Washtech CD 200 ST User manual

CD 200 ST
RACK CONVEYOR DISHWASHER
ServiceManual

Foreword
User documentation
Please read this manual and keep it in a safe place for future reference.
WARNING
Before installation and commissioning, you must read the safety
instructions and warnings carefully and all the warning labels attached to the
equipment.
IMPORTANT
Failure to comply (even partially) with the instructions given in this manual
will invalidate the product warranty and relieves the manufacturer of any
responsibility.
IMPORTANT
The alteration of machine operation, design or the replacement of parts not
approved by the manufacturer may void warranties and approvals.
Warranty Registration
Complete the information below for quick reference.
Model Number_______________Serial Number________________
Purchased from______________ Date of Purchase______________
If you require further information regarding authorised service providers or
recommended detergent suppliers in your region, or have any other queries,
please do not hesitate to contact us.
IMPORTANT
TO VALIDATE YOUR WARRANTY, PLEASE COMPLETE AND
RETURN THE WARRANTY REGISTRATION CARD WITHIN 30
DAYS FROM THE DAY OF PURCHASE.
Information supplied in this manual is copyright. No part of this work may be reproduced
or copied in any form or by any means, electronic or mechanical without the express
permission of the author / publisher. Document subject to change without prior notice.
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Service Manual CD200L 6SD AS(S) 2 Revision 1A

Contents
Safety Instructions .......................................................................................................................................................................4
Installation.........................................................................................................................................................................................5
Installation Diagram ............................................................................................................6
Operation ...........................................................................................................................................................................................7
Description of Controls......................................................................................................7
Operating instructions.........................................................................................................7
Performance.....................................................................................................................................................................................8
Maintenance ....................................................................................................................................................................................9
Troubleshooting Chart.......................................................................................................................................................... 10
Electrical Components.......................................................................................................................................................... 11
Location and Access..........................................................................................................11
CD200 Eco Rinse Tank....................................................................................................12
CD200 Steam Heating ......................................................................................................13
Pressure Switch ..................................................................................................................14
Pressure Switches-Adjustment.........................................................................................15
Rinse Thermostat...............................................................................................................16
Wash Thermostat...............................................................................................................17
Solenoid Valve....................................................................................................................18
Wash Pump.........................................................................................................................19
Pre-Wash Pump .................................................................................................................20
Drive Motor........................................................................................................................21
Electrical Diagram ................................................................................................................................................................... 22
Schematic Diagram............................................................................................................22
Assembly Diagrams ................................................................................................................................................................ 23
Wiring Tray Assembly.......................................................................................................23
Control Panel Assembly ...................................................................................................24
Wash System.......................................................................................................................25
Pre-Wash System ...............................................................................................................26
Wash Upstand ....................................................................................................................27
Pre-Wash Upstand.............................................................................................................28
Drain/Overflow Diagram ................................................................................................29
Rinse System.......................................................................................................................30
Solenoid Valves Assembly................................................................................................31
Rinse Aid Tee Assembly...................................................................................................32
Conveyor Assembly...........................................................................................................33
Drive Shaft Assembly........................................................................................................34
Upper Drive Assembly......................................................................................................35
Final Drive Assembly ........................................................................................................36
Torque Limiter Assembly.................................................................................................37
Spare Parts...................................................................................................................................................................................... 38
Accessories..................................................................................................................................................................................... 40
Revisions.......................................................................................................................................................................................... 41
Service Manual CD200L 6SD AS(S) 3 Revision 1A

Safety Instructions
WARNING
Equipment contains dangerous voltages and can be hazardous if installed or
operated incorrectly. Non-compliance with Warnings or failure to follow
the instructions contained in this manual can result in loss of life, severe
personal injury or serious damage to property.
Installation
♦Use qualified, skilled personnel
♦Follow installation instructions
♦Connect to correct voltage and supply current
♦Provide fully accessible Electrical Isolation Switch
Training and Supervision
♦Read and Understand the Operating instructions
♦Train all staff.
♦This appliance is not intended for use by young children, who must
be supervised to ensure they do not play with the appliance.
♦This appliance is not intended for use by infirm persons without
supervision
♦This appliance is not intended for use as a stepladder
Hot Surfaces
♦Be aware some surfaces can be hot.
Chemicals
♦Commercial dishwashing detergents are hazardous
♦Read and follow the safety information found on the labels of
detergent containers and Material Safety Data Sheets
♦Handle with care
♦Use protective eyewear and clothing if decanting containers
Hot Water
♦Door safety switches are designed for emergency use only.
♦Wait for the green cycle light to go out before opening the door.
♦Wash water is 60°C and contains caustic detergent so DO NOT put
hands in wash water.
Cleaning
♦DO NOT hose down the machine or splash water over the exterior.
♦Watch for broken glass etc when cleaning the inside of the machine.
Service Manual CD200L 6SD AS(S) 4 Revision 1A

