Service Engineers Manual (for software version 0.0.00) Duo Duo Duo 00 Duo 70 File location : Users on ClassicK\Works Print Folder\Under counter warewashers\double skin\duo\engineers manual Duo
Service Engineers Manual Service Engineers Manual For Classic Glass & Dishwashing Systems Duo range of glass and dishwashers. Section Title Page(s).0 Range.0 Features. Fascia layout. Electromechanical features. Software features.0 Water flow patch.0 Electrical circuit. Plug details,. Inputs & Outputs at PLC controller. Top contactor plate arrangement 7. Standard DUO top loom 8. DUO & DUO 00 bottom loom 9. DUO & DUO 70 bottom loom 0.7 Typical heating circuit.8 DUO pump control circuit.9 DUO inlet solenoid valve control circuit.0 DUO ON/OFF control circuit.0 Basic Installation. The site. Electrical connection. Water connection.0 Commissioning 7. Rinse aid & detergent 7. Demonstration 7
.0 Range The basics of the Duo range follow a similar pattern to that of Classic standard single skin machines, with the following comparisons Duo comparable to Eco Duo comparable to Eco Duo 00 comparable to H 00 Duo 70 comparable to H 70 Description Machine Range Duo Duo Duo 00 Duo 70 Type of machine Glasswasher Dishwasher Basket size 00mm² 00mm² 00mm² 00mm² Physical Height (overall) 70mm 80mm 70mm 80mm Width (overall) 7mm 90mm 7mm 90mm Depth (overall) 0mm 0mm 0mm 0mm Minimum pressure 0. bar Supply water Maximum pressure bar (after which a pressure reducing valve will be required) Minimum temperature c Maximum temperature c Volume. litres 7.0 litres. litres 7.0 litres Rinse tank Element power.7 kw.0 kw.7 kw.0 kw Temperature (non adjustable) 0 c 80 c Volume. litres litres. litres litres Wash tank Element power.8 kw. kw.8 kw. kw Temperature (non adjustable) c Rinse aid setting seconds Chemicals Detergent initial setting 70 seconds 0 seconds 0 seconds 90 seconds Detergent cycle setting 0 seconds Page
.0 Features The range of machines within the Duo range have the following features as standard :. Fascia layout. ON / OFF lamp. ON / OFF Switch. Ready / Hot lamp. Cycle lamp. Cycle switch &. Electromechanical features Double skin Features Type A integral airbreak Air pressure switch control water level in rinse tank Machine Range Duo Duo Duo 00 Duo 70 Rinse pump (wattage) 0 w 70 w 0 w 70 w Peristaltic rinse aid pump Fixed rinse thermostats 0 c 80 c Air pressure switch control water level in wash tank Single level Double level Single level Double level Wash pump (wattage) 0 w 70 w 0 w 70 w Peristaltic rinse aid pump Fixed wash thermostats c PLC controller Independent chemical Primary filters Secondary filters Drain pump (wattage) 0 w Drain plug Page
. Software features (version 0.0.00) Features Machine Range Duo Duo Duo 00 Duo 70 Initial fill & heat Inlet solenoid timeout Heat up time prior to initial rinse transfer Heat up time after initial rinse transfer Rinse transfer time n/a minute Until rinse tank achieves rinse temperature seconds (if door is opened, rinse will pause) Std. Wash pump run time 0 seconds seconds Wash cycle If rinse not to temp, wash extends to a max. time, then rinses what ever the rinse temperature Wash timer pauses if door is opened Cycle starting conditions 80 seconds 0 seconds Wash tank full and up to target temperature ( c) Drains from APS = until APS = 0 Cycle drain sec delay ON / OFF, linked to rinse pump timer Drain pump time out Auto start drain down 0 seconds Automatically start seconds after turning the machine OFF at the fascia Drain down Min drain pump run time 90 seconds 0 seconds 90 seconds 0 seconds Rinse pump run time 0 seconds (will pause if door is opened) Drain pump over run Drain down Drain & rinse pump run together, drain pump then runs for a further 0 seconds, also will run while the door is open Auto reset after switch the machine ON at the fascia Reset Cycle Auto reset after switch the machine OFF at the fascia Time outs Auto reset after switch the machine OFF then ON at fascia Page
.0 Water flow path. Rinse tank fill and rinse system Inlet solenoid valave Airbreak Rinse tank Rinse pump Top rinse jets Rinse manifold Bottom rinse jets. Wash pump system. Drain system Page
.0 Electrical circuits Due to the PLC (Programmable Logic Controller), it has been possible to simplify the control circuit within the Duo range, the following diagram have again been subdivided to allow easier understanding of the machine and the working of the circuit. The top control panel has been designed to unplug from the lower loom, these plugs are found at the rear right hand side of the top control panel. The four plugs control the following functions :. Plug details (between top & bottom looms) 8 way plug Pin Top wire Bottom wire Goes to on top loom Goes to on bottom loom Red Red Red at Solenoid contactor Inlet solenoid valve Black Purple Q on PLC & at coil of Solenoid contactor Q on PLC & trigger at chem. timer Rinse pump Wash pump Orange Orange Q on PLC & Wash APS high Drain pump Yellow Yellow Soap signal at chem. timer Soap pump Rinse APS high Rinse APS high, Live supply to bottom loom 7 Grey Grey Rinse aid signal at chem. timer Rinse aid pump 8 Neutral circuit Neutral to pumps way plug Pin Top wire Bottom wire Goes to on top loom Goes to on bottom loom Black Black way plug Rinse element contactor Neutral at terminal block Neutral at coil of rinse element contactor Rinse element live supply Neutral at rinse safety trip Neutral at rinse element Pin Top wire Bottom wire Goes to on top loom Goes to on bottom loom Purple Purple Wash element contactor Live at wash safety trip Neutral at terminal block Neutral at wash safety trip Purple Purple Live at coil of wash element contactor Return from wash operating trip Wash element contactor Supply to wash operating trip Page
way plug (Dishwashers only) Pin Top wire Bottom wire Goes to on top loom Goes to on bottom loom Grey I7 at PLC Live from pin on 8 way plug way plug (Glasswashers only) I at PLC & live at coil of rinse element contactor 80 c rinse operating trip Pin Top wire Bottom wire Goes to on top loom Goes to on bottom loom Grey (not used) I7 at PLC Grey I at PLC & live at coil of rinse element contactor 0 c rinse operating trip. Inputs & Outputs at PLC controller L N I I I I I I I7 I8 AC/DC..0V Classic Part No. : ES0 RUN/STOP INPUT 8xAC/DC LOGO! 0RCo ES0 PLC OUTPUT xrelay/0a Q Q Q Q Inputs Pin Wire Description i ON / OFF signal i Yellow Cycle switch signal i Rinse air pressure switch (APS) high signal i Red Wash tank full and not heating signal i Wash air pressure switch (APS) high signal i Rinse tank full and heating signal i7 Grey Glass / Dish washer signal (live when dishwasher) i8 Purple Door switch signal (live when closed) Outputs Pin Wire Description Q Red Signal to Machine ready lamp Q Orange Signal to Drain pump Q Black Signal to Wash pump Q Signal to Rinse pump Page
. Top contactor plate arrangement 8 7 Ref Description Part No. Notes PLC controller ES0 MUST state software version when ordering Chemical timer CLM Terminal block 7..70 Step relay CONT 7 Rinse element contactor CONT 0 Wash Element contactor CONT 0 7 Circuit breaker TCB 7 Solenoid Contactor CONT 0 Page 7
Chemical Timer 7 8 CR yelet Crimp CR yelet Crimp ascia Earth CR yelet Crimp e Earth Breaker TCB ZE700 90 SD 0 Rinse APS Single (Oval) APS Wash Element Cont CONT 0 0 CT0 A A Rinse Element A Cont A Neutral Trigger Soap R.Aid Live L N I I I I I I I7 I8 Violet Violet Mc On Lamp 7../8 0 L INPUT 8xAC/DC ES0 PLC CT 0 AC/DC..0V Classic Part No. : ES0 RUN/STOP LOGO! 0RCo OUTPUT xrelay/0a Q Q Q Q Chem Timer CLM CLM Double APS Wash 7..90 ADP00 7,8 APS. Standard DUO top loom Switch L7A Sw9 A CONT 7 CT Violet.0mm Black.mm.mm CC Red Bla ck Orange Yellow Brow n Grey Grey Cycle Switch L7A Sw Red Door Sw 7..0/ 0 Sw7 Orange A Violet Violet Yellow Yellow /Green A A Cabinet Earth Mc Ready Lamp 7../9 0 L9 CRHM C C0.mm.mm Purple Purple CRHM CC CONT 0 CT 0.mm.mm.mm.mm.mm Black CRHM CC7 CRHM CC CRHM CRHM CC CC CRHM8 Grey CRHM 8 CC Red Black Orange Yellow Grey 7 8 Earth.0mm.0mm.0mm L L.0mm.0mm.0mm TB 0 L N N 7..70 Terminal Block Earth 0v AC Live 0v AC Neutral Page 8
