Washtech XP Series User manual

XP
PASSTHROUGH DISHWASHER
SERVICE MANUAL

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Service Manual XP3
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Contents
Safety Instructions....................................................................................................................... 4
Installation....................................................................................................................................... 5
Installation Diagram ............................................................................ 7
Installation Checklist........................................................................... 8
Maintenance Checklist........................................................................9
Dishwashing Procedures..........................................................................................................10
Troubleshooting Chart............................................................................................................. 11
Operating Instructions ............................................................................................................. 12
Components................................................................................................................................. 13
Location and Access ...........................................................................13
Rinse Thermostat............................................................................... 14
Wash Thermostat................................................................................15
Solenoid Valve..................................................................................... 16
Pressure Switch...................................................................................17
Wash Pump.......................................................................................... 18
Detergent Pump................................................................................. 19
Rinse Aid Injector................................................................................20
Electronic Timer ..................................................................................21
Assembly & Electrical Diagrams............................................................................................26
Wiring Tray Assembly........................................................................26
Control Panel Assembly ................................................................... 27
Wash System.......................................................................................28
Rinse System........................................................................................29
Wash Arm Assembly.......................................................................... 30
Rinse Tank Assembly .........................................................................31
Door Link Assembly ...........................................................................32
Rack Slide Assembly ..........................................................................33
Schematic Diagrams..........................................................................34
Spare Parts....................................................................................................................................36
Accessories .................................................................................................................................. 38
Appendices....................................................................................................................................39
Rinse Pump Retrofit..................................................................................... 41
Drain Pump Retrofit........................................................................................42
Revisions ........................................................................................................................................41
Notes...............................................................................................................................42
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7
Machine Positioning
•Unpack machine, check for damage and complete delivery.
•Install machine on sound waterproof self-draining floor and use adjustable feet to level
machine.
NOTE: Failure to level the machine correctly may result in leaking during the cycle,
overflowing from the door sill, poor hygiene through the wash tank not being able to
drain correctly, and/or visibly uneven door.
•Allow room for detergent to one side of machine or in adjacent cupboard. 20 litre container
requires approximately W 250mm x D 350mm x H 450 mm, but smaller containers are
available from many suppliers.
Inlet Water
Incoming water should be within the following standard requirements:
•Temperature: 65°C.
NOTE: Low temperatures will increase the recovery time between cycles and depending
on the chemical being used, may result in excessive foaming if the machine is started
before the wash water is up to a suitable temperature.
NOTE: Excessively high temperatures may damage the solenoid which can result in
flooding should this component fail. High temperature solenoids are available and can be
retrofitted if necessary.
•Connection: 20 mm (3/4” BSP) male – flexible hose supplied.
NOTE: Flush supply line before connection. Poor quality supply or excessive water
hardness may affect performance or damage machine – filtration and/or softening is
recommended.
•Flow rate: minimum 20 litres per minute.
•Pressure: between 200 and 350 kPa.
NOTE: If above 350kPa fit pressure limiter valve (LPV). Do not use small diameter plastic
supply lines.
•Consumption: Approximately 2.6 litres per cycle.
•Backflow prevention: Atmospheric Vacuum Breaker (AVB) fitted standard.
Water Quality Requirements
The incoming water should also be within the following parameters:
Hardness ppm pH
min 20 7
max 100 8
Ions Cl- SO4Fe Mn Cu Cl2
Max mg/L 100 400 0.1 0.5 0.05 0.1
NOTE: Levels above or below the stated requirements can be expected to increase
component wear and reduce the expected useful life of the dishwasher. If in doubt, it is
best to consult a water specialist and have the incoming water professionally tested and
treated if necessary.
Power
•Electrical supply required is 15A 240V 50Hz via switched outlet adjacent to machine.
•Easily upgradeable to three phase 15A 415V 50Hz.
NOTE: 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 Instructions
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Chemical
•This dishwasher is supplied with Detergent and Rinse Fluid injector pumps.
•To connect to chemicals, insert pump inlet hose into container of commercial low foam
detergent and rinse fluid.
NOTE: Externally adjustable chemical pumps are fitted and pre-set at an average level,
these need to be calibrated on site according to the chemical being used and site specific
conditions such as the water quality and how the machine is being used. Failure to do so
may result in excessive dosing which can result in foaming and overflowing, or
insufficient dosing which can cause inferior wash results and impact components
through a build up of grease. If in doubt, contact your chemical company for assistance.
NOTE: Commercial detergents can be hazardous – read instructions, store safely and
handle with care. Care needs to be taken when changing chemicals, ensuring that the
detergent is not accidentally connected to the rinse fluid inlet line.
NOTE: If uncertain, please consult a chemical specialist for assistance in selecting the
right chemicals and calibrating machine settings to suit this along with your unique site
conditions and requirements.
Waste
•Connect drain pump hose supplied to upstand or sink waste connection.
•With a standard trap the drain connection height will be about 580mm below the bench
height on the model (320mm above floor with door open height at 900mm).
NOTE: Either copper or PVC may be used for the waste connection – PVC is more
resistant to some harsh detergents. Some authorities suggest that copper is required
because the machine rinses at up to 90°C. It is important to note that rinse water mixes
with the 65°C wash water before discharge and then flows into the trap where the
water is further cooled before entering the drainage plumbing. We recommend
consulting your local authority to ensure your site remains compliant.
Installation Checklist
•Complete attached Installation Checklist to ensure machine is installed and running correctly,
and operator is familiar with operating procedures.
Installation Instructions
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Installation Diagram
XPD Installation Diagram
•Part #: WXP0031
•Date: 16-07-19
•Version: 1-A
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Check Notes
DELIVERY
SUPPLIED COMPLETE? CHECK THERE HAS NOT BEEN ANY TRANSIT DAMAGE
POSITION
LEVEL AND STABLE? ON SOUND, WATERPROOF, SELF-DRAINING FLOOR
WATER
ISOLATOR VALVE FITTED? ACCESSIBLE, ALL FITTINGS SOUND, AND NO LEAKS
TEMPERATURE CORRECT? HOT WATER INLET 65˚C
PRESSURE CORRECT (200 – 350 kPa)? LIMITER FITTED IF ABOVE RANGE
FLOW RATE CORRECT ( ≥ 20L PER MIN)? FLOW RATE AT OR ABOVE MINIMUM RANGE
QUALITY WITHIN REQUIREMENTS? FILTER OR SOFTENER IN PLACE IF OUTSIDE REQUIREMENTS
POWER
ISOLATING SWITCH? FITTED, FUNCTIONAL AND ACCESSIBLE
CORRECT SUPPLY (1P/15A 240V 50Hz)? VOLTAGE, CURRENT, CIRCUIT BREAKER ALL CORRECT
WASTE
CONNECTION TO STANDPIPE/SINK WASTE? CORRECT CONNECTION TO PLUMBING
SUITABLE AIR GAP? REFER INSTALLATION INSTRUCTIONS - WASTE
CHEMICALS
CHEMICAL NAME CONTAINER NO LEAKS PRIMED CALIBRATED
DETERGENT
RINSE FLUID
MACHINE OPERATION
MACHINE RUNNING CORRECTLY? MULTIPLE CYCLES RUN, NO ISSUES
CHEMICAL DOSAGE CORRECT? CORRECTLY FLOWING INTO MACHINE, NO FOAMING
ALL OPERATIONS CORRECT? FILL LEVEL CORRECT, NO DRAINAGE ISSUES
OPERATOR TRAINING
ENSURE THAT THE CUSTOMER HAS BEEN GIVEN THE OPERATION MANUAL AND WALL CHART, AND IS AWARE OF THE
IMPORTANCE OF BOTH USING AND CLEANING THE MACHINE CORRECTLY.
START UP
PRE-RINSE AND RACKING BETTER TO RINSE PLATES THAN REMOVE WASTE FROM MACHINE
MACHINE USE AND CYCLE SELECTION USE LONG CYCLE WHERE POSSIBLE
DRAINING THE MACHINE DRAIN THE MACHINE DAILY
SHUT-DOWN AND DAILY CLEANING CHECK WASH ELEMENTS HAVE COOLED BEFORE CLEANING
WEEKLY MAINTENANCE FULL MACHINE CLEAN INCLUDING WASH/RINSE ARMS
PLANNED SERVICNG IMPORTANCE OF HAVING MACHINE SERVICED REGULARLY7
Installation Checklist
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Installation Troubleshooting
Door not closing properly
•Level the dishwasher.
Machine not starting or filling
•Ensure water supply to machine is turned on.
•Ensure power supply to machine is turned on.
•Check that the water inlet hose isn’t twisted or kinked.
Cycle taking too long
•This machine ships with Thermostop enabled, which allows a cycle to be started at any time,
even if the rinse water is not up to required temperature. To ensure a hygienic result, the
wash cycle continues to run until the rinse temperature reaches the required 83˚C. At this
stage washing will stop and the machine will begin rinsing to complete the cycle.
•Check inlet water temperature is not too low as per our specifications.
Poor wash results
•Check that there are adequate pre-rinse processes in place and staff use longer cycle options
for more heavily soiled items.
•Ensure high quality non-foaming commercial dishwasher detergent has been connected at
the correct dosage for your site, water quality and application. If uncertain, consult a
chemical specialist.
•Check that the wash arm is spinning freely and is not being obstructed.
•Ensure that the wash temperature is between 60°C and 65°C.
Chemical residue on items after the cycle
•Check that nothing is obstructing the wash and rinse arms from rotating.
•Check the rinse fluid dosage is not too high. If uncertain, please consult a chemical specialist.
•Check detergent dosage is within the requirements.
Dishwasher is foaming
•Ensure there is no other soap being transferred into the machine from the sink.
•Ensure high quality non-foaming commercial dishwasher detergent has been connected at
the correct dosage for your site and application. If uncertain, please consult a chemical
specialist.
•Allow wash water to heat to at least 60˚C prior to starting the first cycle as some commercial
dishwasher chemical will foam at low temperatures.
Other equipment in the kitchen has needed filters or has scale
•Due to the high temperatures in dishwashers, scale will build up in the wash tank, on the arms
and in the rinse tank. The incoming water should be treated. If uncertain, please consult a
water specialist.
•As with combi-ovens, high chloride levels will do irreversible damage to a number of the
components inside a commercial dishwasher. The incoming water should be appropriately
treated. If uncertain, please consult a water specialist.
Cycle times not suitable for items being washed
•Some sites may require longer or shorter cycles depending on the items being washed and
the soil levels. Cycle lengths can be adjusted by a qualified service agent accessing the WI-
200 Electronic timer. For adjustment instructions refer to the adjustment section of the
service manual for this model or the WI-200 Timer service manual.
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SHUT DOWN - EVERY NIGHT
•Turn Cycle Selector to 0 and turn off the power from the wall.
•Remove Scrap Trays (1) and Upstand (3) to drain the Wash Tank.
•Once the Wash Tank is fully drained remove and rinse Wash Pump Filter (2) before
replacing back into the machine along with the Upstand (3) and Scrap Trays (1).
CLEANING – AT LEAST ONCE A WEEK
Remove, rinse and replace when machine has cooled down:
Scrap Trays 1
Wash Pump Filters 2
Drain Upstand 3
Wash & Rinse Arms 4
Thumb Screws 5
Inspect and clear all jets in the upper and lower
Wash/Rinse Arms using a small object such as a
toothpick where necessary to remove any
blockages prior to rinsing.
SUGGESTED BEST PRACTICE
Pre-rinse Scrape and/or rinse trays, plates & glasses in cool water.
Chemical Use a good quality non foaming commercial detergent and drying agent – do
not use domestic detergents which will cause the wash tank to foam.
7
Operator Use Guide
START
•Turn on at wall.
•Ensure the Upstand (3) and Wash Pump Filter (2) are
firmly in place.
•Check the Scrap Trays (1) are in place and shut door.
•Turn the Selector Switch to any Cycle (I, II or III).
•Power light glows red and machine fills automatically.
•Once full, rinse heating starts.
OPERATION
•Select required Cycle of I (1 minutes) , II (2 minutes) or
III (3 minutes).
•Load items into the machine and shut door.
•Press Start Button to start machine.
•Start Button glows green while machine operates.
•When Start Button goes out, the cycle is complete.
NOTE: The machine may be started while the rinse water
is being heated – the machine will continue to run the
wash cycle until the rinse water is up to temperature.
Wash Temp Gauge
Cycle Light
Selector Switch
Rinse Temp Gauge
Power On Light
Drain Switch
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Components
WARNING
All service/repair work must be carried out by qualified personnel only.
Location and Access
1. Door Switch
2. Pressure Switch
3. Rinse Over-Temp Cutout
4. Rinse Element
5. Rinse Tank Assembly
6. Wash Pump
7. Solenoid Valve
8. Wash Element
9. Wiring Tray Assembly
10. Electronic Timer
11. Contactor
12. Door Relay
13. Wash Thermostat
14. Rinse Thermostat
15. Detergent Pump
16. Rinse Aid Pump
17. Control Panel Assembly
18. Selector Switch Knob
19. Selector Switch (behind)
20. Power Light
21. Cycle Light
22. Wash Temp Gauge
23. Rinse Temp Gauge
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Rinse Thermostat
Part Number 30201
Function Controls the rinse element
Description The rinse 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 85°C.
Contact switching capacity: 16(4) A 380 V.
Diagram
Replacement Take note of the connections to the wiring loom before disconnecting. Move the capillary
bulb out of the thermostat pocket inside the rinse tank. Replace in reverse order.
Adjustment Remove the capillary bulb of the temperature gauge out of the rinse tank pocket and insert
the probe of a digital thermometer into that pocket. 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.
Re-fit the temperature gauge capillary bulb into the rinse tank pocket.
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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).
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Solenoid Valve
Part Number 3342
Function Controls flow of water into machine during filling of wash tank and final
rinsing.
Description Electromagnetically operating water valve for use with cold and hot water.
Diagram
Replacement Disconnect the wires from the solenoid connectors.
Remove hot water supply hose.
Release a hose clamp on the outlet solenoid hose and remove the hose.
Slide the solenoid valve up off the mounting bracket.
Replace in reverse order.
Adjustment Remove the flow restrictor for installations with flow rate of hot water supply below 20
litres per minute.
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PressureSwitchFill
Part Number
600 30479
Function
Controls filling of wash tank and protects wash elements.
Description
The pressure switch is attached to the pressure bell. As the water level in the wash tank
rises air is trapped in the bell and increasing pressure is transmitted to the pressure switch.
When the tank is full the pressure switch shuts off the fill solenoid valve and switches on
the wash element. It 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 – fill level
DIFFERENTIAL SCREW
CW rotation increases
differential and reduces lower
level settings – refill level
Adjustment
Before making any adjustments; drain wash tank, remove pressure tube from pressure bell,
blow gently into tube to check switching of pressure switch and then fit tube back.
Turn the power switch on, machine should start to fill. The machine should cease filling
when the water attains a level about 10mm below an overflow level of the upstand. Adjust
fill level if necessary by Level adjusting screw on the pressure switch.
Select drain cycle, remove drain upstand and close door to begin draining the wash tank.
Listen for a click from the pressure switch when water level in a wash tank reaches refill
level. Then stop the drain cycle by pressing the Start button or by opening door. Fit back
the upstand and measure the refill water level. The refill level should be set 10-20mm above
the wash element. Adjust if necessary by Differential screw on the pressure switch. Close
door to refill the wash tank and re-check the fill level.
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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WashPump
Part Number
600 30299
Function
Pumps water from the wash tank to the wash arms providing a recirculating wash
cycle.
Description
Electric Pump ZF 320V SX
Power: HP 0.93 Kw 0.68
Voltage: 230 V 50Hz
Amperes: 3.0 A
Capacitor: 12.5 uF
Speed 2800 rpm
Protection: IP 20
Hm Min: 1.0 m
Hm Max: 12.3 m
Diagram
Hydraulic parts
ITEM DESCRIPTION PART #ITEM DESCRIPTION PART #
1 Volute 600 41116 7 O-ring 600 41113
2 Pump flange 600 41117 8 Screw -
3 Fixed seal 600 41110 9 Plug screw -
4 Rotating seal 600 41111 10 O-ring plug -
5 Impeller 600 41115 12 Screw hose
connector -
6 Nut 600 41112 13 O-ring hose
connector -
Replacement
Drain the wash tank and switch off the power.
Disconnect the wires from the pump connectors and the pump capacitor. .
Release the hose clamps on the inlet and outlet pump hoses and remove the pump.
Replace in reverse order.
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DetergentPump
Part Number 600 30526
Function The pump automatically injects detergent into wash tank during filling of the
machine and at the start of each wash cycle.
Description Peristaltic Dosing Pump with Timer
Power: 8 W
Voltage: 230 V
Frequency: 50 Hz
Pressure: 3 Bar
Flow rate: 1.5 L/h
Dosing time: 0-30 sec
Diagram
Replacement
Peristaltic pumps provide reliable and accurate detergent dosing. However over time the squeeze
tube in the pump will flatten and become ineffective, and/or split and leak. We therefore
recommend quarterly inspection of the squeeze tube and replacement every six months in high use
situations, particularly when chlorinated detergents are used.
To replace squeeze tube – wear safety glasses and gloves, switch machine off, remove the
transparent lid, ease the squeeze tube off rollers and replace the new one.
CAUTION – caustic based detergents are hazardous.
To replace complete pump – disassemble the pump after unscrewing two screws from the
support bracket; assemble the new pump in reverse order. To prime pump drain and refill the
machine - detergent will come up to full strength after several cycles.
Adjustment
The detergent pump operates continuously during filling of the wash tank. The concentration
during fill is equal to the detergent dosed (ml/min) / the water filling rate (L/min).
The detergent pump is also set to operate during the wash cycle. The factory setting is 15 seconds.
If the recommended concentration of your detergent differs from 2ml/L then the dosing time
should be adjusted by turning the adjusting screw of the pump. Turning the adjusting screw clockwise
increases the dosing time.
Dosing Time Equation: T = 2.4V x C, where T= Dosing time (sec),
V= Water used per cycle (L), C= Detergent concentration (ml/L).
On glasswashers where cold final rinse is used longer injection times are required to compensate for
the dilution of wash water by the cold rinse.
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RinseAidPump
Part Number 600 30480
Function The pump automatically injects rinse aid fluid into the rinse tank during the rinse
cycle. Each time power is supplied continuously to the pump, it runs for up to 30s.
The injection time can be varied by rotating the Adjusting screw on the pump
body. It is factory pre-set for 12 seconds.
Description Peristaltic Dosing Pump with Timer
Power: 8 W
Voltage: 230 V
Frequency: 50 Hz
Pressure: 3 Bar
Flow rate: 0.4 L/h
Dosing time: 0-30 sec
Diagram
Adjustment Turning the adjusting screw clockwise increases the dosing time from 0 to 30 seconds.
The factory setting is 12 seconds, which equates to about 0.5 ml / litre on a glasswasher
using 2.6 litres per cycle.
The volume of rinse fluid required will depend on factors such as product type, water
hardness and whether glasses or dishes are being washed, but about 0.5 ml per litre of water
is typical. Excessive use can cause de-fizzing of carbonated drinks, streaky or greasy
washware and/or foaming of wash water. If in doubt - reduce injection quantities.
Troubleshooting
1. Check if the inlet hose is submerged in rinse fluid or that there is no blockage or
restriction in one of the hoses, the inlet or the connection tee. Some Rinse Fluids crystallise
or gel over time and can block the inlet.
2. Squeeze tube worn and requires replacement.
3. Non return valve (NRV) attached to tee is inoperative. The NRV should prevent fluid
flowing down the inlet tube at the end of the cycle. Replace if faulty.
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