Vertex PureWaterCooler PWC-400 Service Manual

PWC – 400
PureWaterCooler
SERVICE MANUAL
for
PureWaterCooler
by Vertex
Model PWC-400
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
Table of Contents
1. Introduction
2. Cooler Set-up
3. Remove Top Cover/Side Cover
4. Remove/Replace Float
5. Remove/Replace Hot Tank
6. Dispensing Solenoid – Remove/Replace
7. Circuit Board – Remove/Replace
8. Front Panel – Remove/Replace
9. Hot Tank Reset Button
10. Remove/Replace Hot Tank Thermal Sensors
11. Cold Temperature Adjustment
12. Sanitization Procedure
13. Trouble Shooting
14. Specifications
15. Cooler Exploded View
16. Parts List
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
PWC-400 Cooler
1. Introduction
The PWC-400 line of point of use counter-top coolers are designed to give years of reliable Service. The cooler has a single spigot that dispenses filtered water at 2 different temperature levels – hot and cold temperature water. The main (cold-temp) tank holds 3/4 gallons of water and is constructed of FDA approved plastic. The cold tank can be accessed for servicing the float mechanism and for cleaning by removing the cooler main top cover (see section 4).
The hot tank is made of stainless steel and holds 1/4 gallon of hot water. It is important not to turn on the hot tank when there is no water in it as this will damage the heating element.
The compressor is a sealed unit and is not serviceable in the field. The compressor can be replaced by a qualified refrigeration technician with proper tools and equipment. Please consult the factory if the compressor needs servicing. CAUTION: If the compressor has been stopped by switching it off or unplugging power, WAIT 10 MINUTES before turning the compressor on again. The compressor may stall
and burnout if powered back on without waiting.
The cooler makes clean water by filtration or by the reverse osmosis process. Water enters the
back of the cooler and then passes through the filtration system. A feed water ball valve is Located near the filters and must be turned to the on position to allow the unit to make water. Electrical power is required for the cooler to make purified water. CAUTION: The carbon filtration versions of the cooler (PWC-400F) should not be used with water hardness over 7 grains because of lime scale build up on the heating element. If hardness is higher than 7 grains, softening of the feed water is recommended or another option is to install a “phosphate” filter to the filter system.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
2. Cooler Set-Up
(for new cooler installation)
Feedwater/Drain Connections
-Feed Connection
2.1 Remove 2 screws on back of right side panel and remove right side panel.
2.2 Remove feed water plug (orange) from back of cooler.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
2. Cooler Set-Up cont.
2.3 Connect supplied orange feed water tubing to feed connector on back of cooler.
2.4 Make feed water connection to cold water line.
A self piercing saddle valve is provided.
2.5 Flushing carbon fines from carbon filter
. Most carbon filters have fine particles of carbon material in the filter that will be swept into the water stream when the first water flows through the filter. Although not harmful, these carbon fines in the water are unsightly. Flush the carbon fines out of the filter before filling cooler tanks with the following procedure
2.6 Remove outlet line of carbon filter (bottom)
Feedwater connection (RO & filtration coolers
(For use on copper tubing)
Use supplied self piercing saddle valve. Connect to water inlet on cooler u sing 1/4”
tubing. Clamp saddle valve over copper feed water line (cold water line only). Tighten needle valve until tube is pierced. Retract
needle 1 -2 turns to start water flow.
)
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
2. Cooler Set-Up cont.
2.7 Attach 3 feet of ¼” tubing to the carbon filter outlet port (flush tubing)
2.8 Place flush tubing in bucket to catch water carbon fines
2.9 Turn on feed water at source and turn ball valve
at filter to “on” to let the water flush the filter.
2.10 Flush until water flows clear (1 – 2 gallons)
2.11 Remove flush line. Reconnect tank line to
outlet of carbon filter
2.12 WARNING: Do not turn on cooler hot power
until cooler tanks are full of water.
