Ecolab Formula1 User manual

1
Installation & Operation Manual
Retain this manual for installation, operation,
programming and servicing information.
®
43813/0403/0904 Copyright Ecolab Inc. 2003 9259-2136

2
This page intentionally left blank

3
Table of Contents
1.0 System introduction…………………………………………….…4
2.0 Installation requirements……………………………………….…4
3.0 Specifications………………………………………………………5
4.0 Optional equipment………………………………………………..5
5.0 System installation…………………………………………………5
6.0 Start up………..……………………………………………………14
7.0 User Operation……….……………………………………………15
8.0 Quick Start Programming………………………………….….….16
9.0 Troubleshooting…………………………………………………...34
10.0 Part Photos…….…………………………………………………..38
11.0 Replacement parts…………………………………………….….41
Programming menu…………………………………………………...…48
Wiring Diagram…………………………………………………………...49

4
1.0 System Introduction
1.1 Preface
Formula 1 is the single-step laundry solution for on-premise laundry
customers. The Formula 1 system comes equipped with one main pump
and three delivery valves to service up to three washers. The system
automatically makes a use-solution from a concentrated Formula 1
product. This use-solution is then delivered to the washers automatically
as requested. Formula 1 is an all-in-one formula; however the system has
an optional pump cabinet for delivering a finishing product or sanitizer if
desired. FORMULA 1 IS FOR USE WITH FORMULA 1 PRODUCTS
ONLY. OTHER CHEMICALS MAY HARM THE DISPENSER.
Formula 1 should ideally be used with 35 lb to 150 lb. commercial
washers. Total washroom capacity should not exceed 300 lb. DO NOT
USE FORMULA 1 IN SINGLE WASHER ACCOUNTS.
1.2 System features
-3 washers
-2 formulas
-heavy soil boost
-load counter, heavy soil counter & capsule log
-low voltage washer connections
-pump run time counter
-visual & audible low product alarm
-1 concentrated product + optional finishing product
-programmable delay
-universal washer signal input
-bilingual user prompts
-automatic solution mixing (recirculation)
2.0 Installation requirements
Water supply
- Hot and cold, min 10 psig dynamic (pressure gauge on assembly), ¾”
male garden hose connection
- Hot water temp, min 100°F, max 145°F.
- NOTE: accounts with hot water >145°F require tempering valve kit
9259-1043
Electrical
- 120 VAC, 60Hz, 3 Amp
Floor space
- 30” W X 72”L X 54”H (for dispenser access)
Drain
- Floor drain or drain trench

5
3.0 Specifications
Comm cable: Category 5 cable
Weight: ~ 76 lbs. (34.47 Kg)
Power: 120 VAC, 60Hz
Lift & Run: 7’ lift max, 50’ run max
Pump Flow Rate: approx. 1 GPM
Washers: 3 max
4.0 Optional equipment
FORMULA 1 AUX PMP PKD 9259-1046
TEMPERING VALVE ASSEMBLY 9259-1043 (hot water >145°F)
FORMULA 1 CHART STOP KIT 9259-1059
5.0 System Installation
5.1 Preplanning
It is very important to insure that all necessary equipment is available in order to
complete the Formula 1 installation. A few minutes of planning may save a
considerable amount of time during the installation.
It is necessary to locate a suitable location for the dispenser. Important
considerations are:
•Dispenser size. The dispenser is approximately 20” wide, 25” deep and
36” tall. It is important to leave clearance to provide easy access to the
dispenser, including 1’ on top of the dispenser, 3’ in front & 1’ behind.

