INSTALLATION/OPERATION & TECHNICAL MANUAL

Transcription

1 CHEMICAL SANITIZING DISHMACHINE INSTALLATION/OPERATION & TECHNICAL MANUAL FOR JACKSON MODELS: Delta 5 Delta 5 D October 4, 2007 P/N (Revision A) Jackson MSC LLC. P.O. BOX 1060 HWY. 25E BARBOURVILLE, KY PHONE (606) FAX (606)

2 ALL NEW JACKSON DISHWASHERS ARE WARRANTED TO THE ORIGINAL PURCHASER TO BE FREE FROM DEFECTS IN MATERIAL OR WORKMANSHIP, UNDER NORMAL USE AND OPERATION FOR A PERIOD OF (1) ONE YEAR FROM THE DATE OF PURCHASE, BUT IN NO EVENT TO EXCEED (18) EIGHTEEN MONTHS FROM THE DATE OF SHIPMENT FROM THE FACTORY. Jackson MSC agrees under this warranty to repair or replace, at its discretion, any original part which fails under normal use due to faulty material or workmanship during the warranty period, providing the equipment has been unaltered, and has been properly installed, maintained and operated in accordance with the applicable factory instruction manual furnished with the machine and the failure is reported to the authorized service agency within the warranty period. This includes the use of factory specified genuine replacement parts, purchased directly from a Jackson authorized parts distributor or service agency. Use of generic replacement parts may create a hazard and void warranty certification. The labor to repair or replace such failed part will be paid by Jackson MSC, within the continental United States, Hawaii and Canada, during the warranty period provided a Jackson MSC authorized service agency, or those having prior authorization from the factory, performs the service. Any repair work by persons other than a Jackson MSC authorized service agency is the sole responsibility of the customer. Labor coverage is limited to regular hourly rates, overtime premiums and emergency service charges will not be paid by Jackson MSC. Accessory components not installed by the factory carry a (1) one year parts warranty only. Accessory components such as table limit switches, pressure regulators, pre rinse units, etc. that are shipped with the unit and installed at the site are included. Labor to repair or replace these components is not covered by Jackson MSC. This warranty is void if failure is a direct result from shipping, handling, fire, water, accident, misuse, acts of god, attempted repair by unauthorized persons, improper installation, if serial number has been removed or altered, or if unit is used for purpose other than it was originally intended. TRAVEL LIMITATIONS Jackson MSC limits warranty travel time to (2) two hours and mileage to (100) one hundred miles. Jackson MSC will not pay for travel time and mileage that exceeds this, or any fees such as those for air or boat travel without prior authorization. WARRANTY REGISTRATION CARD The warranty registration card supplied with the machine must be returned to Jackson MSC within 30 days to validate the warranty. REPLACEMENT PARTS WARRANTY Jackson replacement parts are warranted for a period of 90 days from the date of installation or 180 days from the date of shipment from the factory, which ever occurs first. PRODUCT CHANGES AND UPDATES Jackson MSC reserves the right to make changes in design and specification of any equipment as engineering or necessity requires. THIS IS THE ENTIRE AND ONLY WARRANTY OF JACKSON MSC. JACKSON S LIABILITY ON ANY CLAIM OF ANY KIND, INCLUDING NEGLIGENCE, WITH RESPECT TO THE GOODS OR SERVICES COVERED HEREUNDER, SHALL IN NO CASE EXCEED THE PRICE OF THE GOODS OR SERVICES OR PART THEREOF WHICH GIVES RISE TO THE CLAIM. THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING FOR FITNESS OR MERCHANTABILITY, THAT ARE NOT SET FORTH HEREIN, OR THAT EXTEND BEYOND THE DURATION HEREOF. UNDER NO CIRCUMSTANCES WILL JACKSON MSC BE LIABLE FOR ANY LOSS OR DAMAGE, DIRECT OR CONSEQUENTIAL, OR FOR THE DAMAGES IN THE NATURE OF PENALTIES, ARISING OUT OF THE USE OR INABILITY TO USE ANY OF ITS PRODUCTS. ITEMS NOT COVERED MANUFACTURERS WARRANTY ONE YEAR LIMITED PARTS & LABOR WARRANTY This warranty does not cover cleaning or deliming of the unit or any component such as, but not limited to, wash arms, rinse arms or strainers at anytime. Nor does it cover adjustments such as, but not limited to timer cams, thermostats or doors, beyond 30 days from the date of installation. In addition, the warranty will only cover the replacement of wear items such as curtains, drain balls, door guides or gaskets during the first 30 days after installation. Also, not covered are conditions caused by the use of incorrect (non-commercial) grade detergents, incorrect water temperature or pressure, or hard water conditions.

3 STOP! PARE! ARRET! CALL TO REGISTER THIS PRODUCT! FAILURE TO DO SO WILL VOID THE WARRANTY! LLAME AL PARA REGISTRAR ESTE PRODUCTO! AL NO HACERLO LA GARANTIA SERA ANULADA! S.V.P. APPELER POUR ENREGISTRER CE PRODUIT, LA GARANTIE SERA ANNULEE POUR TOUT PRODUIT NON- ENREGISTREE

4 REVISION/ PAGE REVISION DATE MADE BY APPLICABLE ECN DETAILS A MAW N/A Release to production MAW 7934 Changed cover on power junction box ARL QOF 339 Updated programming page diagram. i