Figure 2.7
Drain Connection (for units equipped with RO)
2.13 Remove drain plug (black) from back of cooler
2.14 Connect supplied black water tubing to drain connector on back of cooler
2.15 Attach supplied drain saddle to a
standard 1 ½” drain pipe see fig. 1 below
Drain saddle connection method
Drain connection required only for cooler with reverse osmosis filtration
Figure 1
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
3. Top Cover/Side Panel Removal
3.1 Remove (2) screws on back of cooler top cover
3.2 Slide cover back and lift off.
3.3 Cold tank is now accessible for cleaning and servicing other parts of the cooler.
3.4 Reinstall in reverse order
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
3. Top Cover/Side Panel Removal
3.5 Remove (2) screws on back of cooler side cover
Cont.
3.6 Slide side cover back about half way off until tab in side cover lines up with slot in cooler frame.
3.7 Once slot and tab are lined up, pull side cover away from cooler.
3.8 Reinstall in reverse order
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
4. Remove/Replace Electro/Mechanical Float Assembly
4.1 Remove top cover (See section 3)
4.2 Remove tubing from top of cold tank
4.3 Remove screws from lid of cold tank. (6 plcs)
4.4 Remove outer lid of cold tank
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
4. Remove/Replace Electro/Mechanical Float Assembly
cont.
4.5 Disconnect electrical connector
4.6 Lift off inner lid of cold tank
4.7 To remove float, remove nut from float stem
4.8 Remove float assembly from inner lid.
4.9 Reinstall in reverse order.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
5. Removing/Replacing Hot Tank.
5.0 Unplug power from wall
5.1 Drain water from cooler using front spigots and by removing bottom drain plug.
5.2 Remove top cover and left and right side covers (sec. 3)
5.3 To gain access to the hot tank, the
filter bracket must be moved:
5.4 Remove water line from top of sediment filter
5.5 Put cooler on its’ left side
5.6 Remove 4 screws holding filter bracket to base
5.7 Set filter bracket aside to allow access to hot tank
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
5. Removing/Replacing Hot Tank
5.8 Remove wire from thermal sensors (4 places)
Cont.
5.9 Remove inlet tubing (Access from right side of cooler)
5.10 Remove outlet tubing (Access from left side of
cooler)
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
5. Removing/Replacing Hot Tank
5.11 Remove vent tubing (top of hot tank)
Cont.
5.12 Remove the 2 screws that hold the tank from the bottom of the cooler
5.13 Remove the hot tank from cooler
5.14 Remove (2) heating coil leads from hot tank
5.14 Remove Thermal sensors from hot tank. Save an
install on new hot tank.
5.16 Assemble hot tank in reverse order.
d
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
6. Dispensing Faucet Repair
6.1 Remove top and side covers of cooler (section 3)
6.2 Remove the control panel by grasping the bottom of the panel and pulling out sharply.
6.3 Remove (4) electrical connectors from back of the
control panel. Set control panel aside.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
6. Faucet Repair
Cont.
6.4 Remove hot water tubing from the left (hot) solenoid.
6.5 Remove screw holding solenoid/manifold assembly to the front panel.
6.6 Remove solenoid/manifold assembly by lifting it out of cooler. Disconnect cold water tubing from cold water solenoid (right side).
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
6. Faucet Repair
6.7 Remove screw holding solenoid to manifold and bracket. Slide solenoid off of manifold.
Cont.
6.8 Reassemble in reverse order. Make note of the following:
a. Water flow through the solenoid is
directional. There is an arrow molded in the side of the solenoid body showing water flow direction. Make sure the solenoid is oriented correctly. Water can leak from the solenoid if not installed correctly
b. When installing electrical connectors into
the circuit board please note: the left solenoids’ connector plugs into the left socket on the circuit board (when you are facing the circuit board). The right solenoid plugs into the right
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
7. Remove/Replace Circuit Board
7.1 Remove dispensing control panel (section 6)
7.2 Remove circuit board cover
7.3 Remove (3) screws holding circuit board to panel
7.4 Re-assemble in reverse order
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
8. Remove Front Panel
8.1 Remove top and side covers of cooler (section 3)
8.2 Remove the control panel and dispensing solenoid assembly (section 6.2)
8.3 Remove (2) screws from the top of the front panel. The
lower part of the front panel sets on two pins.