Installation
WARNING
Installer must be suitably qualified and ensure compliance with all local codes and
standards including AS/NZS 3500.1.
Failure to comply even partially with installation instructions may void the
warranty.
Install machine on sound waterproof self-draining floor and use adjustable feet to
level machine. Bench work detail drawing available on request.
Allow room for detergent to one side of machine or in adjacent cupboard. 20litre
container requires about 450H x 250W x 350D, but smaller containers are available
from many suppliers.
Water Supply Hot
Temperature Hot 65°C ± 5°C
Connection 15 mm (1/2” BSP Male)
Consumption 300 litres per hour approx.
Pressure 200-400 KPa (30-60 Psi) – above this range fit pressure
limiter
Water Supply Cold
Connection 15 mm (1/2” BSP Male)
Pressure 200-400 KPa (30-60 Psi) – above this range fit pressure
limiter
Flush supply lines before connection.
Do not use small diameter plastic supply lines.
Waste Connection 40 mm, direct waste pipe behind machine or through
open base – refer points B on installation diagram
Power Electrical supply must be 3 Phase, Neutral and Earth 400/415V 20A 50Hz.
Permanent wiring via wall switch to point C on installation diagram. Wash pump
rotation must be checked after installation to ensure correct direction (causes
excessive noise and damage)
Steam Connection 15 mm (1/2” BSP Male)
Pressure 100-200 KPa (1-2 Bars) with recommended operating
pressure of 1.5 Bar
Commissioning Procedures
Connect all services as above. Ensure that all internal components such as filters
and drain upstands are in place. Turn on water and switch on power. Close
machine door and switch machine on, machine will fill. When water sprays from
rinse arms inside machine, switch machine off at wall. Remove lower front panel
and switch commissioning switch by breaking label over same. Close panel and
switch machine on. Machine is now ready for use – refer operating instructions.
Detergent Pump
Refer your professional chemical supplier for advice on wash and rinse chemicals
and dispensers.
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Service Manual CD200L 6SD AS(S) 5 Revision 1A

Service Manual CD200L 6SD AS(S) 6 Revision 1A

Operation
Description of Controls
Operating Instructions
Start up Fit drain upstands, wash pump filters, scrap trays and shut doors.
Turn wall and machine power switches on.
Power light glows red and machine fills automatically.
When wash tanks are full, filling automatically stops.
Ready light glows amber when the machine is up to required temperature.
Operation Press Start button to operate machine.
Green Cycle light glows during an operation.
When Ready light is illuminated racks can be fed into the machine.
The pumps will stop operating after about 2 minutes if there are no racks in the
machine. When rack is fed into machine the pumps will start automatically.
NOTE: Conveyor will not operate unless amber Ready light is illuminated.
Shut down every night
Press Stop button.
Turn machine and wall power switches off.
Remove scrap trays and rinse clean.
Remove drain upstands to drain tanks.
Remove wash pump inlet filters and rinse clean.
Replace drain upstands, filters and scrap trays.
NOTE: Shortest upstand into Ecowash (exit end).
Shorter upstand into pre-wash tank (entry end).
Service Manual CD200L 6SD AS(S) 7 Revision 1A