5 NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL Delta 5 Delta 5 - Low temperature, chemically sanitizing, with a booster tank. Detergent, rinse aid & sanitizer chemical feeder pumps Delta 5 D - Dual door. Low temperature, chemically sanitizing, with a booster tank. detergent, rinse aid & sanitizer chemmical feeder pumps Model: Serial No.: Installation Date: Service Rep. Name: Phone No.: Jackson MSC LLC. provides technical support for all of the dishmachines detailed in this manual. We strongly recommend that you refer to this manual before making a call to our technical support staff. Please have this manual with you when you call so that our staff can refer you, if necessary, to the proper page. Technical support is available from 8:00 a.m. to 5:00 p.m. (EST), Monday through Friday. Technical support is not available on holidays. Contact technical support toll free at Please remember that technical support is available for service personnel only. ii

6 TABLE OF CONTENTS SECTION DESCRIPTION PAGE I. SPECIFICATION INFORMATION Specifications 2 Dimensions 3 II. INSTALLATION/OPERATION INSTRUCTIONS Installation Instructions 5 Electrical Installation Instructions 6 Operation Instructions 7 Chemical Dispensing Equipment 9 Universal Timer Operation 10 Detergent Control 11 III. PREVENTATIVE MAINTENANCE 13 IV. TROUBLESHOOTING SECTION Common Problems 16 V. PARTS SECTION Chemical Feeder Pump Assembly 18 Solenoid Valve Repair Parts 19 Control Box Assembly 22 Peripump Box Assembly 23 Electrical Connection Box Assembly 24 Frame Assembly 25 Hood Assembly 26 Switch Panel Assembly 27 Tub Assembly 29 Frame & Motor Assembly 31 Pump and Motor Assembly 32 Booster Tank Assembly 33 Incoming Plumbing Assembly 34 Door Components 35 Front Panel Assembly 36 VI. ELECTRICAL SCHEMATICS Delta 5 (115 Volt, 60 Hz, Single Phase) 38 VII. JACKSON MAINTENANCE & REPAIR CENTERS 40 i

7 SECTION 1: SPECIFICATION INFORMATION 1

8 SECTION 1: SPECIFICATION INFORMATION SPECIFICATIONS OF THE DELTA 5 OPERATING CAPACITY ( NSF RATED): RACKS PER HOUR 29 DISHES PER HOUR 725 GLASSES PER HOUR 725 OPERATING CYCLES (SECONDS): NORMAL CYCLE: WASH TIME 45 RINSE TIME 25 TOTAL CYCLE TIME 90 WASH TANK CAPACITY (GALLONS): 1.2 WASH PUMP CAPACITY (GPM): 61 OPERATING TEMPERATURES: WASH (MINIMUM) (48.9 C) 120 F WASH (RECOMMENDED) (60.0 C) 140 F RINSE (MINIMUM) (48.9 C) 120 F RINSE (RECOMMENDED) (60.0 C) 140 F WATER REQUIREMENTS: WATER LINE SIZE NPT 1/2 DRAIN LINE SIZE NPT 2 FLOW PRESSURE 20 5 PSI MINIMUM CHLORINE REQUIRED (PPM): 50 ELECTRICAL REQUIREMENTS: WASH PUMP MOTOR HP 3/4 RINSE TYPICAL HEATER TOTAL ELECTRICAL VOLTS PH HZ RATINGS AMPS CIRCUIT KW@110V *16 A 20 AMP * This dishmachine is designed so that the wash motor is never running when the wash heater is on. Service load is based upon the higher of the two amperages. NOTE: Typical Electrical Circuit is based upon (1) 125% of the full amperage load of the machine and (2) typical fixed-trip circuit breaker sizes as listed in the NEC 2002 Edition. Local codes may require more stringent protection than what is displayed here. Always verify with your electrical service contractor that your circuit protection is adequate and meets all applicable national and local codes. These numbers are provided in this manual simply for reference and may change without notice at any given time. FRAME DIMENSIONS: WIDTH (622.3mm) 24 1/2 DEPTH (641.35mm) 25 1/4 DEPTH, WITH FRONT DOOR OPEN (933.45mm) 36 3/4 HEIGHT (990.6mm) 39 MAXIMUM WASH CHAMBER CLEARANCE (292.1mm) 11 1/2 FRAME DIMENSION (DOUBLE DOOR): WIDTH (622.3MM) 24 1/2 DEPTH ( MM) 28 1/8 DEPTH, WITH DOOR OPEN ( MM) 51 5/8 HEIGHT (990.6MM) 39 CHAMBER CLEARANCE (292.1MM) 11 1/2 NOTE: Always refer to the machine data plate for specific electrical and water requirements. The material provided on this page is for reference only and may be subject to change without notice. 2

9 SECTION 1: SPECIFICATION INFORMATION DIMENSIONS 25 1/4 (642 mm) A - Incoming Water Connection B - Drain Connection - 2" IPS C - Electrical Connection Point 24 1/2 (622 mm) NOTE: All vertical dimensions are at lowest point due to adjustable bullet feet and may be raised an additional 2 3/4". 36 3/4 (933 mm) 11 1/2 (292 mm) DISH CLEARANCE C A C 39 (991 mm) 20 (508 mm) 21 1/4 (540 mm) 12 1/4 (311 mm) A 7 3/4 (197 mm) 3 (76 mm) 6 (152 mm) 6 3/4 (171 mm) B B 17 (432 mm) 21 1/4 (540 mm) 3