8.4 Lift front panel off of the two pins. Remove cover
8.5 Re-assemble in reverse order
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
9. Hot Tank Reset Button
9.0 To access the hot tank, remove the left side cover per section 3.3
9.1 Observe that there are two circular sensors attached to the hot tank. The upper one is the main controller at 82 ºC and the lower sensor is the over-temp cut off.
The power switch for the hot tank (at the back of the cooler) should not be turned on until water can be dispensed from the hot spigot. If the hot power is turned on without water in the hot tank the heating element will over heat. To prevent this, the lower thermal sensor on the hot tank will cut power to the heating element before any damage takes place. If this happens the switch on the thermal sensor can be reset to operational mode manually by the following procedure.
9.2 Make sure the power cord is unplugged.
9.3 Find the lower thermal sensor on the hot tank
9.4 Using a long thin object such as a screw driver or a pen, depress the small button at the center of the lower thermal switch. You should
feel a click when you depress the button. This action resets the over-temp sensor.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
10. Remove/Replace Thermal Sensor
10.0 The hot tank thermal sensors are located on the outside of the hot tank. There are two thermal sensors. The sensor located higher on the hot tank controls the daily operation of the heating element. The lower thermal sensor is an overheat safety switch and cuts power to the hot tank should a malfunction occur and the tank starts to overheat.
10.1 Unplug cooler from power source for this operation.
10.2 Remove left side cover per sec. 3.3
10.4 There are (2) thermal sensors attached with screws to the hot tank. The upper sensor auto­matically turns the heating element on and off to maintain the water at 180 ºF. The lower sensor is the over temperature sensor. This sensor activates if the temperature on the tank goes over 212 ºF. If this sensor is activated due to a overheat condition, it will cut the power to the heating element. If this happens, it can be reset by pressing the button at the center of the sensor.
To check if either thermal sensor is good, use a continuity tester (ohm meter) to check for continuity across the thermal sensor. Make sure the thermal sensor is at ambient temperature for this test. If there is no continuity, replace the sensor.
10.5 To change either sensor, disconnect (2)
electrical terminals from sensor.
10.6 Remove (2) screws holding sensor to tank.
10.7 Install new thermal sensor, replace screws,
reconnect electrical terminals to sensor.
10.8 Replace left side cover.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
11. Cold Tank Temperature Adjustment
11.0 The cold water temperature adjustment
is located on the back of the cooler in the middle of the panel. An expansion tube senses temperature in the cold tank and open and closes the thermostat.
11.1 The cold adjustment is a shaft with a
screw driver slot on the end.
11.2 To make the water colder, using a
screw driver, rotate the shaft clockwise. For warmer water rotate the shaft counter clockwise. There are stops on the adjustment shaft. DO NOT force the control shaft over the stop. If this happens, it will be necessary to replace the temperature controller
270º Travel
STOP
WARMEST
COLDEST
STOP
Normal Travel is 270º
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
12. Sanitization Procedure
The sanitization procedure is performed to reduce/eliminate any bacteriological
growth in the cooler tanks and dispensing plumbing. Bacteriological growth can be the cause of some taste and odor in the water.
The procedure is as follows:
1. Mix 1 teaspoon of common household bleach (5.25%) in 2 gallons of clean water.
2. Unplug the cooler from the power source.
3. Drain all water from the cooler tanks.
4. Pour the sanitizing solution into the main (cold temperature) tank until full.
5. Open all spigots to allow sanitizing solution to fill the dispensing faucets. Close the spigots.
6. Let the sanitizing solution stand in the cooler for 10 minutes.
CAUTION: Leaving the sanitizing solution in the cooler for more than 10 minutes can cause taste problems in the water.
7. Completely drain the sanitizing solution from all the tanks per section 5
8. Fill the main (cold temp.) tank with clear tap water to rinse out the sanitizing solution.
9. Completely empty the rinse water from the tanks.
10. The cooler is now sanitized and ready for filling with filtered water.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
13. Trouble Shooting
Water not cold from cold tank
(Water dispenses from spigot but is not cold)
Possible causes Solution .