Performance
Hot Water Supply
An adequate supply of water at the correct temperature and pressure is essential
for effective operation of your machine. Refer Installation information for detail.
Water softening is recommended in hard water areas - especially for glasswashing.
Pre-rinsing Pre-scraping of dishes is required by Food Hygiene Regulations. The best method
is to pre-rinse with warm water with a Fisher Pre-rinse Unit - or alternatively by
scraping or dunking in water. Cutlery should be pre-soaked in warm water,
preferably containing cutlery pre-soak compound - refer your chemical supplier.
Racking Procedures
Do not overload racks or cutlery containers, minimise the overlap of crockery.
Cycle times are short and water consumption per cycle low - so there is no
advantage in overloading racks.
Cycle Times For multi-cycle machine use the longest cycle whenever possible. Note that water
consumption does not increase with longer cycles. Only switch to faster cycles
when it is necessary.
Detergent Use of correct type and quantity of detergent is essential to the performance of the
machine. Low foam specialty products are recommended. We strongly
recommend that you use a professional dishmachine chemical supplier - and will
be pleased to recommend a supplier in your region. Discuss with them the use of
cutlery pre soak solution, detergent and drying agent.
Drying Single tank commercial dishwashers do not have a drying cycle. However, the
machines do rinse at high temperatures which promote fast drying particularly
when drying agents are used. We recommend prompt removal of the rack from
the machine - leave the rack on the bench for 2 to 3 minutes before emptying.
This time will be reduced with correct use of drying agent (rinse fluid) which
reduces water surface tension and allows water to drain quickly from wash ware.
For advice on drying agents and injectors refer to your chemical supplier.
Daily CleaningIt is essential that the machine is drained and cleaned at the end of each day. Drain
the machine then remove, clean and replace filters as per the operating
instructions. Regularly check the wash and rinse jets and clean them if necessary –
refer Maintenance section.
Service Manual CD200L 6SD AS(S) 8 Revision 1A

Maintenance
Regular Cleaning
1. Remove upstandXto drain wash tank. Remove scrap traysYand wash pump
inlet filterZ. Clean them with water and a brush to clear grids.
2. Remove wash arms[– lift to unhook and then withdraw. Remove rinse arms\
– twist and withdraw. Flush arms with water using a toothpick or paperclip, if
necessary, to clear jets.
\
[
[
Y
\
Z
X
Regular Servicing
Regular servicing of the dishwasher is essential to keep the machine in top working
condition and get the best performance results.
Please contact your Service Provider to organize regular servicing of the
dishwasher.
Service Manual CD200L 6SD AS(S) 9 Revision 1A

Troubleshooting Chart
PROBLEM POSSIBLE CAUSES REMEDY (Check/Adjust/Replace)
Rack/s not moving
Rinse Temperature too low Check incoming water
temperature. Recommended 65°C
Incoming water pressure too
high
Fit pressure limiting valve to suit
200 – 400 kPa
Clutch set too light for load
Tighten clutch, refer drawing
600 90052
Limit switch activated
(if fitted)
Remove rack / adjust
Pawl bar jammed
Remove obstruction
Wash pump stops
Upstand not secure
Re-fit upstand
O-ring missing on upstand
(earlier models)
Replace O-ring ARP 027
Pump overload tripped
Adjust setting, confirm current
draw
Auto timer timed out ( if fitted)
Slide new rack in inlet end
Not rinsing
Rinse actuator not operating
Adjust switch / Remove
obstruction
Water isolating valve off
Turn on
Y filter blocked
Remove filter and clean
Rinse jets blocked
Remove arm and flush
Rinse arm not secure
Remove and relocate correctly
Service Manual CD200L 6SD AS(S) 10 Revision 1A

Electrical Components
WARNING
All service/repair work must be carried out by qualified personnel only.
Location and Access
CD R – L WASH TANK SECTION
1. Rinse Thermostat
2. Commissioning Switch
3. Wash Thermostat
4. Motor Contactors with Overloads
5. Heating Contactors
6. Circuit Breakers
7. Rinse Actuator Magnetic Switch
8. Pressure Switch
9. Magnetic Door Switch
10. Wash Heating Elements
11. Conveyor Drive Motor
12. Solenoid Valves
13. Wash Pump
14. Rinse Aid Tee
15. Rinse Heating Elements
Service Manual CD200L 6SD AS(S) 11 Revision 1A

CD 200 Eco Rinse Tank
1. Eco Rinse Electrical Heating Elements
2. Eco Rinse Thermostat
1
2
Service Manual CD200L 6SD AS(S) 12 Revision 1A

CD200 Steam Heating
Steam Solenoids and Traps
Wash and Rinse Steam Heating
Service Manual CD200L 6SD AS(S) 13 Revision 1A

Pressure Switch
Part Number 600 30252
Function The wash tank pressure switches control filling of the wash tank and protect the wash
elements.
The pre-wash pressure switch controls filling of the pre-wash tank.
Description Each pressure switch is attached to an individual pressure bell. As the water level in the
tank rises air is trapped in the bell and increasing pressure is transmitted to the pressure
switch.
When the pre-wash tank is full its pressure switch shuts off the pre-wash tank fill solenoid
valve. The pressure switch differential allows a drop of the water level in the tank with an
operation of the pre-wash pump without causing refilling of the tank.
When the wash tank is full the wash tank upper pressure switch shuts off the wash tank fill
solenoid valve and switches on the wash elements. The lower pressure switch allows a
water level differential so that the tank level may drop with the operation of the wash
pump, without causing refilling of the machine.
Diagram
LEVEL ADJUSTING SCREW
CW rotation increases upper level
setting
DIFFERENTIAL SCREW
CW rotation increases
differential and reduces lower
level settings
Replacement To remove the switch take note of the electrical connections and remove the wires. Slide
the switch from the mounting bracket and remove the rubber tube from the switch
connector. Replace in reverse order. Whilst in the process of replacing the pressure switch,
ensure that the pressure tube is in good order and clear of obstruction.
IMPORTANT
Ensure the tube from the air bell always goes up to the pressure switch.
Do not use thin wall vacuum tube for replacement.
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Service Manual CD200L 6SD AS(S) 14 Revision 1A

CD150 PRESSURE SWITCHES - ADJUSTMENT
(For double wash tank pressure switches)
Pre-Setting The following adjustments should be made to pressure switches supplied as spares, before
installation in the machine:
Wash tank pressure switches:
No adjustments are required.
Pre-wash tank pressure switch:
Level adjusting screw – 2 turns clockwise
Differential screw – 2 turns clockwise.
Adjustment Before making any adjustments drain the wash tank, remove the pressure tube from
pressure bell, blow gently into tube to check switching of pressure switches and then fit
tube back.
Turn the power switch on, and the machine should start filling the wash and pre-wash
tanks.
Wash Tank Pressure Switches
The machine should cease filling the wash tank when the water attains a level at 20mm
below an overflow level of the wash tank upstand (230mm above the bottom of the tank -
see Overflow diagram in the Assembly Diagrams section). Adjust fill level if necessary by
Level adjusting screw on the Upper pressure switch.
Drain machine by removing upstand to check a refill level. When refilling starts fit an
upstand, turn machine off and measure the water level. The refill level should be set at 15-
25 mm above the wash elements (110-115 mm above the bottom of the tank). Adjust if
necessary by Level adjusting screw on the Lower pressure switch. Turn on power switch to
refill the tank and re-check the fill level.
Pre-Wash Tank Pressure Switch
The machine should cease filling the pre-wash tank when the water attains a level at 10mm
below an overflow level of the pre-wash tank upstand (205 mm above the bottom of the
tank). Adjust fill level if necessary by Level adjusting screw on the pre-wash pressure switch.
Drain machine by removing upstand to check a refill level. When refilling starts fit an
upstand, turn machine off and measure the water level. A refill level should be set at 145
mm above the bottom of the pre-wash tank. Adjust if necessary by Differential screw on
the pressure switch. Turn on power switch to refill the tank and re-check the fill level.
EL 007 09/02/06 1C
Service Manual CD200L 6SD AS(S) 15 Revision 1A

Rinse Thermostat
Part Number 3020
Function Controls the rinse heating elements and prevents operation of machine if the rinse
temperature is below that required.
Description The rinse thermostat is a specially calibrated 3 pole capillary type temperature operated
device. The thermostat does not have a control knob and it is factory set to the
temperatures required by Hygiene Regulations. The first pole’s LTCO changeover contact
is set to operate at 83 ±3°C, the other two poles HTCO contacts are set to 90±3°C.
Switching capacity: 16(4) A 380 V.
Diagrams
LTCO – Low Temp Cut Out
HTCO – High Temp Cut Out
Replacement Take note of the connections to the wiring loom before disconnecting. Remove the
capillary bulb from the rinse tank pocket. Select a new thermostat and carefully unwind
enough capillary to reach from the pocket to the thermostat mounting position. Carefully
position the tube with no kink or stress on the tube, also have due regard for the protection
of the tube against contact with live electrical terminals – secure or insulate as appropriate.
Adjustment
IMPORTANT
To make adjustments to the thermostat you will need a good quality thermometer
fitted with a “type K” thermo junction. The use of a stainless steel probe is not
permitted as slow response time in the device will cause inaccurate settings.
Insert the thermo junction into the rinse tank pocket for the machine’s temperature gauge.
Energize the elements and check all temperatures on temperature rise. Remove the grey
tape covering three adjusting screws and adjust LTCO and HTCO settings if required (one
or both HTCO poles are used depends on model – check which HTCO terminals are
wired before making adjustments). Clockwise rotation of the screws increases the setting,
anticlockwise – decreases it.
IMPORTANT
Do not break the seal or attempt to adjust the central MULTI POLE
ADJUSTING SCREW that is sealed with red compound.
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Service Manual CD200L 6SD AS(S) 16 Revision 1A