6
•Product delivery tubing should not be hung higher than 7 ft off the floor,
and the distance to the furthest washer should be less than 50 ft.
•Proximity to water (hot and cold) should be less than 15’
•Proximity to power sources (120V) should be less than 9’.
•Easy access for account personnel to change product capsule.
•The communication cables to be run from the dispenser to the user
interface module at the washing machine are 14’ and 25’ long. (if
necessary, a 50’ cord may be ordered separately.)
•Drain proximity for overflow connection should be less than 5’.
•If the optional auxiliary pump will be used, space must be available on
the wall for mounting the cabinet, and on the floor for the extra product
pail.
Additionally, to prepare for the installation:
•Verify the correct tubing and tools are available.
•If a finishing product will be used, an auxiliary pump assembly must be
ordered separately. See section 4.0
•Product capsules must be available for the account to start-up
immediately.
•User Interface Module should be mounted to facilitate convenient user
operation.
Note: Before removing pre-existing dispensing equipment, plug in
and turn on the Formula 1 dispenser to verify PLC operation.
Display should read “Ecolab Serves Team Formula 1” and you
should see 2 green lights to the left of the display.
5.2 Materials to Be Ordered Separately
Part Description Part Number
Tubing Flex ½ O.D. Poly-Flo 8501-5139 (250’ roll)
14’ CAT-5 Communication
Cable 8985-3113
25’ CAT-5 Communication
Cable 8985-3005
50’ CAT-5 Communication
Cable 8985-3009
Washer Interface Module (only 2
modules included with dispenser) 9259-1048
Optional Auxiliary pump (if
finishing product is to be used) 9259-1046
Tempering Valve Assembly (if
hot water is over 145°F) 9259-1043
Chart Stop Kit (only if necessary) 9259-1059

7
5.3 Installation Plumbing
Fig 5.3.1 Rear View
Fig 5.3.2 Tank interior

8
5.3.1 Dispenser wiring
Formula 1 requires 120 VAC to operate. The dispenser comes with a
pre-installed 9’ electrical cord and is ready to plug in. If a condition exists
where the cord cannot be used (i.e., distances greater than 9’) the
following procedure should be used.
NOTE: It is not recommended to use power from a laundry
machine to operate the dispenser.
NOTE: This dispenser must remain powered constantly, do
not use outlets that can be shut off manually (GFI
outlets are OK).
NOTE: If a condition exists where the cord cannot be used
(i.e., distances greater than 9’) a minimum of 14-ga.
wire enclosed in conduit or Seal-Tite is required. All
local codes must be followed.
1. Remove the existing BROWN and BLUE wires off of the terminal
posts on the back of the ON/OFF circuit breaker (BROWN is hot,
BLUE is neutral).
2. Remove the GREEN wire with the YELLOW tracer from the ground
lug (GREEN is ground).
3. Remove the 9’ power cord from the dispenser electrical enclosure.
4. Field-wire a new HOT, NEUTRAL and GROUNDWIRES within the
electrical enclosure. These MUST BE brought into the electrical
enclosure in conduit or Seal-Tite.
5. Attach the HOT and NEUTRAL wires to the terminal posts on the
back of the ON/OFF circuit breaker. Use the same polarity as the cord
installation. Brown is hot, blue is neutral.
6. Attach the GROUND wire to the grounding lug located on the front of
the electrical enclosure.

9
5.3.2 Overflow Connection
An overflow outlet for the dispenser’s tank is provided to direct the
solution to a drain should the tank level sensors or water solenoid fail.
The overflow outlet (blue hose barb) is located on the back of dispenser.
The 5/8” PVC tubing must be connected to the outlet.
fig 5.3.2.1
1. Measure the distance to the floor drain and cut your 5/8” PVC tubing
to the desired length.
2. Connect the 5/8” PVC tube to the tank overflow outlet (blue drain
tube) located on the back of this dispenser. See fig 5.3.2.1
3. Secure the connection with a hose clamp.
4. Route the opposite end of the PVC tubing to a floor drain or drain
trench.
5. If possible, try to secure the end of the PVC tube to the floor drain with
a cable tie. This prevents the hose from being “kicked around”.
NOTE: If a drain is unavailable, use an empty five-gallon pail.
5.3.3 Vacuum breaker mounting bracket
Attach the vacuum breaker bracket to the electrical enclosure using the
two supplied #8-32 screws (factory-installed at the mounting location).
Insert the inlet tube (originating from the base of the dispenser) into the
inlet (lower) fitting on the vacuum breaker. Insert the outlet tube (factory-
inserted in the vacuum breaker outlet) into the upper elbow fitting (to main
spray nozzle) on the rear of the dispenser. (Refer to fig. 5.3.1)

10
5.34 External Strainer Connection
Remove the two lower left screws from the access plate on the rear of the
dispenser
Position the line strainer with mounting bracket over the two holes on
access plate. Replace the two access plate screws to secure the strainer
bracket to the dispenser. Connect the recirculation tube to the left side
(inlet) of the line strainer and then connect the tube attached to the right
side (outlet) of the strainer to the elbow entering the middle of the tank
(see photo below).
5.3.5 Water Supply Connection
Remove
These Two
Recirculation
Tube
Strainer
Outlet

