Washtech 3 Series User manual

PW2Series 3
PASSTHROUGH WAREWASHER
ServiceManual

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.
We have checked that the contents of this document correspond to the model described. There may be
discrepancies nevertheless, and no guarantee can be given that they are completely identical. The information
contained in this document is reviewed regularly and any necessary changes will be included in the next
edition. We welcome suggestions for improvement.
Document subject to change without prior notice.
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.
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Contents
Safety Instructions ...........................................................................................................................................................................4
Installation ...........................................................................................................................................................................................5
Installation Diagram ............................................................................................................6
Installation Checklist ...........................................................................................................7
Maintenance Checklist ........................................................................................................8
Operating Instructions..................................................................................................................................................................9
Dishwashing Procedures .......................................................................................................................................................... 10
Troubleshooting Chart............................................................................................................................................................... 12
Components .................................................................................................................................................................................... 14
Location and Access..........................................................................................................14
Timer....................................................................................................................................15
Rinse Thermostat...............................................................................................................16
Wash Thermostat...............................................................................................................17
Solenoid Valve....................................................................................................................18
Pressure Switch ..................................................................................................................19
Wash Pump.........................................................................................................................20
Detergent Pump.................................................................................................................21
Assembly & Electrical Diagrams.......................................................................................................................................... 22
Wiring Tray Assembly.......................................................................................................22
Control Panel Assembly ...................................................................................................23
Wash Assembly ..................................................................................................................24
Rinse Assembly ..................................................................................................................25
Rinse Tank Assembly ........................................................................................................26
Solenoid Valve Assembly .................................................................................................27
Schematic Diagram............................................................................................................28
Wiring Diagram..................................................................................................................29
Spare Parts ........................................................................................................................................................................................ 30
Accessories ....................................................................................................................................................................................... 32
Appendices....................................................................................................................................................................................... 33
Rinse Aid Injector Kit .......................................................................................................33
Drain Pump Kit .................................................................................................................34
Revisions............................................................................................................................................................................................ 35
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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
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Installation
WARNING
Installer must be suitably qualified and ensure compliance with all codes and
standards including AS/NZS3500.1.
Failure to comply even partially with installation instructions may void the
warranty.
Positioning Unpack machine, check for damage and complete delivery. Install machine on
sound waterproof self-draining floor and use adjustable feet to level machine.
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.
Benchwork Refer to the installation diagram. Recommended bench depth is 850 mm, height
900 mm. We recommend sink smaller than rack with guide to prevent rack falling
into sink. Align sink with dishrack path as shown on the installation diagram.
Water Supply Hot water temperature 65°C ± 5°C
Connection 20 mm (3/4"BSP Male)
Flow rate minimum 20 litres per minute
Consumption per cycle 4 litres approximately
Backflow prevention Dual Check Valve fitted standard
Pressure 200-350 KPa = 30-50 Psi.
Above this range fit pressure limiter. Don’t use small diameter plastic supply lines.
FLUSH supply line before connection. Poor quality supply or excessive water
hardness may affect performance or damage machine – filtration and/or softening
is recommended.
Waste 40 mm gravity drain – refer point B on installation diagram – run waste directly
behind the machine.
Power Machine requires 3 Phase, Neutral and Earth, 415V, 50Hz, 18kW, 27A/ph,
permanently wired via wall switch mounted adjacent to machine. Wash pump
rotation must be checked after installation to ensure correct direction (excessive
noise and damage with incorrect direction).
Detergent Insert detergent pump inlet hose into container of commercial low foam detergent.
Open machine door and switch machine on. Press and hold detergent prime
switch behind front cover until chemical flows into machine.
Commercial detergents can be hazardous – read instructions and handle with care.
Installation Checklist
Complete attached Installation Checklist to ensure machine is installed and
running correctly, and operator is familiar with operating procedures.
Troubleshooting
If the machine doesn’t fill after switching on the power, check and ensure that the
hot water supply tap is open, water supply pressure is not below specification and
Dual Check Valve is correctly installed (arrows on the dual check valve’s body
specify water flow direction).
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Installation Checklist
CHECK OK / NOTES
Delivery
Supplied complete no transit damage
Position
Level and stable on sound, waterproof, self draining floor
Water
Isolator valve fitted Accessible, all fittings sound, no leaks
DCVs fitted (Washtech only) Correct direction
Temperature 65 ± 5°C
Flow rate Minimum 20 litres per minute
Pressure 200-350 kpa, limiter fitted if above this range
Booster fitted if below this range
Cold water when required Pressure not above 350 kpa
Hardness Filter or softening if required
Power
Isolating switch Fitted, functional and accessible
Supply as specified Voltage, current, circuit breaker
Waste
Usually 40 mm Sound, no leaks
Air gap on pumped drain
Chemicals
product name container no leaks primed conc.OK
Detergent
RinseAid
Machine operation
Run several cycles
Confirm correct operation Including correct fill levels
Operator training
Confirm Operator has copy of Operator Manual and is familiar with procedures
Start-up Model / Serial
Pre-rinse and racking Owner
Machine operation Location
Drain Technician
Clean Date
Shut-down Signed
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Maintenance Checklist
CHECK OK / NOTES
Installation – use Installation Checklist on previous page to check all services, operator training
and chemical issues
Services water, power, drain etc.
Operator trained / has instructions
Chemicals squeeze tube checked – replacement
recommended every 6 months,
product type, container, leaks etc.
General conditions
Cleanliness of machine daily maintenance
Presence of pests
Leaks
Operation
Temp °C Amps
Elements Wash 60
Rinse 83
Pumps Wash n/a
Rinse n/a
Drain functional n/a
Water Flow Wash arms and jets jets clear, good rotation, bushes OK
Rinse arms and jets jets clear, good rotation, bushes OK
Cycle Fill levels pressure switch settings
Drain operation upstand/pump
Noise sounds OK
Recovery between cycles
Controls Door switch including auto start if fitted
Switches, lights, gauges all sound and functional including door/s
Performance Wash and rinse effective
Electrical
Safety test if required
Cabinet
Door / Handle / Catch operational
Rack slide good rack entry / withdrawal
Comment / Action Required
Model / Serial Technician
Owner Signed
Location Date
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Operating Instructions
Start up
Fit drain upstand, wash pump filters,
scrap trays and shut door.
Turn wall power switch on and select
any cycle (1, 2 or 3).
Power light glows red and machine fills
automatically.
Wash Ready light (water symbol) glows
amber when wash tank is ready.
Rinse Ready light (tick symbol) glows
amber when the machine is up to
required temperature and ready to run.
Operation
Select required cycle (1, 2 or 3 for
2, 4 or 6 minutes cycle accordingly).
Try cycle 3 initially and switch to faster
cycles only if necessary.
Load rack into machine and close door.
Press Start button to start the machine.
Cycle light glows green while machine
operates.
When Cycle light goes out, cycle is
complete.
Open door and remove rack.
NOTE: Machine will not operate unless
Ready lights are on.
Shut down every night
Turn machine and wall power switches off.
Remove drain upstand to drain wash tank.
Remove scrap trays and wash pump filters and rinse clean.
Replace drain upstand, filters and scrap trays.
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Dishwashing Procedures forbest results
Note: these are general instructions to assist in getting the best performance from Washtech dishwashers –
some comments and / or illustrations may not apply to every unit.
Installation
Read the Operator Manual. Correct installation, including an adequate supply of
water at the correct temperature and pressure is essential for effective operation of
your machine. Refer installation instructions for details. Drain hose outlet height
is important on some models. Always install on a sound self-draining floor.
Water softening is recommended in hard water areas - especially for glasswashing
Pre-rinsing
Pre-scraping of dishes is required by hygiene regulations.
The best method is to pre-rinse with a pre-rinse spray unit -
or alternatively by scraping or dunking in water.
Cutlery Procedures
Pre-soak cutlery in warm water, preferably containing cutlery
pre-soak compound - refer your chemical supplier.
Do not overfill cutlery containers. Cutlery should be loose with
handles down. Sort after washing rather than before. Cutlery
of only one type nests together and obscures wash water.
Racking Procedures
Do not overload racks, minimize 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 choose shorter, faster
cycles when necessary.
Detergent
Use of correct type and quantity of low foaming commercial grade
detergent is essential to the performance of the machine. 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.
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Dishwashing Procedures forbest results
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 washware.
For advice on drying agents and injectors refer to your
chemical supplier.
Daily Cleaning
It 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 –
see below.
Regular Cleaning
Remove scrap traysand wash pump inlet filter, where
fitted, and rinse or brush clean.
Remove wash and rinse arms by undoing the central
thumbscrews. If necessary, remove the end cap screws
from the wash arms and the end screwsfrom the rinse
arms and flush the arms with water and/or use a toothpick or
paperclip to clear jets.
Note: arms and filters vary with model and may appear
different from this illustration e.g. those models with plastic
wash arms have removable jets for ease of cleaning
Regular Servicing
Regular servicing is essential for optimum performance and
long machine life. Maintenance is recommended at least
once every six months – especially when chemical injectors
are fitted.
Please contact Moffat or your Authorised Service Provider
to organize regular servicing of the dishwasher - discuss a
Preventative Maintenance Agreement.
Note: these are general instructions to assist in getting the best performance from Washtech dishwashers –
some comments and / or illustrations may not apply to every unit.
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Troubleshooting Chart
PROBLEM POSSIBLE CAUSES REMEDY (Check/Adjust/Replace)
Filling
Not filling Water supply valve shut Water supply valve
Door switch faulty Door switch
Solenoid valve faulty Solenoid valve
Rinse lines blocked Rinse pump, solenoid valve filter
Pressure switch faulty Pressure switch
Won't stop filling Solenoid valve faulty Solenoid valve
Pressure switch set too high/faulty Pressure switch
Pressure bell blocked, hose broken Pressure bell, hose, hose connections
Filling during Pressure switch refill level too high Pressure switch
wash cycle Upstand does not fit properly Drain upstand
Heating
Rinse not heating Over-temp thermostat tripped Over-temp thermostat, rinse element
Rinse thermostat settings or fault Rinse thermostat
Rinse element faulty Rinse element
Overheating Thermostat adjustment Thermostat
Thermostat probe out of pocket Insert & secure probe
Wash water cold Wash thermostat set too low Wash thermostat
Wash element faulty Wash element
Machine not rinsing Solenoid valve, water supply
Rinsing but not hot Thermostats & elements, water supply
Rinsing cycle too short Timer
Cycle start
Does not start Not up to temperature Give machine reasonable time initially
Rinse thermostat faulty Rinse thermostat
Door switch faulty Door switch
Cycle finish
Rinse doesn’t stop Solenoid jammed open Solenoid valve
Timer stuck Timer
Pressure switch faulty Pressure switch
Wash continues Timer jammed Timer / Timer motors
Cycle time
Cycle too long Timer faulty Timer / Timer motors
Cycles selection (for multi-cycle machines)
Time not changed Selector switch faulty Selector switch
Advance timer motor faulty 6 sec advance timer motor
Timer micro switches faulty T4 or T5 timer micro switches
Delays
At start or Rinse element faulty Rinse element
between Water supply cold Supply hot water
cycles Water supply pressure excessive Restrict supply pressure
Rinse cycle too long Timer
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Troubleshooting Chart
PROBLEM POSSIBLE CAUSES REMEDY (Check/Adjust/Replace)
Drainage
Flooding Drain waste blocked Drain waste
Leaks
Leak from pumps Seal failure Pump seal
Leak from hoses Hose damage Hoses
Hose clamp loose Hose clamps
Splash from door Wash arm end caps missing End caps
Wash jets blocked Wash arm jets
Wash jets missing Wash arm jets
Arms not rotating Arms and bushes
Arms not level Arms
Wash Arms
Not rotating Wash jets not clean Wash jets
Arm bushes worn Bushes
Wash pump not working Wash pump
Rinse Arms
Not rotating Rinse jets not clean Rinse jets
Arm bushes worn Bushes
Water supply pressure low Water supply
Rinse pump not working (if fitted) Rinse pump (if fitted)
Noise
Noisy rinse cycle Rinse pump squeals Low pressure / blocked water supply
Noisy wash cycle Wash pump noisy Wash pump including inlet filter
Performance
Poor wash result Detergent not used Use quality low foam product
Detergent pump faulty Detergent pump
Squeeze tube to be replaced Detergent pump squeeze tube
Overloading racks Do not overload racks
Not pre-rinsing Use Fisher pre-rinse
Wash arms not rotating Remove and clean arms/check bushes
Wash jets blocked Remove arms and clean jets
Low wash pressure through arms Wash pump impellor
Wash temperature low Check wash /rinse heating
Excessive soiling Pre-rinse/use long cycle
Unrealistic expectation E.g. baked on soiling requires pre-
soaking
Poor rinse results Rinse jets blocked Remove arms and clean jets
Rinse arms not turning Remove arms, clean jets, check bushes
Poor racking procedures Do not overload racks
Excessive wash tank soil build up Pre-rinse, change wash water regularly
Not drying Poor wash/rinse performance Refer above
Low temperatures Check heating systems
Drying agent not used Use quality drying agent/rinse fluid
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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. Rinse Tank
3. Rinse Over-Temp. Thermostat
4. Rinse Heating Elements
5. L/H Wash Pump
6. Wash Heating Elements
7. Adjustable Feet
8. Contactors
9. Rinse Thermostat
10. Test Switch
11. Detergent Prime Switch
12. Wash Thermostat
13. Control Relays
14. Timer
15. Detergent Pump
16. Fill /Rinse Solenoid Valve
Assembly
17. Power/Chemical Supply
Terminal
18. R/H Wash Pump
19. Upper Level Pressure Switch
20. Lower Level Pressure Switch
21. Power/Cycle Selector Switch
22. Cycle Light
23. Rinse Ready Light
24. Wash Ready Light
25. Power On Light
26. Rinse Temperature Gauge
27. Wash Temperature Gauge
28. Start Button
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Timer
Part Number 32787
Function Provides an automatic timing sequence of the wash, rinse, detergent and rinse aid injection
stages in a dishwashing cycle.
Description The electromechanical timer has a main drive motor and gearbox which produce a full
rotation of the seven cams in 360 seconds. The advance motor and gearbox speed the
rotation of the timer to produce shorter cycles of 120 and 240 seconds. The timer cams
operate individual changeover switches in sequence during the rotation. The cams are
numbered from the main motor end. T1 controls the main motor, T2 – wash, T3 – rinse,
T4 – rapid advance motor for 120s cycle, T5 – rapid advance motor for 240s cycle, T6 –
detergent injector if fitted, T7 – may be used for electric rinse fluid injector if required.
Diagram
Replacement To replace the timer take note of the position of each connection, preferably on paper.
Disconnect all wires and remove the timer from the tray. Compare the cam setting of the
old and new timer to ensure that special settings are duplicated. Fit new timer taking care to
locate cam T1 in the same relative position. Reconnect the wires ensuring that no
termination is under strain. Test the machine to confirm correct operation.
Adjustment The timer cams T2, T3, T6 and T7 are adjustable. The time settings on these cams can be
increased by making the gap in a cam wider, or reduced by reducing the gap. Use a timer
adjusting tool, supplied with the machine to modify a gap in the timer cams.
IMPORTANT
The factory setting of the cam T3 allows for a 15 sec hot rinse. Reduction of this
time is prohibited by Health regulations. Extending this setting will increase hot
water consumption of the machine and may result in delays between the cycles as
this additional water is heated.
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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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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 600 30289
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.
Type Burkert 6213
Body material: DR Brass Duty cycle: continuous
Seal material: EPDM Ambient temperature: Max. +55°C
Media: Oil, fat-free fluids Pressure: 0 - 10 Bar
Voltage: 230 V Flow rate: 1.9m³/h (at1bar)
Frequency: 50 Hz Media temperature: -30 to +120°C
Power: 8 W Construction: IP65
Diagram
Replacement Solenoid coil
Release electrical connector fixing screw and detach electrical connector from
solenoid coil. Unscrew fastening nut on top of solenoid coil and slide up 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.
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Pressure Switch
Part Number 600 30266
Function Control filling of wash tank and protect 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 upper pressure switch shuts off the fill solenoid valve and switches
on the wash elements. When the water level in the tank drops below the reset level of the
lower pressure switch the wash elements are switched off and the fill solenoid valve starts
refilling the tank. Using two pressure switches allows greater water level differential so that
the tank level may drop with the operation of the wash pumps, 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
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 upper pressure switch.
Remove drain upstand to begin draining the wash tank. Fit back the upstand when Wash
Ready light goes off and measure the refill water level. A refill level should be set 15-25mm
above the wash element. Adjust if necessary by Differential screw on the lower 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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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
Power: HP 2 Kw 1.4
Voltage: 415 V
Frequency: 50 Hz
Speed: 2800 rpm
Amperes: 3.1 A
Construction: IP44
Diagram
Replacement Drain the wash tank and switch off the power.
Disconnect the wires from the wiring connectors inside the pump junction box.
Remove two M8 bolts that fasten the pump to the platform.
Release the hose clamps on the inlet and outlet pump hoses and remove the pump.
Replace in reverse order.
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