Wash Thermostat
Part Number 30201
Function Controls the wash element
Description The wash thermostat is a single pole capillary type device. It has a single changeover contact
and a rotating shaft for a manual temperature adjustment.
Factory default setting is 65°C.
Contact switching capacity: 16(4) A 380 V.
Diagram
Replacement Drain the wash tank. Take note of the connections to the wiring loom before
disconnecting. Release thermostat’s gland nut, move the capillary bulb out of the mounting
bracket inside the tank and remove the bulb from the wash tank (remove the probe from
the pocket in the wash tank on the models supplied with a pocket for the thermostat
probe). Replace in reverse order.
Adjustment Insert the probe of a digital thermometer into the wash tank. Check the thermostat settings
on a temperature rise. Adjustment is performed by rotating the adjustment shaft of the
thermostat. Clockwise rotation of the shaft increases the setting, anticlockwise– decreases it.
NOTE: the adjustment shaft in a flat horizontal position is a factory default setting
corresponding to 65°C (see the diagram).
Service Manual CD200L 6SD AS(S) 17 Revision 1A

Solenoid Valve
Part Number 3321/3324
Function Controls flow of water into the machine during filling of the tank and
final rinsing.
Description Electromagnetically operating water valve for use with cold and hot water.
Danfoss Valve Type EV220B
Voltage: 230 V Pressure: 0.1-20 Bar
Frequency: 50 Hz Temperature: -10°C →+90°C
Power: 10 W Construction: IP67
Diagram
Replacement Solenoid coil
Release four screws fastening electrical connector to solenoid coil and detach
electrical connector from solenoid coil. Slide up the solenoid coil off solenoid
body. Replace in reverse order.
Solenoid body
See assembly drawing in the Assembly Diagrams section.
Adjustment There is no adjustments are required.
Service Manual CD200L 6SD AS(S) 18 Revision 1A

Wash Pump
Part Number 3906
Function Pumps water from the wash tank to the wash arms providing a recirculating wash
cycle.
Description Electric Pump FIR 1204
Power: HP 2 Kw 1.4
Voltage: 220 / 380 V
Frequency: 50 Hz
Amperes: 5.9 / 3.4 A
Speed: 2800 rpm
Construction: IP 44
Lift: 10 mWS
Delivery: 550 L/min
Diagram
Replacement Drain the wash tank and switch off the power.
Disconnect the wires from the pump connectors.
Remove M8 bolts that fasten the pump to the floor of the machine.
Release the hose clamps on the inlet and outlet pump hoses and remove the pump.
Replace in reverse order.
Service Manual CD200L 6SD AS(S) 19 Revision 1A

Pre-Wash Pump
Part Number 3904
Function Pumps water from the pre-wash tank to the pre-wash arms providing a
recirculating pre-wash cycle.
Description Electric Pump FIR
Power: HP 1 Kw 0.73
Voltage: 240 V
Frequency: 50 Hz
Speed: 2750 rpm
Amperes: 4.1 A
Capacitor: 12.5 uF / 450 V
Diagram
Replacement Switch off the power and drain the tank.
Disconnect the wires from the pump electrical connector and the pump capacitor.
Remove M6 bolts that fasten the pump to the floor of the machine.
Release the hose clamps on the inlet and outlet pump hoses and remove the pump.
Replace in reverse order.
ITEM DESCRIPTION PART NO:
1 Pump 3904
2 Volute Back 39045
3 Seal 0802
4 Impellor 39042
5 Gasket 39046
6 Volute 39044
Service Manual CD200L 6SD AS(S) 20 Revision 1A