11
The dispenser automatically alternates between hot and cold water during
the fill cycle. Hot water >145°F can cause separation of the detergent
use-solution and can adversely affect the enzymes contained in some
Formula-1 products. For installations with hot water in excess of 145°F,
tempering valve kit 9259-1043 must be ordered. The following
instructions assume hot water temperature <145°F.
5.3.5.1 Hose Plumbing Method
The following steps describe the water supply connection using the
rubber hose plumbing method.
1. If necessary, use the ‘Y’ hose-connectors (located in
installation kit) and provide hot and cold water sources for
the dispenser.
2. Route one of the provided 15’ hoses from the hot water
source to the fitting at the regulator assembly. (See fig
5.3.4.1)
3. Repeat step 2 with the cold water line.
Fig 5.3.4.1

12
5.3.5.2 Hard Copper Plumbing Method
If the water supply connection must be copper tubing, the territory
manager will be responsible for the correct pipe fittings and
connectors to complete the installation. The water supply line must be
a minimum 3/8” copper tube. Do not solder the inlet connection,
damage to the regulator may occur.
Note: To save time, you should now dock a product capsule and
initiate dissolution cycle (see section 6). The remaining installation
procedures can be performed while the tank is filling.
5.3.6 Product-delivery Tube Connection
A 1/2” OD PE tube (8501-5139) is used to deliver the detergent to each
laundry machine. It is important that the outlet tubing DOES NOT exceed
50’ (15 meters) under normal installation.
1. Locate the three ½” tubes on the back of the dispenser (see fig
5.3.5.1). The tube for laundry machine #1 is located on the left,
washing machine #2 is in the middle and machine #3 is on the right
(as viewed from behind). Connect 1/2” PE tubing to discharge tubes
(mentioned above) using the ½” union connector located in the
installation kit. A plug was put on the line for machine #3 at the
factory. This is done to prevent leaking from this line in accounts with
only two washers. If connecting to a third washer, remove the plug
assembly from the tube. If the tube is crimped from the plug, cut the
tube just behind the crimp to ensure that the union connector will
make a good seal. Note: Tubes must be inserted ~0.75” for
proper engagement. Tubes not being connected to washers
should be kinked and secured with a cable tie to plug. Do not
shorten.
Fig 5.3.5.1

13
2. Route the 1/2” OD PE tube from the dispenser to each corresponding
laundry machine. (it will be helpful to label each tube with its washer
number)
Note: Leave 2’-3’ of extra length to allow the dispenser to be moved
or the pump tray to be pulled out.
3. A check valve is included in the install kit for each washing machine.
This valve is vital for accurate and consistent product dispensing.
This check valve should be installed in the line 1 to 2 inches from the
injection port.
IMPORTANT: Insure that the arrow on the check valve is
pointing towards the injection port (the direction fluid will be
flowing). If the check valve is backwards, product will not flow to the
laundry machine. Secure the tubing at the injection port of each
laundry machine.
4. Anchor the tubing to the wall or rigid piping to provide strain relief and
to keep the installation looking neat and clean.
5.4 Washer Interface Module Installation
The Washer Interface Module is supplied with the following components (one
needed for each washing machine):
•Signal interface module with supply signal input board and input
connectors.
•User interface module with rotary Switch board
•14 or 25 ft. Communications Cable
•Dual-lock®strips for mounting
5.4.1 Washer Interface Module
1. Insure the circuit breaker supplying power to the laundry machine is
disconnected.
2. Mount the washer interface box to the laundry machine controller box,
using the conduit elbow.
3. Route the black (for detergent), brown (for Finish product) and white
(common) to the inside of the laundry machine controller. Locate the
washing machine supply signals inside the laundry machine (see
figure 5.4.1.1)
NOTE: The Supply Signal Input Board adjusts automatically to
accept 24, 120 or 240 volt supply signals from the washing machine.
NOTE: You may want to pull an extra signal, in addition to the
detergent, to allow for the placement of an auxiliary product in the
future. A few extra minutes here will save a considerable amount of
time in the future if an extra product is added.
Refer to the Laundry Machine Wiring Handbook or Call Technical Service
for assistance.