. DUO & DUO 00 bottom loom L N 7../ way Male Violet Yellow Yellow 7 Rinse Pump DS0000 UP09, P E R. P. Capacitor DS000 7WC00 8,9 C IS C LC N + Wh ite Wh ite C N L C E Ye llow + W. P. Capacitor 7..0 8,9 C Wash Pump 8..0/R H7 P0 CR Eyelet Crimp Yellow Drain Pump DP DPS09 P E (PE) 00 CR Eyelet Crimp N L.0mm Violet Wash Element 9.. 7/. MRS 7 7../DW Wash Safety Trip Rinse Element 9. 9. 8 E8 8 E.0mm R. Aid Prime 7../ C BLACK 0 Sw Rinse Aid So ap L N L N Chemical Pump Assy 8LPPDS,0 P Trip 7../DX 70 MRS L N way Female Crim p Cover CRHF CC.0mm Violet.0mm Trip [ 7../ 79 SRS CRHF CC0 Dish Washer (80 Deg) CRHF CC8 SRS 79 7../ Trip[ CRHF Glass Washer (0 Deg) CC9 Grey SRS 79 7.. / Trip[ CRHF8 CC Red Violet Orange Yellow Brow n Grey way Fem ale CRHF 0 CC Purple.mm.mm CRHF 7 8 CC.mm Black.mm CRHF CC CRHF CC7 Grey CRHF 8 CC Red Violet Orange Yellow Grey 7 8 9 Page
Rinse Aid So ap L N L N 7../ 7 8 7 IS Rinse Element HY0 80 E C LC N Trip 7../DX 70 MRS N E (PE) Chemical Pump Assy 8LPPDS,0 P way Male Violet Yellow Yellow L MRS 7 7../DW Wash Safety Trip L N Colour Rinse Pump DS0000 UP09, P E R. P. Capacit or DS000 7WC00 8,9 C + C N L C E Ye llow W. P. Capacitor 7..0 + 8,9 C Wash Pump 9..0/R H7 P CR Eyelet Crimp Ye llo w Drain Pump DP DPS09 P 00 CR Eyelet Crimp N L.0mm Violet Wash Element 9..7/. 8 E.0mm R. Aid Prime 7../ C BLACK 0 Sw.0mm way Female Crim p Cover CRHF CC.0mm Violet.0mm Trip[ 7../ 79 SRS CC0.0mm Black.0mm.0mm.0mm.0mm CRHF Dish Washer (80 Deg) CC8 SR S 79 7../ Trip[ CRHF Glass Washer (0 Deg) Grey SR S 79 7../ Trip[ CC Red way Fem ale CRHF 0 CC.mm.mm Violet Violet CRHF Orange Yellow CC Grey CC9 CRHF CRHF8.mm.mm.mm.mm.mm 7 8 Black CRHF CC7 CRHF CC Grey CRHF8 C C Red Violet Orange Yellow Grey. DUO & DUO 70 bottom loom Page 0
On/Of f Switch L7A Sw CONT 7 CT8 Breaker TCB ZE700 90 SD Double APS Wash 7.. 90 ADP00 7,8 APS7 A A Rinse APS Single (Oval) APS8 CT7 0 N L A A Wash Element Cont CONT 0 Wash Element 9..7/. 0 CT A 8 E0 A 0 M RS7 7 7../DW Wash Safety Trip Trip[ 7../ 79 SRS CC8 CRHF CC8 Glass Washer (0 Deg) CRHF CC8 CRHM Rinse Element Cont Rinse Element HY0 80 E9 Trip 7../DX 70 MRS8 N L.7 Typical heating circuit (DUO & DUO 70 shown) 0V Liv e Supply 0V Neutral Supply SRS7 79 7../ Trip[ Dish Washer (80 Deg) SRS 79 7../ Trip[ Page
L N I I I I I I I7 I8 AC/DC..0V Classic Part No. : ES0 RUN/S TOP INPUT 8xAC/DC LOGO! 0RCo OUTPUT xrelay /0A Q Q Q Q Drain Pump DP DPS09 P L N Wash Pump 9..0/R H7 P E C N L C W. P. Capac itor 7..0 8,9 C7 + Rinse Pump DS0000 UP09, P 7 R. P. Capacitor DS000 7WC00 8,9 C8 + E C LC N.8 DUO pump control circuit Ye low 0 ES0 PLC7 Door Sw 7.. 0/ 0 Sw Double APS Wash 7..90 ADP0 0 7,8 APS 0V Live Supply Breaker TCB ZE700 90 SD8 0V Neutral Supply Page
.9 DUO inlet solenoid valve control circuit Breaker TCB ZE700 90 SD 0 On/Off Swit ch L7A Sw7 CONT 7 CT A A ES0 PLC L N I I I I I I I7 I8 AC/DC..0V INPUT 8xAC/DC Classic Part No. : ES0 RUN/STOP LOGO! 0RCo OUTPUT xrelay/0a Q Q Q Q CONT 0 CT7 0 Rinse APS Single (Oval) APS A A 7../ 7 IS 0V Liv e Supply 0V Neutral Supply Page
.0 DUO ON/ OFF control circuit Breaker TCB ZE700 90 SD 0 On/Off Switch L7A Sw Mc On Lamp 7../8 0 L CONT 7 CT A A ES0 PLC L N I I I I I I I7 I8 AC/DC..0V INPUT 8xAC/DC Classic Part No. : ES0 RUN/STOP LOGO! 0RCo OUTPUT xrelay/0a Q Q Q Q Cycle Switch L7A Sw Rinse APS Single (Oval) APS0 Double APS Wash 7.. 90 A D P00 7,8 APS9 0V Liv e Supply 0V Neutral Supply Page
.0 Basic Installation. The site : Ensure that there is sufficient space for the installation, servicing and easy access to all mains Isolator switches / valves (i.e. electricity and water). Ensure that the surface the appliance is going to be installed onto is adequately stable and capable of supporting the appliance during normal operation, listed below are the approximate machine weights when fully laden during normal operation. Once installed ensure that the appliance is stable and secure, with its weight being distributed equally and does not tilt more than in any direction. Machine sizes Duo & Duo 00 Duo & Duo 70 Weight 90 Kgs Kgs. Electrical connection : All electrical connections MUST be carried out by an authorised technician and in accordance with local regulations. As a minimum Classic recommends that the following standards are maintained : All appliances are connected via a residual current device (R.C.D.) or earth leakage protection device. EN 00 Supply isolator switch must have all pole separation of more than mm. EN 0 The appliance must be connected to a equipotential conductor, the connection stud is located at the rear of the appliance (a suitable ring terminal shall be required), this is in addition to the earthed electrical supply. Prior to connecting the appliance, ensure that the voltage and the supply fuse complies with the rating plate on the appliance... Electrical rating : Within the Classic range several of the 00mm² basket appliances can be either down rated or up rated electrically, such a procedure MUST be carried out by a Classic approved technician. The down / up rating of the machine is carried out by configuring the terminal block within the appliance to the following Amp Single phase Links removed between L, L and L Ensure link remains between neutrals (N) 0 Amp Single phase Ensure all link remains between lives terminals (L, L and L) Ensure link remains between neutrals (N) Three phase To ensure safety standards are maintained, converting a single phase appliance to three phase requires conversion kit KIT0PH, which must be ordered from Classic and installed as instructed in the above kit. Page
. Water connection : The appliance comes with a water supply hose requiring a ¾ BSP male threaded connection at the mains water supply, upon installation and commissioning all water joints must be checked for leaks)... Water supply restrictions : Water supply constraints must be ad herded to : Incoming water temperature c minimum c maximum Supply water dynamic pressure (air break machines, low water pressure not a issue). 0 to bar Rinse booster pump required to bar No modifications required to bar Flow restrictor required bar plus Pressure reducing valve required.. Drainage systems All Duo appliances are pumped drain, upon installation the waste hose and stand pipe must be configured as shown within this manual, also all installations must be with a running / P trap to ensure hygiene : Ø0mm (Ø ½ ) standpipe required Standpipe must be 00 to 0mm ( to ) below the top of the appliance. The end of the waste outlet hose in the standpipe must not be lower than the bottom of the door. The waste outlet hose must be a loose fit within the standpipe. Page
.0 Commissioning. Rinse aid & detergent : Ensure chemical tubes are attached correctly to the individual chemical pumps (pumps located behind front lower panel of the appliance). At the bottle end of the chemical tubes, slide the bottle weight onto the tube, now place the tube and bottle weight into the correct chemical bottle. Ensure correct chemical tubes now go to the corresponding chemical bottles. WARNING : Only rinse aids and detergents developed for commercial glass and dishwashers are to be used, rinse aids must be suitable for water temperatures down to 0 c... Rinse aid prime : Switch machine ON and allow to fill Remove the lower front panel (do not to touch any wire connections). Depress and hold button located on the chemical pump bracket. To fully prime, this will take approx ½ minutes. Replace the front lower panel... Detergent / Soap prime : The detergent / soap pump system on these appliances is self priming... Chemical dosage : Chemical doses are preset to the following nominal values, however these values should be calibrated to suit individual sites requirements Preset values (in seconds) Machine sizes Rinse aid Cycle Initial Detergent Cycle Duo 70 0 Duo 0 0 Duo 00 0 0 Duo 70 90 0 Adjustment of chemical dose is via the timer located under the top panel of the appliance, the timer allows the following values to be calibrated to suit the sites requirements. Demonstration : Classic recommends that prior to leaving the site / installation, the installer demonstrates the following to the end user, as this will ensure the appliance is correctly used What to do in case of an emergency, i.e. how to isolate the mains electricity and water Switching the appliance on. Operating the appliance. Draining down. Switch the appliance off. Clean the appliance, including removal and replacement of all filters. Replenishing and priming of rinse aid and detergent. Page 7
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