1. Cooler not plugged in Make sure power cord is plugged
into wall socket
2. Power switch not on Make sure cold power switch on
the back panel is on.
3. Adjust temperature control The thermostat temperature control
adjustment is located on the back of the cooler. (see section 11)
4. All cold water has been drained Cooler needs time to recover.
wait 10-15 minutes until water cools
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
13. Trouble Shooting
Cont.
No Hot Water from Hot Tank
Possible Causes Solution
1. Cooler not plugged in Make sure power cord is plugged into wall socket
2. Power switch not on Make sure Hot power switch on back panel is on and hot power light on front is illuminated
3. Electrical terminal Check to see that both wires are
disconnected connected to the heating element
terminals. These are located at the bottom of the hot tank
4. Heating element failure Check for continuity across hot tank
due to scaling heater terminals. To do this, unplug
unit from wall power. Disconnect one of the connector at the heating element terminals (at bottom of tank). Using an ohm meter, check for continuity across the 2 terminals. If there is no continuity (open), the tank must be replaced.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
13. Trouble Shooting Cont.
No Hot Water from Hot Tank cont.
Possible causes Solution .
5. Thermal sensor failure The thermal sensors are attached to the hot tank. The upper sensor is a 96 ºC sensor and functions as an over heat safety. The lower sensor is a 82 ºC sensor and controls the heating element function. The lower sensor would be the problem if there was no hot water. To see if the sensor is functioning properly, first unplug the cooler from the wall. remove the terminal from the sensor. Using an ohm meter, check for continuity If there is no continuity (open), replace sensor
as per section 10.
6. Hot tank turned on without The hot power should never be turned on
water in tank without water in the tank. If this happens,
the upper thermal sensor on the hot tank will switch, cutting power to the hot tank. This is a safety device to prevent the heating element from burning itself out due to dry heating. Once the hot tank cools off the switch can be reset to operating condition. See section 9.
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
13. Trouble Shooting Cont.
No Hot Water from Hot Tank cont.
An indicator of a hot tank problem can also be the lights on the front control panel. Below is a table of trouble shooting help.
If the Hot Tank is not heating and the front panel lights are:
Front Panel Lights Cause Check
Hot Power – on Heating element disconnected No Continuity across Heating - on or burned out heating element
No lights at all Lower thermal sensor Reset Press reset button / Including cold power button disengaged or sensor No Continuity across
burned out thermal sensor –replace sensor
Hot Power – on Upper thermal sensor No Continuity across Heating -- off disconnected or burned out lower thermal sensor
Copyright 2008 Vertex Water Products
PWC – 400
PureWaterCooler
14. Specifications
PWC-400
Voltage/Frequency 120 VAC/ 60 Hz
Weight (dry) 48 lbs.
Total Water Capacity 1.5 gallons
Hot tank .5 gallons
Cold tank 1.0 gallons
Power Consumption Total 600 Watts
Hot Tank 500 Watts
Cold Tank 100 Watts
Temperature
Hot 180 ºF average Cold (adjustable) 38 ºF average
Refrigerant R134a 36 mg.
Copyright 2008 Vertex Water Products
4/09
PWC-400 Part List
Item No. Description Part Number Item No. Description Part Number
P1 Top Cover cl4 9500 E1 Control Board, Rev C cl4 9529 P2 Front Panel cl4 9501 E1.1 Cntrl Brd w/beep snd, RevD,E cl4 9587 P3 Control Pnl/Fct Cover, Rev F cl4 9581 E1.2 Cntrl Brd w/beep snd, Rev F cl4 9580 P3 Cntrl Pnl/Fct Cover, Rev C,D cl4 9502 E2 Compressor cl1 9218 P4 Base cl4 9503 E3 Cold Temperature Switch cl4 9219 P5 Drip Tray Set cl4 9504 E4 Transformer cl4 9220 P6 Left Side Panel cl4 9505 E5 Power Cord cl4 9221 P7 Right Side Panel cl4 9506 E6 Control Box, Level Sensor cl4 9222 P8 Handle cl1 9235/EG E7 Fan cl4 9223 P9 Water Spout and T Manifold cl4 9508 E8 Condensor cl4 9224
P10 Cover, Circuit Board cl4 9509 E9 On/Off Switch cl1 9238
P10.1 Cover, Circt Brd, REV D,E,F cl4 9507 E10 Fuse Holder cl1 9252
P11 Strain Relief cl4 9510 E11 Fuse cl1 9262 P12 1/4" tubing cl4 9511 E12 Sol.Valve, Dspnsng,cold,24vd
E13 Wiring Harness cl4 9544 E14 Wire Harness cl4 9542 E15 Wire Harness cl4 9543
P16 Dispense Nozzle Cover cl4 9547 E16 Sol.Valve, Dspnsng,hot,24vdc cl4 9590
OBSOLETE REV E Control panel Assy cl4 9588 M1 Frame, Upper cl4 9512 REV F Control panel Assy cl4 9591 M2 Frame, Front cl4 9513 M3 Rear Panel cl4 9514 H1 Hot Tank cl4 9545 M4 Screw cl4 9515 H2 92 C Temperature sensor cl1 9277 M5 Screw cl4 9516 H3 82 C Temperature sensor cl2 9030 M6 Screen, Stainless 304 cl4 9528 H4 Screw cl4 9548 M7 Screw cl4 9517 H5 Screw cl4 9549 M8 Screw cl4 9518 H6 Stopper cl4 9555 M9 Bracket cl4 9519 H7 Insulating Foam cl4 9551
M10 Probe, Leak detector cl4 9520 H8 Silicon Tube cl4 9552 M11 H9 Silicon Tube, 175 x 4 elbow cl4 9553 M12 Screw cl4 9521 H10 Silicon Tube cl4 9554 M13 Dryer cl4 9522 M14 Screw cl4 9523 M15 Screw cl4 9524 M16 Screw cl4 9525 M17 Bracket cl4 9526 M18 Screw cl4 9527 M19
c cl4 9540
Vertex Water Products 2009
1 Rev F, 7/11
PWC-400 Part List
Item No. Description Part Number Item No. Description Part Number
C1 Lid, Outer, Cold Tank cl4 9556 REV D, 7/09 1/4/2013 C2 Lid, Inner, Cold Tank cl4 9557 Updated 4/6/10 C3 Cold Tank Assembly cl4 9558 Updated 10/1/10 C4 Screw cl4 9559 Updated 12/31/10 C5 Silicon Tube cl4 9560 REV F, 7/11 C6 Level Sensor cl4 9579 C7 Capillary Tube cl4 9561 C8 Insulation cl4 9562 C9 Nut cl4 9578
C10 Fitting cl4 9563 C11 Insulation cl4 9564 C12 Insulation cl4 9565 C13 Insulation cl4 9566 C14 Bracket, Cold Tank cl4 9567 C15 Plug cl4 9568 C16 Screw cl4 9569
O1 Sticker, Cntrl Pnl, Rev C,D,E cl4 9573 O1 Sticker, Cntrl Pnl, Rev F cl4 9582 O2 O3 Double backed Tape cl4 9575 O4 Nut cl4 9576 O5 Solenoid Valve, 115 VAC cl2 9086 O6 Screw cl4 9570 O7 Filter Bracket cl4 9541
Fittng,Bulkhead
(nt usd aftr 8.09)
cl4 9574
Sediment Filter Cart.-rplcmnt ifa 4035 Carbon Filter Cart.-rplcment ifa 4034 Membrane, 50 gpd-rplcmnt ma 4203 UV bulb, 6 watt - rplcment uv 4061
O52 Straight, 1/4mpt x 1/4 tube md 2624 O53 Elbow, 1/4 mpt x 1/4 tube md 2625 O54 Bulkhead fitting, 1/4" dm 2733 O55 Stem Elbow, 1/4stem x 1/4t md 2626 O56 Filter Screen, 1/4"
Vertex Water Products 2009
2 Rev F, 7/11
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