10 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS 4

11 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS VISUAL INSPECTION: Before installing the unit, check the container and the machine for any damage. A damaged container could be an indication of damage to the unit. If there is damage to both the container and the unit, DO NOT throw away the container. The dishmachine has been inspected and packed at the factory with the expectation that it will arrive to you in new, undamaged condition. However, rough handling by carriers or others may damage the unit while in transit. If this situation does occur, do not return the unit to Ecolab; instead contact the carrier and ask them to inspect the damage to the unit and to complete an inspection report. You must contact the carrier within 48 hours of receiving the machine. Also, contact your Ecolab representative. UNPACKING THE DISHMACHINE: Remove the machine from the container and inspect for any missing parts. If an item appears to be missing, contact your Ecolab representative immediately to report it. LEVEL THE DISHMACHINE: The dishmachine(s) covered in this manual are designed to operate on a level surface. Ensure that the machine is level from side to side and from front to back; adjust the unit s bullet feet as required. Failure to level the dishmachine may cause decreased washing performance. PLUMBING THE DISHMACHINE: All plumbing connections must comply with all applicable local, state and national plumbing codes. The plumber is responsible for flushing the incoming water line prior to connecting it to remove all foreign debris that may get trapped in the valves or cause an obstruction. Any valves that are fouled by matter left in the water line and the expenses resulting are not the responsibility of the manufacturer. CONNECTING THE DRAIN LINE: The Omega 5 drain requires a minimum 2 NPT piping that is pitched at least 1/4 per foot. There must also be an air gap between the machine drain line and the floor sink or drain. If a grease trap is required by code, it should have a flow capacity of 5 gallons per minute. Raise Lower Frame with Adjustable Foot WATER SUPPLY CONNECTION: Install the water supply line (1/2 NPT minimum) to the dishmachine line y-strainer using copper pipe. It is recommended that a water shut-off valve be installed between the main supply and the machine to allow for service. The water supply line must be capable of 20 5 PSI flow pressure at the recommended temperature as indicated on the data plate. Drain Connection In areas where the water pressure fluctuates or is greater than the recommended pressure, it is suggested that a water pressure regulator be installed. The Omega 5 does not come with a water pressure regulator as standard equipment. It is also recommended that a shock absorber (not supplied with the Omega 5) be installed in the incoming water line. This prevents line hammer (hydraulic shock), induced by the solenoid valve, which can cause damage to the equipment. Y-Strainer PLUMBING CHECK: Slowly turn on the water supply to the machine after connecting the incoming fill line and drain line. Check for leaks and repair as required. Leaks must be repaired prior to placing the machine in operation. 5

12 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS ELECTRICAL INSTALLATION INSTRUCTIONS ELECTRICAL POWER CONNECTION: Electrical and grounding connections must comply with all applicable portions of the National Electric Code (ANSI/NFPA 70) and/or other electrical codes that may apply. Disconnect the electrical power supply and lockout the disconnect switch to indicate that you are working on the circuit. The dishmachine data plate is located on the left front corner of the machine. Refer to this data plate for information concerning the unit s specific electrical requirements. To install the incoming power lines, open the connection box by removing the connection box lid. Install 1/2 conduit into the pre-punched holes in the back of the connection box. Route the power wires and connect to the power block and grounding lug. Install the service wires (L1 and N) to the appropriate terminals as they are marked on the terminal block. Install the grounding wire into the lug provided. Wires should be firmly secured in place. It is recommended that De-Ox or another similar anti-oxidation agent be used on all voltage connections. VOLTAGE CHECK: Ensure that the machine is off and apply power to the machine. Check the incoming power at the terminal block and ensure it corresponds to the voltage on the machine data plate. Do not run the dishmachine if the voltage is too high or too low. Shut off the service breaker and mark it as being for the dishmachine. Advise all personnel of the location of the service breaker. Replace all covers and tighten the screws. Ground Lug Power Block NOTE: Always refer to the machine data plate for specific electrical and water requirements. The material provided on this page is for reference only and may be subject to change without notice. 6

13 OPERATIONAL START-UP AND CHECK: Before proceeding with the start-up, verify the following: 1. Open the door and verify that the sump strainer is correctly installed in the sump. 2. Verify that the drain stopper is in position. 3. Check that the plugs are securely screwed into the ends of the wash arm. 4. Check that the wash arm is securely screwed into the stationary base and that it rotates freely. 5. Check the levels in all chemical containers and replace if necessary. INSTALLATION/INITIAL START-UP PROCEDURE: 1. Turn on dishmachine a) Turn on the incoming power to the machine at the circuit disconnect box. b) Turn on the dishmachine by pressing the ON/OFF button. The red light will come on. c) Check voltage at incoming terminals L1& L2. The voltage measured at these points should match data plate voltage. d) If voltages are in required range, close the control box cover. 2. Fill Rinse Booster Heater with Water a) Before the heater element can be energized, the rinse booster heater must be initially filled with water. Damage to the heater element will occur if the element is not submerged in water. To initially fill the booster heater with water: i) Press and hold the FILL button to turn on the incoming water solenoid valve. Continue holding the button until you hear water entering the wash chamber through the airgap, then release the button. The rinse booster heater is now filled with water. ii) Turn off the unit by pressing the on/off switch. 3. Enable Heater Element a) For the initial start-up only, the heater element must be enabled. The machine is shipped from the factory with the heater element disabled. This is done to ensure that the heater element is not damaged by energizing the element without the element being submerged in water. To enable the heater element: i) Remove the booster heater cover panel. ii) Connect the tagged white/blue wires. iii) Replace heater cover. iv) Press the on/off switch, heaters will energize to maintain booster heater temperature. Note: Water must be in the sump while the machine is running to avoid running the pump dry and causing damage to the pump seal. 4. Adjust dishmachine fill level. SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS OPERATION INSTRUCTIONS If the water level is not between the linses on the drain standpipe, it will require adjustment. Check to ensure that the recommended water pressure is being supplied to the machine (20 ±5 PSI is required). If the water pressure is correct then the electronic timer will need adjustment. Use the following steps to adjust the fill time. A. Open control box cover. B. Adjust fill time as per instructions on [aseio of this section. C.Open and close the door to run a cycle, then check the water level. Adjust as necessary then close the control box cover. 7

14 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS OPERATION INSTRUCTIONS (CONTINUED) NOTE: The machine must run a complete cycle to drain and fill. If the machine is not allowed to drain, the water will build up inside the tub. After the initial fill, the rinse water for the current cycle will become the wash water for the next cycle. The dishmachine is now ready to proceed with the washing of dishes. WARNING: Certain materials, including silver, silver plate, aluminum and pewter, are attacked by sodium hypochlorite sanitizers (bleach). PREPARING DISHES: Preparation of the ware will help ensure good results and less re-washes. If not done properly the dishes will not be clean and will reduce the efficiency of the dishmachine. The following steps should be followed to ensure good results: A. Remove all scraps and gross soil into a garbage can. B. Separate and pre-soak silverware. C. Separate and pre-soak the egg and casserole dishes. D. Scrape all ware with a brush or spatula. E. Flush cups, bowls and glasses with running water. F. Prewash dishware by soaking or spraying with a pre-rinse hose. G. Place dishes and cups in dish rack. Cups should be upside down (so they don t hold water). H. Place glasses and flatware in their respective racks. Scatter flatware loosely in rack. Glasses should be placed upside down in a properly sized rack. For optimal results, flatware should be washed twice, the first being horizontal, the second in a special rack to hold flatware vertical. DAILY MACHINE PREPARATION: Before proceeding with start-up, verify the following: A. Open door and verify that the sump strainer is in place in the sump. B. Verify that the drain stopper is in position. C. Check that the plugs are securely screwed into the ends of all wash arms. D. Check that the wash arms are securely screwed into the stationary bases and rotate freely. E. Check levels in all chemical containers and replace if empty. F. For initial fill, close doors then depress the FILL switch to the FILL position. WASHING A RACK OF WARE: A. Open doors, place a full rack into the machine, and close doors. Push the start switch and hold until unit starts (about 2 seconds). B. After cycle is completed open doors and remove rack. C. Repeat steps A and B. SHUT DOWN AND CLEANING: A. At the end of mealtime, move the ON/OFF switch to the OFF position. B. Open doors and manually remove drain stopper to drain the unit. C. Remove and clean upper and lower wash arms. D. Remove and clean the sump strainer. 8

15 WARNING: CHLORINE-BASED SANITIZERS CAN BE DETRIMENTAL TO YOUR MACHINE IF THE CHEMICAL SOLUTION IS TOO STRONG. SEE YOUR CHEMICAL PROFESSIONAL TO ENSURE YOUR DISPENSER IS SET UP CORRECTLY. This equipment is not recommend for use with deionized water or other aggressive fluids. Use of deionized water or other aggressive fluids will result in corrosion and failure of materials and components. Use of deionized water or other aggressive fluids will void the manufacturer's warranty. TO PREPARE CHEMICAL FEEDER PUMPS FOR OPERATION The Delta 5 dismachines are supplied with detergent, rinse additive and sanitizer dispensing chemical feeder pumps. Locate the open ends of the chemical tubes with the tube stiffeners and place each one in the appropriate container. A. Red Tubing = Detergent B. Blue Tubing = Rinse Aid C. White Tubing = Sanitizer PRIMING CHEMICAL FEEDER PUMPS SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS CHEMICAL DISPENSING EQUIPMENT Chemical feeder pumps need priming when the machine is first installed or if for some reason the chemical lines have been removed and air is allowed to enter. CAUTION: Water must be in the sump and wash tank prior to the dispensing of chemicals. Sanitizer in con centration is caustic and may cause damage without dilution. 1. Verify that the proper chemical tube stiffener inlet is in the proper container. 2. Use the prime switches located on the control panel at the bottom of the unit to prime each pump. The switches are clearly marked as to what chemical feeder pump they are assigned to. 3. To prime the pumps, hold the switch in the momentary position until chemical can be observed entering the sump. 4. Detergent is dispensed as required during the wash cycle by the universal timer. The amount of detergent may need to be increased or decreased depending on water quality and type of detergent. 5. Rinse additive is dispensed as required into the final rinse. The amount of rinse aid may need to be adjusted depending on water hardness and results. 6. Sanitizer (either chlorine or iodine) is dispensed into the final rinse. The amount of sanitizer may need to be adjusted depending on the concentration and type of sanitizer used. 7. Please refer to the next page for instruction on adjusting the chemical feeder pumps on the universal timer. WARNING: Some of the chemicals used in dishwashing may cause chemical burns if they come in contact with your skin. Wear protective gear when handling these chemicals. If you do come in contact with these chemicals, immediately flush the affected area with fresh water. 9

16 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS PROGRAMMING INSTRUCTIONS FOR CHEMICAL FEEDER PUMPS (FOR INSTALLATION TECHNICIAN ONLY) To access the programming mode, the machine must be ON, and idle (between cycles). On the timer board, press and hold both the MOVE and ENTER buttons on the timer board simultaneously for two seconds. The PROGRAM light will illumniate. Once in the programming mode, the MOVE button is used to scroll between the programming categories and the ENTER button is used to select the category. Press the MOVE button to move the blinking light between FILL, RINSE AID, DETERGENT or SANITIZER. Press the ENTER button for the chosen category. The PROGRAM light will illuminate. To change the value of a parameter, use the MOVE button to illuminate the light next to the time option (time is in seconds). In the time categories, each second in use will light up. To deselect the option, press ENTER and the light will go off, press ENTER again and it will illuminate. Once you have set your time category, press the MOVE button to the ACCEPT option and press ENTER. This will save the changed parameters. Once you press the ENTER button when the ACCEPT option is illuminated, you will exit the programming mode. To change any other values, you will have to return to the programming mode. To revert back to a previous setting, you must return to that option and change the parameter back to the previous setting. Once in the programming mode, if there have been no keypad inputs for approximately 2 minutes, the system will automatically exit out of the programming mode. Any changes to parameters will be saved when the programming mode is automatically exited. The wash and drain settings are not adjustable. All time adjustments are in seconds. Refer to the chart below for the adjustable outputs. Timer Programming Board Time in Seconds Rinse Aid Fill Sanitizer Detergent Issued: Revised:

17 SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS DETERGENT CONTROL Detergent usage and water hardness are two factors that contribute greatly to how efficiently your dishmachine will operate. Using detergent in the proper amount can become, in time, a source of substantial savings. A qualified water treatment specialist can tell you what is needed for maximum efficiency from your detergent, but you should still know some basics so you ll understand what they are talking about. First, you must understand that hard water greatly effects the performance of the dishmachine. Water hardness is the amount of dissolved calcium and magnesium in the water supply. The more dissolved solids in the water, the greater the water hardness. Hard water works against detergent, thereby causing the amount of detergent required for washing to increase. As you use more detergent, your costs for operating the dishmachine will increase and the results will decrease. The solids in hard water also may build-up as a scale on wash and rinse heaters, decreasing their ability to heat water. Water temperature is important in removing soil and sanitizing dishes. If the water cannot get hot enough, your results may not be satisfactory. This is why Jackson recommends that if you have installed the machine in an area with hard water, that you also install some type of water treatment equipment to help remove the dissolved solids from the water before it gets to the dishmachine. Second, hard water may have you adding drying agents to your operating cycle to prevent spotting, when the real problem is deposited solids on your ware. As the water evaporates off of the ware, the solids will be left behind to form the spotting and no amount of drying agent will prevent this. Again, using treated water will undoubtedly reduce the occurrences of this problem. Third, treated water may not be suitable for use in other areas of your operation. For instance, coffee made with soft water may have an acid or bitter flavor. It may only be feasible to install a small treatment unit for the water going into the dishmachine itself. Discuss this option with your qualified water treatment specialist. Even after the water hardness problems have been solved, there still must be proper training of dishmachine operators in how much detergent is to be used per cycle. Talk with your water treatment specialist and detergent vendor and come up with a complete training program for operators. Using too much detergent has as detrimental effects as using too little. The proper amount of detergent must be used for job. It is important to remember that certain menu items may require extra detergent by their nature and personnel need to be made aware of this. Experience in using the dishmachine under a variety of conditions, along with good training in the operation of the machine, can go a long way in ensuring your dishmachine operates as efficiently as possible. Certain dishmachine models require that chemicals be provided for proper operation and sanitization. Some models even require the installation of third-party chemical feeders to introduce those chemicals to the machine. Jackson does not recommend or endorse any brand name of chemicals or chemical dispensing equipment. Contact your local chemical distributor for questions concerning these subjects. Some dishmachines come equipped with integral solid detergent dispensers. These dispensers are designed to accommodate detergents in a certain sized container. If you have such a unit, remember to explain this to your chemical distributor upon first contacting them. As explained before, water temperature is an important factor in ensuring that your dishmachine functions properly. The data plate located on each unit details what the minimum temperatures must be for either the incoming water supply, the wash tank and the rinse tank, depending on what model of dishmachine you have installed. These temperatures may also be followed by temperatures that Jackson recommends to ensure the highest performance from you dishmachine. However, if the minimum requirements are not met, the chances are your dishes will not be clean or sanitized. Remember, a dish can look clean, but it may not be sanitized. Instruct your dishmachine operators to observe the required temperatures and to report when they fall below the minimum allowed. A loss of temperature can indicate a much larger problem such as a failed heater or it could also indicate that the hot water heater for your operation is not up to capacity and a larger one may need to be installed. There are several factors to consider when installing your dishmachine to ensure that you get the best possible results from it and that it operates at peak efficiency for many years. Discuss your concerns with your local chemical distributor and water treatment specialist before there is a problem. 11

18 SECTION 3: PREVENTATIVE MAINTENANCE 12

19 SECTION 3: PREVENTATIVE MAINTENANCE PREVENTATIVE MAINTENANCE The dishmachines covered in this manual are designed to operate with a minimum of interaction with the operator. However, this does not mean that some items will not wear out in time. Jackson highly recommends that any maintenance and repairs not specifically discussed in this manual should be performed by QUALIFIED SERVICE PERSONNEL ONLY. Performing maintenance on your dishmachine may void your warranty if it is still in effect. There are many things that operators can do to prevent catastrophic damage to the dishmachine. One of the major causes of component failure has to do with prescrapping procedures. A dishmachine is not a garbage disposal; any large pieces of material that are put into the machine shall remain in the machine until they are either broken up (after spreading out on your ware!) or physically removed. Strainers are installed to help catch debris, but they do no good if they are clogged. Have operators regularly inspect the pan strainers to ensure (1) that they are free of soil and debris and (2) they are laying flat in the tub. When cleaning out strainers, do NOT beat them on waste cans. The strainers are made of metal and can be forgiving; but once severe damage is done, it is next to impossible for the strainer to work in the way it was designed to. Wipe out strainers with a rag and rinse under a faucet if necessary. For stubborn debris, a toothpick should be able to dislodge any obstructions from the perforations. Always ensure that strainers are placed back in the machine before operation and that they lay flat in the tub. You may wish to also refer to the page entitled Detergent Control in order to learn more about how your water hardness will effect the performance of your machine. Hard water makes dishmachines work harder and decreases efficiency. Again, it is important to remind operators that trying to perform corrective maintenance on the dishmachine could lead to larger problems or even cause harm to the operator. If a problem is discovered; secure the dishmachine using proper shut down procedures as listed in this manual and contact a QUALIFIED SERVICE AGENCY. Some problems, however, may having nothing to do with the machine itself and no amount of preventative maintenence is going to help. A common problem has to do with temperatures being too low. Verify that the water temperatures coming to your dishmachine match the requirements listed on the machine data plate. There can be a variety of reasons why your water temperature could be too low and you should discuss it with a QUALIFIED SERVICE AGENCY to determine what can be done. By following the operating and cleaning instructions in this manual, you should get the most efficient results from your machine. As a reminder, here are some steps to take to ensure that you are using the dishmachine the way it was designed to work: 1. Ensure that the water temperatures match those listed on the machine data plate. 2. Ensure that all strainers are in place before operating the machine. 3. Ensure that all wash and/or rinse arms are secure in the machine before operating. 4. Ensure that drains are closed/sealed before operating. 5. Remove as much soil from dishes by hand as possible before loading into racks. 6. Do not overfill racks. 7. Ensure that glasses are placed upside down in the rack. 8. Ensure that all chemicals being injected to machine have been verified as being at the correct concentrations. 9. Clean out the machine at the end of every workday as per the instructions in the manual. 10. Always contact a QUALIFIED SERVICE AGENCY whenever a serious problem arises. 11. Follow all safety procedures, whether listed in this manual or put forth by local, state or national codes/regulations. 13

20 SECTION 4: TROUBLESHOOTING 14

21 SECTION 4: TROUBLESHOOTING SECTION COMMON PROBLEMS WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service per sonnel. Certain procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reapply power to test. When replacing electrical parts, disconnect power at source circuit breaker. Problem: Water overflow from bottom of door. 1. Clogged drain. Remove obstruction. 2. Machine not level. Level machine, or increase height to the front. 3. Excessive inlet pressure. Install pressure reducing valve, or adjust if one is present. Ensure flow is 20 5 PSI. 4. Detergent foaming. Reduce detergent quantity. 5. Excessive fill time. Adjust timer fill time as per Section 2. Problem: Wash motor doesn t operate on manual wash. 1. Loose or broken wires. Reconnect or replace wires in motor. 2. Defective manual wash switch. Replace. 3. Defective motor starting relay. Replace. Problem: Motor operates on manual wash/delime but not on automatic. 1. Defective circuit in manual wash switch. Replace switch. Problem: No water comes through the rinse arms when the FILL switch is depressed. 1. Water not turned on. Turn water on. 2. Defective solenoid valve. Replace solenoid valve. Problem: Little or no water coming through the rinse assemblies. 1. Limed up rinse heads or piping. Delime rinse heads. 2. Low water pressure. Increase pipe size to machine. Adjust pressure regulator. Problem: Rinse water runs continuously with breaker turned off. 1. Defective plunger in solenoid valve. Replace. 2. Defective diaphragm in solenoid valve. Replace diaphragm. Problem: Wash temperature not at required reading on thermometer. 1. Check that white/blue wires are connected. See note on page Defective thermometer. Replace. 3. Defective thermostat. Adjust thermostat. Replace thermostat. 4. Rinse heater defective. Replace heater element. 5. Defective heater contactor R2. Replace. 6. Incoming inlet water temperature below required minmum. 7. Defective heater delay relay (R4). Replace 15

22 WARNING: Inspection, testing and repair of electrical equipment should be performed only by qualified service personnel. Certain procedures in this section require electrical tests or measurements while power is applied to the machine. Exercise extreme caution at all times. If test points are not easily accessible, disconnect power, attach test equipment and reapply power to test. When replacing electrical parts, disconnect power at source circuit breaker. Problem: Rinse water not at required temperature range. SECTON 4: TROUBLESHOOTING SECTION COMMON PROBLEMS 1. Check that white/blue wires are connected. See note in installation instructions. 2. Thermometer is defective. Replace. 3. Thermostat is defective. Adjust the thermostat. Replace if necessary. 4. Incoming rinse water does not meet minimum criteria indicated on machine data plate. Adjust as required. Problem: No indication of pressure. 1. Water turned off. Turn water on. 2. Pressure gauge defective. Replace pressure gauge. 16

23 SECTION 5: PARTS SECTION 17

24 SECTION 5: PARTS SECTION CHEMICAL FEEDER PUMP ASSEMBLY Squeeze Tube Lubricant Housing Kit (Red roller) Mfg. No.: Roller, Red (Detergent/Sanitizer) Mfg. No.: Roller, White (Rinse Aid) Mfg. No.: Roller, Black Mfg. No.: Squeeze Tube, Detergent/Sanitizer (Use with the red roller.) Mfg. No.: Clear Squeeze Tube, Rinse Aid (Use with the white roller.) Mfg. No.: Tube, Small 7/32 (Use with the black roller.) Mfg. No.: Motor, 36 RPM 115V Detergent/Sanitizer Feeder Pump Mfg. No.: Motor, 14 RPM 115V Rinse Aid Feeder Pump Mfg. No.: Motor, 36 RPM 240V Detergent/Sanitizer Feeder Pump Mfg. No.: Motor, 14 RPM 240V Rinse Aid Feeder Pump Mfg. No.: Motor, 14 RPM 24V Rinse Aid Feeder Pump Mfg. No.: /4 Sight Tube Ecolab No.: Mfg. No.: N/A 3/8 Sight Tube Ecolab No.: Mfg. No.:

25 SECTION 5: PARTS SECTION SOLENOID VALVE REPAIR PARTS KITS Screw Data Plate Cap Screw Coil and Housing Data Plate Valve Bonnet Spring position is moved for clarity. Goes below the plunger. Spring & Plunger Kit Cap Cap Retainer Diaphragm Retainer O-Ring & Diaphragm O-Ring Plunger Screen Retainer Mesh Screen Components of Repair Kit Body Valve Body Complete Vacuum Breaker Assembly, 1/2 NPT Complete 110 Volt Solenoid Valve Assembly, 1/ Coil & Housing only, 1/ Water Hammer Arrestor, 1/2" NPT Water Hammer Arrestor Assembly Complete 220 Volt Solenoid Valve Assembly, 1/ Coil & Housing only, 1/ Tee, 1/2 x 1/2 x 1/ Close Nipple, 1/

26 SECTION 5: PARTS SECTION CONTROL BOX ASSEMBLY 1 9, Normal/Delime 3 7 Rinse Aid/Detergent 8 Sanitizer 4 11, 27 11, , 13, 28 20

27 SECTION 5: PARTS SECTION CONTROL BOX ASSEMBLY 16, , 28 18, , , 27 25, 26, , 23 21

28 SECTION 5: PARTS SECTION CONTROL BOX ASSEMBLY (CONTINUED) ITEM QTY DESCRIPTION Mfg. No. 1 1 Control Box Weldment Control Box Cover Decal, Warning - Disconnect Power Screw, x 1/2 Long, Phillips Tusshead Decal, Peri-pump Prime Switch, Delime/Normal Detergent/Rinse Aid Pump Prime Switch Sanitizer Pump Prime Switch Locknut, 1/4-20 S/S Hex with Nylon Insert Washer, 1/4-20 S/S Contactor Timer, Universal Bracket, Timer Fitting, Conduit, Heyco 1/ Fitting, 1/2 Straight Snap In Clamp, 5/8 Nylon Relay, 2 Pole Terminal Board Harness, Switch Panel Fitting, 1/2 90 Deg. Snap In Conduit, 1/2 x Cycle Counter, 115V Screw, 4-40 x 1/4 Phillips Pan Head Terminal Board Terminal Board Decal, Terminal Board 8 Position Locknut, S/S Hex with Nylon Insert Locknut, 6-32 S/S Hex with Nylon Insert Harness, Wash Pump Harness, Drain Solenoid Harness, Peri-pump Conduit, 1/2 x

29 SECTION 5: PARTS SECTION PERI-PUMP BOX ASSEMBLY Sanitizer Detergent Rinse Aid ITEM QTY DESCRIPTION Peri-pump Assembly, 36 RPM Peri-pump Assembly, 14 RPM Drip Channel Weldment, Peri-pump Box Weldment, Peri-pump Box Cover Fitting, Conduit, Heyco 1/2 Clamp, 5/8 Nylon (Located inside of box) Clamp, 1 Nylon Screw, x 1/2 Long, Phillips Tusshead Locknut, S/S Hex with Nylon Insert Tube Stiffener (Not Shown) Tubing, 1/4 OD x 60 Long, Blue Tubing, 1/4 OD x 60 Long, White Tubing, 1/4 OD x 60 Long, Red Terminal Board (Not Shown) Tubing,1/4 OD x 120 Long Blue Tubing,1/4 OD x 120 Long Write Tubing,1/4 OD x 120 Long Red Mfg. No

30 SECTION 5: PARTS SECTION ELECTRICAL CONNECTION BOX ASSEMBLY A A A 9 ITEM QTY DESCRIPTION ECOLAB No. Mfg. No. 1 1 Box, Power Junction Weldment Terminal Block Spacer Terminal Block Locknut, 6-32 with Nylon Insert Locknut, with Nylon Insert Lug, Ground Decal, Power Connection Decal, Warning to Disconnect Power Screw, x 1/2 Long, Phillips Trusshead N/A Decal, Copper Conductors Only Cover, Solenoid Box Issued: Revised:

31 SECTION 5: PARTS SECTION FRAME ASSEMBLY 5 ITEM QTY DESCRIPTION Mfg. No. 1 1 Frame Weldment Frame Weldment Double Door Foot, 3 Adjustable Plate, Hinge Weldment Washer, Hinge Weldment Spacer, PB Bolt Clamp, Pipe Washer, 1/4-20 S/S Keeper, Door Panel Latch Locknut, 1/4-20 S/S Hex with Nylon Insert Nut, Hex 1/ Booster Mounting Plate Weldment Bracket, Temperature Gauge Bolt, 1/4-20 x 1/2 Long

32 SECTION 5: PARTS SECTION HOOD ASSEMBLY ITEM QTY DESCRIPTION Mfg. No. 1 1 Hood Weldment a 1 Hood Weldment Double Door Switch, 115V Reed Bracket, Limit Switch Locknut, with Nylon Insert Clamp, Pipe 5/ Rack Rail Weldment Washer, 1/4-20 I.D Gasket, Side Panel (5.3 Feet)

33 SECTION 5: PARTS SECTION SWITCH PANEL ASSEMBLY ITEM QTY DESCRIPTION Mfg. No. Complete Side Panel Assembly Complete Side Fanel Assembly (Double Door) Side Panel Weldment a 1 Side Panel Weldment (Double Door) (3) Switch, Prime Assembly Switch, On/Off Assembly (2) Light, Amber (2) Light, Red Decal, Switch Panel Fitting, (2) Plug, 3/4 hole Locknut, with Nylon Insert Washer, # Decal Switch Panel (Double Door Only) Fitting (Double Door Only) switch (Double Door Only) bracket (Double Door Only) Terminal Board ALL NUMBERS THAT ARE IN PARENTHISES ARE FOR THE DOUBLE DOOR 27

34 SECTION 5: PARTS SECTION TUB ASSEMBLY 14b 14a 14c 27b 27a 16a 16b 30e 30d 30b 30c 30a 17c 17b 17a 28

35 SECTION 5: PARTS SECTION TUB ASSEMBLY CONTINUED ITEM QTY DESCRIPTION Mfg. No. 1 1 Tub Weldment a 1 Tub Weldment (Double Door) Lower Manifold Weldment Manifold Gasket Drain Seat Insert Spillway Gasket Spillway Weldment Locknut, 1/4-20 S/S Hex with Nylon Insert Manifold O-Ring Modified Casting Wedge Bolt, 3/8-16 x 1 1/4 S/S Washer, 3/8 Bevel-Square Iron Lockwasher, 3/ Nut, 3/8-16 S/S Hex Complete Wash Arm Assembly a 1 Wash Arm Weldment w/ End Plugs Wash Arm End Plugs b 1 Wash Arm O-ring c 1 Wash Arm Bearing Assembly Sump Strainer a 1 Stand Pipe Weldment b 1 Stopper, Stand Pipe Drain Link Assembly a 1 Drain Link b 1 Nut, Hex, 5/ c 1 Drain Link Connector Hair Pin, 1/8 to Fill Tube Weldment Washer, 1/4-20 I.D Chemical Tube Grommet (2) Pivot Plate, Left Door Complete Assembly a 1 Door Pivot Plate Left Weldment b 1 Door Pivot Plate Bearing (2) Pivot Plate, Right Door Complete Assembly a 1 Door Pivot Plate Right Weldment b 1 Door Pivot Plate Bearing Bolt, 1/4-20 x 1/2 Long Screw, 1/4-20 x 5/8 Long Air Gap Weldment Halo Assembly a 1 Halo Weldment b 4 Spray Nozzle and Receptacle Gasket, Air Gap Clamp, 1 Nylon (Not Shown, located on bottom of tub.) Drain Solenoid Box Assembly a 1 Solenoid Box Weldment b 1 Drain Solenoid, 115V c 4 Locknut, with Nylon Insert d 1 Decal, Warning e 1 Solenoid Box Cover ALL NUMBERS THAT ARE IN PARENTHISES ARE FOR THE DOUBLE DOOR 29

36 SECTION 5: PARTS SECTION FRAME AND MOTOR ASSEMBLY See Motor Assembly Page a 6 3b 12 See Plumbing Assembly Page See Booster Assembly Page See Frame Assembly Page 30

37 SECTION 5: PARTS SECTION FRAME AND MOTOR ASSEMBLY (CONTINUED) ITEM QTY DESCRIPTION Mfg. No. 1 1 Discharge Tube Connector Pump Suction Hose Discharge Hose Assembly a 2 Fitting, 1/2 Pushlock, Female, Brass b 1 Hose, 1/2 x 22 1/2 Long Wash Restrictor Accumulator Strainer Weldment Accumulator Weldment Bolt, 1/4-20 x 1/2 Long Locknut, 1/4-20 S/S Hex with Nylon Insert Washer, 1/4-20 S/S Hose Clamp, 13/16 TO 1 1/ Hose Clamp, 1 1/16 to 2 1/ Close Nipple, 1/2 Brass Gauge, Thermometer

38 Complete Pump & Motor Assembly Mfg. No.: SECTION 5: PARTS SECTION MOTOR & PUMP ASSEMBLY Pump Only Assembly Mfg. No.: Motor Only Mfg. No.: Shim Kit Mfg. No.: Impeller Assembly Mfg. No.: Case Capscrew Mfg. No.: Pump Casing Mfg. No.: Mechanical Seal Mfg. No.: Case O-Ring Mfg. No.: Seal Plate Mfg. No.: Other parts not shown. Drain Plug Mfg. No.: Lockwasher, 3/8 Mfg. No.: Nut, Hex 3/8-16 S/S Mfg. No.: Motor Mounting Bracket Mfg. No.: Bolt, 3/8 x 3/4 Long Hex Head Mfg. No.:

39 SECTION 5: PARTS SECTION BOOSTER TANK ASSEMBLY ITEM QTY DESCRIPTION Mfg. No. 1 1 Booster Tank Weldment Heater, 120V, 2000 Watts Heater Gasket Thermostat Fitting, Imperial Brass Plug, 1/4 Brass Lockwasher, 5/ Nut, 5/16-18 S/S Hex Locknut, 6-32 S/S Hex w/ Nylon Insert Booster Tank Cover Decal, Warning, Disconnect Power Screw, x 3/ Fitting, 1/2 NPT x 90 Deg. Elbow a 1 Nut, 1/2 NPT Nylon

40 SECTION 5: PARTS SECTION INCOMING PLUMBING ASSEMBLY ITEM QTY DESCRIPTION Mfg. No. 1 1 Incoming Plumbing Assy Y-Strainer Nipple, Close, 1/2 NPT, Brass Valve, Solenoid, 1/2 NPT, 115V Plumbing, incoming Union Fitting, Liquidtiht

41 SECTION 5: PARTS SECTION DOOR ASSEMBLY ITEM QTY DESCRIPTION Mfg. No. Complete Door Assembly (2) Door Weldment (2) Magnet, Reed Switch (2) Locknut, 6-32 S/S Hex with Nylon Insert (4) Locknut, 1/4-20 S/S Hex with Nylon Insert (2) Nut, Hex 1/4-20 S/S (2) Bolt, 1/4-20 Eye, S/S (2) Spring, Door ALL NUMBERS THAT ARE IN PARENTHISES ARE FOR THE DOUBLE DOOR 35

42 SECTION 5: PARTS SECTION FRONT PANEL ASSEMBLY Double Door Only Panel Clips 2 per machine (Double Door Only) Back Panel Weldment 1 per machine ITEM QTY DESCRIPTION Mfg. No. Complete Panel Assembly Panel Weldment Handle Back panel weldment Panel clips