14
4. Connect the washer supply signals to the Signal Interface Module.
(see Fig 5.4.1.2 on the following page)
Note: The washer’s hot detergent supply signal (signal #1) is connected
to the black wire. The common for detergent is connected to the white
wire.
If a Finish product is used, connect the hot supply signal (signal #2) to the
brown wire. The common for the Finish product is to be connected to the
white wire as well.
Both signals are converted into low voltage (+24 VDC), and transported
back to the Formula 1 dispenser via the CAT-5 cable (wires green and
brown at the Formula 1 controller input connector).
5. Mount the user interface module to the washer in an operator-
accessible location using the provided Dual Lock®strips
6. Repeat the preceding instructions for laundry machine Washer
Interface Modules # 2 and # 3, if required.
7. Re-Connect the power to the laundry machine.
Fig. 5.4.1.1 Fig. 5.4.1.2
5.4.2 Communications Cable
Warning!! Communication cable and ports must not get wet.
The communications cable is used to link the Washer Interface Module
with the Programming Module in the dispenser. Cables (14’ & 25’) come

15
in the installation kit – one for each user interface. 25’ is the
recommended max cable length. Use the 50’ cable only when necessary.
1. Route the cable from the Washer Interface Module to the back of the
dispenser and connect to communication port. (Refer to fig. 5.3.1)
Note: It is helpful to label the communication cable for
identification.
2. The communication cables are keyed to fit in one way only. Insert
cable gently into the comm port of the washer interface module. If the
cable connector does not fit into port easily, rotate the cable 180
degrees and try again. Do not force cable.
6.0 Start up
6.1 Dock product capsule
1. Lift dock lid.
2. Remove and discard cap on new product capsule.
3. Dock new capsule.
4. Close lid.
5. Press Start key.
Water will now be sprayed into the capsule until the tank level reaches the high
level. The dispenser will automatically activate the hot and cold water valves to
alternate the water spray between hot and cold water (the hot water valve will
always be turned on first). The water valves are alternated to provide effective
capsule rinse-out while maintaining a tank sump temperature below 105ºF.
The water pressure regulators are factory-set to 10 psi (±0.5 psi) when valve is
open. If adjustment is necessary, adjust the hot and cold water pressure
regulators on the regulator mounting plate to read 10 psi when in flow (see figure
5.3.1). You should only adjust the hot regulator when the hot water valve is
active. You should only adjust the cold water regulator when the cold water
valve is active. The entire capsule contents will be rinsed into the tank. Total
time to fill the tank will be 10-30 minutes. The dispenser will begin to recirculate
the solution and continues to do so automatically every hour.
6.2 Prime product-delivery tubes
See “Prime” section of quick start programming guide (Section 8)
6.3 Calibrate dispenser
See “Calibrate” section of quick start programming guide (Section 8)
6.4 Program formula amounts
See Formula Progr. Menu (page 31 of the Appendix) or the attached
programming flow chart

16
6.5 Verify delivery amounts
With the controller in the Formula Program menu; use the Heavy Soil Signal
switch on the User Interface Module to trigger a delivery of the programmed
amount of solution to a graduated cylinder to verify the programmed amount.
NOTE: TM should check calibration every 12 months to ensure accuracy.
7.0 User Operation
7.1 Replacing product capsule
Note: Replace capsule only when dispenser calls for new capsule (amber
light, alarm, message on controller display). This information is outlined
on the Formula 1 wall chart. If capsule is replaced before the tank is empty,
the dispenser will not rinse out the capsule. However, the product in the
capsule will dry out which will inhibit the dispenser’s ability to rinse the
capsule thoroughly.
1. Lift dock lid.
2. Remove empty capsule and discard.
3. Remove and discard cap on new product capsule.
4. Dock new capsule.
5. Close lid.
6. Press Start key.
Note: An alarm will notify the user when the tank level is low. The user
should replace the product capsule at that time. However, there is a grace
period of several loads before the lock out. At lock out, the dispenser will
not deliver product and will alarm upon every request thereafter. The user
must then replace the empty capsule with a new capsule and press start to
unlock the dispenser and return to normal operation.
7.2 Selecting formula
Use selector switch on washer interface module to select one of two formulas
(use formula stickers to indicate which formula corresponds with each position)
7.3 Selecting heavy soil
User may toggle the heavy soil switch any time before detergent injection to
request extra detergent. Switch must be held for 0.3 seconds to register. The
dispenser will inject 150% of the programmed amount of detergent for the current
load only. The next injection will be a normal amount unless the heavy soil
switch is toggled again.
Note: The heavy soil switch applies to detergent only, not the finishing
product.

17
8.0 Quick Start Programming
For detailed programming information, see Appendix
Description Key Sequence Display
Idle Screen
Press <F6> Ecolab, Inc. Serves:
(Account Name Here)
Password Screen
Ecolab, Inc. ©
Enter Password:XXXX
Key in correct password (4-digit default:
1234).
Press <Ent>
System
Programming
Screen
->F10 to Exit Progr.
Account Menu
Formula Progr. Menu
Records Menu
Prime/Diag. Menu
Time Calibratn Menu
Press <Up>/<Down> arrow to select this
option.
->Prime/Diag. Menu
Press <Ent>
Prime ->Esc=Previous Menu
Prime Detergent
Prime Aux
Valves on (manual)
Alarm/Light on?
Tank Level?
Press <Up>/<Down> arrow to select this
option.
-> Prime Detergent
Press <Ent>
Press and Hold F7 (or F8, or F9) to prime
the product delivery tube to Washer #1 (or
W2, or W3 respectively). Can also press
and hold the Heavy Soil Switch at each
User Interface Module to prime.
PressTo Prime(HvySw
to W1=F7;W2=F8;W3=F9
Press <Esc>. Press <Up>/<Down> arrow
to select this option.
-> Prime Aux
Press <Ent>
Press and Hold F7 (or F8, or F9) to prime
the product delivery tube to Washer #1 (or
W2, or W3 respectively). Can also press
and hold the Heavy Soil Switch at each
User Interface Module to prime.
PressTo Prime AUX
W1=F7;W2=F8;W3=F9
Press <Esc> twice to get back to System
Programming Screen
System
Programming
Screen
->F10 to Exit Progr.
Account Menu
Formula Progr. Menu
Records Menu
Prime/Diag. Menu
Time Calibratn Menu

18
Press <Up>/<Down> arrow to select this
option.
-> Time Calibratn Menu
Press <Ent>
Calibration ->Esc=Previous Menu
Cal Det to Wash1
Cal Det to Wash2
Cal Det to Wash3
Cal Aux to Wash #1
Cal Aux to Wash#2
Cal Aux to Wash#3
(Note 1) Press <Up>/<Down> arrow to select this
option.
-> Cal Det to Wash1
(Note 1) Press <Ent>
(Note 1) This step is designed to calibrate Formula
1 product to Washer #1: Use a container
that can hold about 24 oz. Press and hold
F7 for at least 2 sec. to start a 5.0 sec.
pump time to Washer #1 (OR press the
Heavy Soil Switch at corresponding
Washer Interface Module). Enter the
actual amount collected in fl. Oz (Note: the
decimal point is pre-programmed, i.e. if
you need to enter 16.4 oz, key in 164 using
the keypad): press <Ent> to change the
cursor to dark blinking square. Key in the
new amount. Press <Ent> again to save.
Press <Esc> when finished.
Note 1: Repeat these steps for Washer #2
and #3 using F8 and F9.
W1 Cal: 5 s.UseF7/Hvy
Ent actual amt:XX.Xoz
(Note 2) Press <Up>/<Down> arrow to select this
option.
-> Cal Aux to Wash #1
(Note 2) This step is designed to calibrate Auxiliary
Product to Washer #1: Use a container
that can hold about 24 oz. Press and hold
F7 for at least 2 sec. to start a 20.0 sec.
pump time to Washer #1. OR press the
Heavy Soil Switch at corresponding
Washer Interface Module to calibrate.
Enter the actual amount collected in fl. Oz
(Note: the decimal point is pre-
programmed, i.e. if you need to enter 3.4
oz, key in 34 using the keypad): press
<Ent> to change the cursor to dark blinking
square. Key in the new amount. Press
<Ent> again to save. Press <Esc> when
finished.
Note 2: Repeat these steps for Washer #2
and #3 using F8 and F9.
W1 AUX Cal:20 s.UseF7
Ent actual amt:XX.Xoz

19
Press <Esc> twice to get back to System
Programming Screen
System
Programming
Screen
->F10 to Exit Progr.
Account Menu
Formula Progr. Menu
Records Menu
Prime/Diag. Menu
Time Calibratn Menu
Press <F10> to exit the system
programming screen and back to Idle
Screen.
Idle Screen Ecolab, Inc. Serves:
(Account Name Here)

20
Detailed Programming
Keypad Functions and Legend
Customer’s Keypad: