts close, sending 12v DC to the black spark ignition module via the grey wire.

• The ignition module simultaneously effects a spark through the high limit switch through the heavy yellow wire to the spark ignition probe over the burner and sends 12v combination gas valve via the blue wire. Two ignition attempts last up to a maximum of

5.5 seconds. The digital temperature read-out displays (if installed, otherwise, check temperature on spring gauges).

• Ignition of the burner’s center element is effected and the flame is proofed and monitored through the same yellow wire by the spark ignition module.

• The micro-processor on the control board monitors water temperature with the T-mid thermisters twice per second and varies voltage 0 – 22v DC to the gas modulating valve, varying gas flow to burner in order to maintain constant temperature output.

• Burner will modulate down as tank temperature approaches set temperature.

•

extinguished for any reason, the gas valve will shut off in less than 1 second and re-ignition will be attempted.

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PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 21

PT-56 Gas Booster Heater Sequence of Operation

senses the water temperature is below set temperature, it

and the burner is shut off. Note: If the flame is

The PT-56 is an unvented gas booster heater designed to supply 180° final rinse water to a single rack door warewasher. The sequence of operation is as follows:

• Power is on, the power switch glows and the green LED flashes. The re-circulating pump draws cooler water from the bottom of the stainless tank and pumps it through the copper heat exchanger.

• The water from the copper heat exchanger returns to the stainless tank via the tee fitting in the top of the stainless tank.

Note: The next 5 steps take place in 3-5 seconds.

• If the T-mid thermistor sends a signal to the green control board.

• The green control board, which is powered by the 12 VDC converter, sends 12 VDC through the black wire to the spark ignition module.

• The Ignition module simultaneously effects a spark through the heavy yellow wire to the spark ignition probe over the burner and sends 12 VDC to the combination gas valve via the blue and white wire. (Up to three ignition

attempts lasting up to 5.5 seconds max each).

• Ignition of the burner’s center element is effected and the flame is proofed and monitored through the same yellow wire to the ignition module.

• The green control board sends 12 VDC via the back & white wire to the modulating gas valve for one second to effect flame cross-over.

• The micro-processor on the green control board monitors water temperature with the T-mid thermistor twice / second and varies voltage 0 –12 VDC to the gas modulating valve in order to maintain constant temperature output.

• As the water in the stainless tank approaches set temperature, the gas flow is cut back by the modulating gas valve by reducing the DC voltage to the valve down to 0 volts. This is by-pass (low) gas flow.

• Burner remains lit until set temperature of the circulating water is reached. This is sensed by the T-mid thermistor extinguished for any reason, the combination gas valve will shut off is less than 1 second and re-ignition will be attempted.

• When the rinse solenoid of the warewasher opens, rinse water flows from the tee fitting in the top of the stainless tank through the fitting on the bottom of the

heater to the warewasher. Cooler make-up water enters through the bottom tank fitting.

• Burner will cycle on and off as the warewasher draws hot rinse water from the stainless tank.

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PT-200 FT Service Codes

The following service codes are shown by the red flashing LED located on the front of the electronics drawer behind the front access door. These codes indicate the type of malfunction. Consult the corresponding service bulletin in the service manual or call PrecisionTemp at 1-800934-9690 for corrective action. Prior to calling, ensure that you have the booster heater serial number and software version on hand.

For all codes except the single red flash, heater will continue to operate, but the problem should be addressed to ensure optimum performance and temperature control. Codes will flash each second followed by a three second pause. A green flashing LED without any red flashing LED indicates normal operation. If the green LED flashes while the red LED flashes, ignore the green LED and only count the red flashes. NOTE: You may want to physically cover the green LED with your finger, so as not to confuse the flashes.

Note: Service codes will continue to flash after the problem has been corrected. To ensure that problem has been corrected, the power switch on the booster should be turned off, wait 10 seconds, and then turned back on.

Single red flash- * pause * pause * pause

Indicates T-mid thermistor (yellow wire) has failed or is unplugged. Booster heater will not operate correctly until problem is corrected. Consult SB-15 or SB17 to correct.

Two red flashes- ** pause ** pause ** pause

Indicates T-out thermistor (red wire) has failed or is unplugged. Booster heater will not operate correctly until problem is corrected. Consult SB-16 or SB-17 to correct.

Three red flashes-

Indicates T-in thermistor (blue wire) has failed or is unplugged. Booster heater will not operate correctly until problem is corrected. Consult SB-16 or SB-17 to correct.

Four red flashes-

Indicates T-out is not in normal operating range, but the booster heater will continue to operate; user may notice temperature shift. Consult SB-16 or SB-17 to correct.

Five red flashes-

Indicates T-in is not in normal operating range, but the booster heater will continue to operate; user may notice temperature shift. Consult SB-16 or SB-17 to correct.

Six red flashes-

Indicates the booster hot water outlet and cold water inlet lines are connected in reverse. Temperature will be too low or will fluctuate radically. Reverse connections to correct.

Seven red flashes-

The direct spark ignition board (DSI) has locked out. The DSI will automatically reset within 45 seconds, but LED will continue to flash. Booster heater can be manually reset immediately by turning power switch off, wait 10 seconds, and turn back on.

***

****

*****

******

*******

pause

***

pause

****

pause

*****

pause

******

*******

***

****

*****

pause

******

pause

*******

pause

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 35

PT-200RC & PT-56 (Recirculating) Service Codes

The following service codes are shown by the red and green flashing LED located on the front of the electronics drawer behind the front access door. These codes indicate the type of malfunction.

Alternating green and red flash

Lost auto calibration or no auto calibration displays. See SB-7-RC

Steady red and flashing green LED T-mid or T-out Thermistor failure. See SB-15 and SB-17.

Red and green LEDs flashing together

Lock out after 10 ignition attempts. Turn booster power switch off, wait 15 seconds and turn back on.

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 36

SB-1 12 Volt Power Supply Change Procedure

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools Required: Phillips screwdriver

Process:

1. Turn booster heater power switch off, unplug the unit from the 110v AC wall outlet and remove front cover.

2. Ensure that the power supply you are replacing is for 12 Volts and not 24 Volts. If you attempt to install the incorrect power supply, it will damage the unit and void any warranty.

3. Remove the 4 screws holding the power supply bracket and remove the power supply.

4. On the new power supply find the wire that has the white printing (+). Attach this lead to the circuit breaker located in the control drawer. The plain black lead (-) connects to the ground terminal.

5. Place the power supply in the bracket and re-attach.

6. Plug 110v AC into outlet and turn booster heater power.

7. Verify that the green LED is flashing; ensure proper operation by running several racks through the dish machine.

Kit Parts List:

AS 1897 12v DC Power supply assembly

Reference Illustrations: None

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 37

SB-1A 24 Volt Power Supply Change Procedure

Model: PT-200FT & PT-200RC

Software version: All

Tools Required: Phillips screwdriver

Process:

1. Turn booster heater power switch off and unplug the unit from the 110 VAC wall outlet.

2. Remove the front cover. Remove the 4 screws holding the power supply bracket and remove the power supply.

3. On the new power supply find the wire that has the Female socket (+). Attach this lead to the “Molex” connector supplying the white power wire to the gas modulating valve. The plain black lead (-) with the Ring connector, connects to the ground screw located below the control drawer on the burner saddle.

4. Place the power supply in the bracket and re-attach it.

5. Plug the 110v AC power cable tightly into the back of the 24 volt power supply, and plug the power cable back into the wall outlet.

6. Lock the dish machine into a rinse mode and turn power ON, verify that the

PT-200 ignites and the modulating gas valve ramps up to high fire.

Kit Parts List:

AS 1613 24v DC Power supply assembly

Reference Illustrations:

None

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 38

SB-2 Pressure Switch Adjustment

Model: PT-200FT and PT-200RC

Software version: All

Tools Required: Flat blade screw driver or 5/64 Allen wrench

Process:

1. Lock the dish machine into a rinse mode.

2. Turn the booster heater power switch on.

3. With the dish machine rinse running and the booster heater blower

running, turn the adjustment screw on the pressure switch (type may vary) counter-clockwise until the burner ignites.

4. Disconnect the exhaust flue at the first joint outside the booster heater

case. Block flue exiting the booster heater and verify burner extinguishes. If it does not, turn screw clockwise until it does extinguish.

5. Unblock flue and verify burner ignites. If booster ignites, reconnect the

exhaust flue.

6. After adjusting the pressure switch, replace front cover and run several

racks through the dish machine to verify proper adjustment of the pressure switch.

Parts Kit:

None

Reference Illustrations: 200-6 & 200-2937

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 39

SB-3 Circuit Board Replacement

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools Required: Needle-nose pliers

SB-7 Auto-calibration service bulletin (match software version)

Process:

1. Turn booster heater power switch off.

2. Disconnect all electrical connectors at the circuit board.

3. Remove the circuit board. Needle-nose pliers can be used to remove the circuit board nylon standoffs.

4. Install the new board with the LED’s located at the front of the drawer and aligned with LED sockets on drawer.

5. Reconnect all connectors to the board. CAUTION: there are three two-pin connectors. Be sure that the power supply connector (red and green wire) goes to upper right corner (red connector) and the modulating valve connector (black wire) goes to lower right (blue connector) (see Fig. 200-14). The third two-pin connector is not used.

6. The booster heater outlet temperature has been preset to 4.20 VDC (192°F). Refer to manual if a further adjustment is needed. See SB-10.

7. Perform auto-calibration per SB-7. Be sure to refer to present software version for auto-calibration bulletin.

Kit Parts List:

EL 90XX Micro-controller chip-already installed in board

(9098 series is for PT-200RC & PT-56, 9097& 9099 series is for PT-200)

EL 1325 Standoffs (already installed in board) AS 1841- Circuit board

Reference Illustrations: 200-14

Rev 8/2014

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SB-3 Circuit Board Replacement Software Reference

Model: PT-200FT, PT-200RC, PT-56

Software versions:

9097 software is for the standard Flow Through model, current version available 9097J or T (4-5 gpm rinse cycle)

9099 software is for the OR Flow Through model, current version available 9099D or T (2-3 gpm rinse cycle)

9098 software is for the Recirculation model, current version available 9098O (recirculation)

Rev 8/2014

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Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 42

SB-5 Igniter Change Procedure & Spark Gap Adjustment

burner was

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools Required: Phillips screwdriver

Needle Nose Pliers (to adjust probes)

Process:

1. Turn power to booster heater OFF and close the gas supply valve to the booster heater.

2. Remove the front door and locate the igniter (see figure 200-10).

3. Disconnect the ignition wire from the igniter.

4. Using a Phillips screwdriver remove the two screws attaching the igniter to burner and remove.

5. Install the new igniter and check that the igniter probes are 0.125 - 0.250” above the center burner blade as shown in figure below. Gap between two probes should be about 0.125”.

6. Turn gas ON and check for leaks with AGA approved leak detector solution (if the removed).

7. Turn power ON and verify that the unit ignites properly and that spark is affected for maximum of 5 seconds.

Parts Kit:

Reference Illustrations:

200-10 Spark Ignition and Probe

Rev 8/2014

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SB-6 Direct Spark Ignition (DSI) Board Change

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools Required: screw driver

Process:

1. Turn booster power switch off and remove front cover.

2. Open the electrical drawer and pull all the way out from its saddle.

3. Remove the DSI board.

4. Install the new DSI board and re-attach the wire harnesses. Be sure to route the yellow or black ignition wire separate from the other control harnesses. (If a new harness is supplied, use it and discard the old harness.)

5. Replace front cover and turn booster power switch on.

6. Ensure proper operation of the booster heater by running several racks through the dish machine and ensuring that proper rinse water temperature is reached.

Kit Parts List:

P/N 3158 Direct Spark Ignition (DSI) board

(#3166 bracket if required)

Reference Illustrations: 200-3158 & 200-3166

Rev 8/2014

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SB-7-FT Automatic Calibration (AutoCal) Procedure

Model: PT- 200FT

Software version: 9097-I,J & T and 9099-C, D & T

Tools Required: Needle-nose pliers

CAUTION: During this test the unit will be performing several self tests. Do not

attempt to use dish machine. The booster heater will increase the gas flow from minimum to maximum over 8 minutes. Be sure to monitor the unit for safe operation.

Process:

1. Turn power off and remove front cover. Open electronic drawer. Ensure that the software version on the microprocessor is one that is listed above. From the front circuit board, remove the 2-pin jumper cap from ACAL (back jumper) using pliers or fingers (see figure 200-14).

2. Lock the dish machine in rinse mode. (Rinse MUST stay on for the entire procedure).

3. Turn heater power on. Green LED should flash and burner comes on to high burn and immediately drops back to low burn. If red light flashes there is a problem that must be corrected first, and then restart this entire procedure. See PT-200FT service codes for what each code means.

4. Over the next 8 minutes the unit will increase the gas flow to calibrate the valve. The unit will run the test by itself and only requires monitoring for safety. When the test is ended the red LED will flash rapidly and the burner will shut off.

5. Replace the 2-pin jumper cap on the board.

6. Turn power OFF, wait 20 seconds and turn power back on.

7. Check the unit for normal operation. If operation appears normal the procedure is complete. If the unit does not operate correctly or gas flow varies excessively repeat the procedure.

Kit Parts List:

None

Reference Illustrations:

Figure 200-14 Control Board

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 45

SB-7 Automatic Calibration (AutoCal) Procedure

the gas

or gas flow varies excessively repeat the

Model: PT- 200FT

Software version: 9097-A, 9097-B, 9097-C, 9097-D, 9097-E, 9097-F, 9097-G and 9099-A

Tools Required:

Needle-nose pliers

Process: CAUTION:

attempt to use the dish machine during this period. The booster heater will increase flow from minimum to maximum over about 8 minutes. Be sure to monitor the unit for safe operation.

1. Turn booster heater power switch off and remove front cover. Open electronic drawer. Ensure that the software version on the microprocessor is one that is listed above.

2. From the front circuit board, remove the 2-pin jumper cap from ACAL (back jumper) using pliers or fingers (see figure 200-14).

3. Lock the dish machine in rinse mode. (Rinse MUST stay on for the duration of this process).

4. Place a magnet on the modulating gas line just right of the electrical coil and move it slowly towards the gas solenoid.

5. Turn booster heater power switch on. Green LED should flash and burner ignite to high burn. If red light flashes there is a problem that must be corrected before continuing. See service code guide.

6. Remove the magnet SLOWLY from the gas line. Burner should return to low burn.

7. Over the next 8 minutes the unit will increase the gas flow to calibrate the valve. When the test is complete, the burner will shut down and the red LED will flash rapidly.

8. Turn power switch off and wait 20 seconds.

9. Replace the 2-pin jumper cap on the circuit board and turn power switch back on.

10. Check the unit for normal operation. If operation appears normal the procedure is complete. If the unit does not operate normally procedure.

Kit Parts List:

Reference Illustrations:

Figure 200-14 View of Control Board

During this procedure, the unit will be performing several self tests. Do not

None

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 46

SB-7-RC Auto-Calibration Procedure

te the gas flow will change slightly as the computer

several racks through the dish machine and ensure proper rinse temperature

Model: PT-200RC & PT-56

Software version: 9098-K, 9099-L, 9098-M, 9098-N & 9098-O

Tools Required: Needle Nose Pliers

Process:

1. Turn booster heater power switch off and remove front cover. Open the electronic drawer. Ensure that the software version on the microprocessor is one that is listed above.

2. From the control circuit board remove the 2-pin (rear) jumper cap from terminal marked Acal using pliers or fingers (see figure 200-14). Be sure water in recirculating system is cooler than set temperature on booster (under 140°F). If unable to verify, keep booster heater power off and run the dishmachine rinse.

3. Turn booster heater power switch on. The unit will ignite and then stay in high burn. Over the next 1 minu determines the proper voltage for minimum flow. After the computer completes auto-calibration the burner will automatically shut off.

4. Turn power to heater off for a minimum of 20 seconds.

5. Replace the jumper on the circuit board.

6. Turn power to heater back on. To check the unit for normal operation, run

is reached.

Kit Parts List: None

Reference Illustrations:

200-14 Electronic Control board

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 47

SB-7-RC-B Auto-Calibration Procedure

. Open the electronic

Ensure that the software version on the microprocessor is one that is

Model: PT-200RC

Software version: 9098-A, 9098-B, 9098-C, 9098-D, 9098-E, 9098-F, 9098-G, 9098-H, 9098-I, and 9098-J.

Tools Required: Needle Nose Pliers

Process:

1. Turn power switch on heater off and remove front cover drawer. listed above.

2. From the control circuit board, remove the 2-pin (rear) jumper from terminal marked Acal using pliers or fingers (see figure 200-14). Be sure water in recirculating system is cooler than set temperature on booster (under 140°F). If unable to verify, keep booster heater power off and run the dishmachine rinse.

3. Place magnet on modulating valve just to the right of the coil and move it about 3/4” to the right.

4. Turn power switch on booster on. The burner will ignite in high burn.

5. Slowly remove magnet from modulating valve.

6. Over the next minute the gas flow will change slightly as the computer determines the proper voltage for minimum flow. After the computer completes auto-calibration the burner will automatically shut off.

7. Turn off power.

8. Wait at least 20 seconds, and replace jumper on the circuit board.

9. Turn power on and check the unit for normal operation.

Parts Kit List:

None

Reference Illustrations:

200-14 Electronic Control board

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 48

SB-8 Modulating Valve Replacement

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools Required: Pipe wrench

12” Adjustable wrench

Process:

1. Turn off power switch on booster and shut gas off at valve outside booster case.

2. Unplug the modulating valve 2-pin connector. It is the 2 pin black and white wire connection just in front of the gas train assembly.

3. Place adjustable wrench on the union (located in front of the burner manifold) in front of the modulating valve and loosen to remove. Unscrew modulating valve from the gas solenoid using pipe wrench.

4. IMPORTANT! USE AGA-APPROVED SEALANT ON ALL GAS THREAD CONNECTIONS BEING VERY CAREFUL NOT TO ALLOW ANY TO PENETRATE THE MODULATING VALVE CAVITY. IF THIS IS NOT STRICTLY FOLLOWED IT WILL CAUSE THE MODULATING VALVE TO BECOME STICKY AND MALFUNCTION AND HEATER WILL NOT CORRECTLY OPERATE.

5. Re-assemble the heater reversing the procedure. Ensure that the gas is flowing in the direction of the arrow on the collar of the valve.

6. Reconnect wire connector and retighten union.

7. Turn on gas supply. Check for gas leaks.

8. Power up unit.

9. An Auto Calibration (see SB-7) procedure must be completed. Be sure to use the Auto Calibration procedure specific to your type of unit (Recirculating or Flow Through) and software version. Strictly follow the instructions. Failure of this process will cause system malfunction.

10. After completing Auto Calibration procedure, lock the dish machine into rinse mode and check for normal operation.

Kit Parts List:

Modulating Valve assembly

Reference Illustrations:

200-12

Rev 8/2014

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SB-10 Changing Outlet Temperature Setting

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools Required: Small flat blade screw driver

Digital Multi meter/Voltmeter

Process: NOTE: The temperature on the booster heater has been factory set to

approximately 192°F. It is not recommended that you change this setting. Doing so could result in water temperature too low to sanitize dishware or high enough to bake food matter onto dishes, or cause booster heater to overheat water and shut down. If it is necessary to change the setting it can be done as follows:

1. Open access door of heater. Open the electronic drawer. The adjustment

screw is located on a small blue block at the lower right corner of the electronics board (see reference illustration #200-14).

2. Use a voltmeter and insert the black lead in black test point and the red

lead in blue test point (see reference illustration #200-14). A reading of

4.20 VDC from the voltmeter will set the temperature control at 192°F. A small blade screwdriver should be used to adjust the temperature screw. To decrease temperature, turn screw counterclockwise. To increase temperature, turn screw clockwise. Each full turn will change the water temperature approximately 7°F.

3. Check the water temperature on digital display of booster heater or at

temperature gauge on dish machine and adjust as necessary.

Kit Parts List:

None

Reference Illustrations:

200-14 Electronic Control Board

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 50

SB-11 Fan Relay Test Procedure

DC on the relay

AC side of the relay.

Model: PT-200FT and PT-200RC

Software version: All

Tools Required: DC Multimeter

Needle-nose pliers

Process:

Turn heater power switch off and remove front cover. Locate the fan relay.

2. Set your multimeter to volts DC. Using the illustration below, connect your meter

to the 12v DC side of the relay.

3. Turn the power on to the booster heater and verify you have 12v

(the relay will only be energized for 8 seconds after power is turned on).

4. If power is present, continue to next step. If not, please refer back to the

troubleshooting guide.

5. Switch your multimeter to 120v AC. Turn the booster heater off.

6. Using the illustration below, connect your meter to the 120v

7. Turn booster heater power switch on and verify you have 120v AC on the relay.

8. If 120v AC is present, turn to booster heater off and connect the orange and

black wire.

9. Turn the power on to the booster heater. If the fan comes on, replace the relay.

If the fan does not come on, replace the blower fan.

Kit Part List:

None

Reference Illustrations:

200-14 Electronic Control Board

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 51

SB-12 Combination Gas Valve Replacement

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools required: Pipe wrench

12” adjustable wrench Pipe sealant

Process:

1. Disconnect the power to the booster heater.

2. Disconnect the blue & white wires connected to the combination gas

valve.

3. Turn off the gas supply to the booster heater.

4. Separate the closest gas union outside of the booster heater.

5. Remove all gas line plumbing between the gas valve and half union.

6. Separate the union to the left of the modulating gas valve.

7. Remove the combination gas valve and modulating gas valve from the

remaining gas train.

8. Install new combination gas valve in reverse order using approved pipe

sealant, ensuring that sealant does not get into the modulating gas valve.

9. Pressurize the gas line.

Be sure to check all gas fittings with an approved leak test solution before restarting the PT-200.

Note:

It may take several ignition attempts to purge all the air from the refitted gas line.

Kit Parts List:

PT-200 & PT-56 Solenoid Valve

Reference Illustrations:

200-9 Combination Gas Valve

Rev 8/2014

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SB-13 Flow Meter Check and Replacement

Model: PT-200FT

Software version: All

Tools required: 2 adjustable wrenches or slip joint pliers

Phillips screw driver

Process:

Check Operation

1. Lock the dish machine into the rinse mode.

2. Turn the power to the PT-200 on.

3. Check for a plumbing bypass (if there is, make sure it is closed to assure flow of

rinse water through the booster.)

4. Watch the flashing green LED on the green control board. Once you see a

pause, start counting the green flashes until the next pause. Verify the count twice.

5. Divide the number of flashes between pauses by 3. This resulting number will be

the flow rate in gallons per minute. Example - 15 flashes between pauses divided by 3 = 5 GPM.

6. If you do not see a pause in the green LED with the rinse running, the flow meter

is not sensing flow or no water is passing through booster or you have a recirculating booster heater (See PT-200RC troubleshooting diagram).

Adjustment or Replacement

1. Be sure the pick-up wire on top of flow meter (2354) is tight.

2. Check flow meter connector to control board.

3. Replace flow meter by the following procedure: a. Turn off water at shut off valve outside of booster. b. Remove 4 Phillips screws from side access panel (digital display) &

let panel hang from side. Take care not to damage digital display wiring.

c. Ensure that the water in the pipe is cool. Using 2 wrenches or slip

joint pliers loosen the union nuts on either side of the flow meter and remove the flow meter and gaskets (2354 Flowmeter only).

d. Verifying flow direction, install new meter with 2 new gaskets (2354

Flowmeter only) and tighten union nuts (do not over tighten 3226

Flowmeter union nuts). e. Replace access panel. f. Test

Parts Kit List:

2354 or 3226 Flowmeter

Illustrations: 200-3226 & 200-4

Rev 8/2014

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SB-14 Burner Manifold Pressure Check and Adjustment

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools required: DC Multi-meter

Manometer

Process:

1. Disconnect the power to the PT-200/56 and turn the gas supply off at the manual valve outside of the booster heater.

2. Remove the 1/8” brass plug on the left side of the burner manifold.

3. Once you have removed the 1/8” plug, connect the manometer.

4. Locate the two pin connector coming from the gas modulating valve (Illustration 200-12).

5. Switch multi-meter to 20v DC scale.

6. Slide the probes behind the two wires of the 2-pin connector coming from the gas modulating valve. Red probe to the white wire and black probe to black wire.

7. Turn on the gas supply at the manual valve and turn power to booster heater back on.

8. With your manometer and multi-meter connected, lock the dish machine into a rinse mode, reconnect electrical power to the booster heater and turn the PT-200/56 on.

9. At ignition there should be 0v DC going to the gas modulating valve coil, the manometer should read approximately 0.25 - 0.50 WCI.

10. If all conditions are correct, once the flame is detected you should have approximately 22v DC (12vDC PT-56) and 2.85 WCI - 3.70WCI @ full burn depending on model year & type gas, refer to product label on access door.

11. Remove manometer and replace 1/8” plug using approved pipe dope.

Adjusting Manifold Pressure

1. Remove cap from combination gas valve regulator. (ILL. 200-9)

2. Turn screw under cap clockwise to increase manifold pressure and counter-clockwise

to reduce pressure to the correct reading.

3. Replace cap on the combination gas valve.

Be sure to check all gas fittings with approved leak test solution before restarting the PT-200/56.

Kit Parts List:

None

Reference Illustrations:

200-12 Gas Modulation Valve 200-9 Combination Gas Valve

Rev 8/2014

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SB-15 T-Mid Thermistor Change Procedure

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools required: 9/16” Open end wrench

Adjustable wrench

Process:

1. Turn power off and turn off water supply at shut off valve outside of the booster heater.

2. Remove old thermistor and disconnect from harness. CAUTION: Use two wrenches, one on the hex (9/16”) of the thermistor and an adjustable wrench on the hex located on the heat exchanger fitting. Failure to do so may damage the heat exchanger.

3. Insert the end of the thermistor without electrical leads into the heat exchanger until the heat shrink (black) on the thermistor touches the fitting and tighten the fitting finger-tight. The final tightening should be done using two wrenches as described in step 1.

4. Connect the thermistor to the wiring harness.

5. After installing the mid thermistor lock the dish machine into rinse mode and check for normal operation. If the booster outgoing temperature fluctuates more than 5 degrees from the set temperature perform the Auto Calibration procedure.

6. If the Auto Calibration (see SB-7) procedure is needed be sure to use the AutoCal specific to your type of unit (Recirculating or Flow Through), check for correct software version.

Parts Kit List:

1854 T-Mid Thermistor CPI Fitting

Reference Illustrations: 200-13 Thermistor Harness

Rev 8/2014

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SB-16 T-Out/ T-In Thermistor Change Procedure

Model: PT-200FT, PT-200RC & PT-56

Software version: All

Tools Required: Scissors (or other cutting tool)

Process:

1. Disconnect power to the booster.

2. Remove the wire ties, metal tape, and old thermistor. Clean off the old heat sink and be sure copper is wiped clean.

3. Place a pea size amount of heat sink compound on the pipe where the thermistor will be located.

4. Place the thermistor into the heat sink with the wire leads pointing down along the tube.

5. Wrap metal tape around the tube and thermistor.

6. Attach the wire tie. Wrap the wire tie about 1/2” away from the thermistor head to hold the thermistor against the tube. CAUTION: 1) Do not place the tie wrap over the thermistor tip as this may damage the thermistor, do not over-tighten the wire tie.

7. Connect the thermistor to the wiring harness.

8. Replace front cover of booster heater and turn power switch back on.

9. Perform test of the unit by running several racks through the dish machine to ensure that proper rinse temperature is reached.

Kit Parts List:

1436 T-in Thermistor Assembly Kit 1437 T-out Thermistor Assembly Kit

Reference Illustrations:

200-13 Thermistor Harness

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 56

SB-17 Thermistor Reading Procedure

Model: PT-200FT, PT200RC & PT-56

Software version: All

Tools required: DC Multi meter

The precise temperature of the water in the heater can be determined by reading thermistor DC voltages at the colored test points on the green control board (See Electronic Control Board—Illustration #200-14) with a multi-meter and referring to the "Thermistor Calibration" table.

The black multi-meter probe should go into the black test point and the red probe should go into the following test points:

Orange/Red Test Point = Outlet temperature (T-Out) Yellow Test Point = Mid temperature (T-Mid)

Inlet temperature (T-In) is read from inboard blue wire on connector #1329

(thermistor harness plug) of the green control board.

Power must be on for the booster to take the readings. Refer to the DC voltage reading in the "volts" column on the "Thermistor Calibration" chart. The corresponding temperature is the column to the left of the volt reading.

Kit Parts List:

None

Reference Illustrations:

200-14 Electronic Control Board

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 57

Rev 8/2014

PrecisionTemp, Inc • 11 Sunnybrook Drive • Cincinnati, Ohio, 45237 • 1-800-934-9690 • fax 513-641-0733 58

SB-18 PT-56 Tank Assembly Change Procedure

Model: PT-56

PrecisionTemp PT-200FT, PT-200RC, PT-56 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual