DUAL TEMPERATURE, GAS HEATED DOOR-TYPE DISHMACHINES TECHNICAL MANUAL INSTALLATION MANUAL FOR EXPORT UNITS SERVICE MANUAL FOR DOMESTIC UNITS FOR JACKSON MODEL: TEMPSTAR GP An June 24, 2004 P/N 7610-0011-90-68 (Revision B) Company Jackson MSC, Inc. P.O. BOX 1060 HWY. 25E BARBOURVILLE, KY. 40906 FAX (606) 523-9196 PHONE (606) 523-9795 www.jacksonmsc.
TABLE OF CONTENTS GENERAL Specifications ............................................................................................ PAGE 1 INSTALLATION Unpacking................................................................................................... Plumbing Connections................................................................................ Electrical Connections................................................................................ Gas Connection.............................
SPECIFICATIONS OF THE TEMPSTAR GP PERFORMANCE/CAPABILITIES ELECTRICAL REQUIREMENTS OPERATING CAPACITY (RACKS/HOUR) RACKS PER HOUR 57 DISHES PER HOUR 1425 GLASSES PER HOUR 1425 WASH PUMP MOTOR HP 3/4 CIRCULATOR PUMP MOTOR HP 1/12 VOLTS OPERATING CYCLE (SECONDS) PHASE AMPS 208 - 240 1 6.7 110 - 120 1 13.4 WASH TIME 45 RINSE TIME 11 WATER REQUIREMENTS DWELL TIME 2 INLET TEMPERATURE 110 -140°F TOTAL CYCLE TIME 60 GALLONS PER HOUR 52.0 WATER LINE SIZE I.P.S.
INSTALLATION INSTRUCTIONS VISUAL INSPECTION: Before installing the unit, check the container and machine for damage. A damaged container is an indicator that there may be some damage to the machine. If there is damage to both the container and machine, do not throw away the container. The dishmachine has been inspected and packed at the factory and is expected to arrive to you in new, undamaged condition.
GAS CONNECTION It is very important that the type and inlet pressure of the gas used corresponds to the machine data plate. This machine is equipped with a 1/2” female line for connection of gas. The gas line used should be of the type approved for use with natural gas or propane, depending on the gas selected to be used in this machine. The gas line should be sized to carry the maximum flow of 55,000 BTUs. Too small of a gas line will result in poor performance.
OPERATION INSTRUCTIONS PREPARATION: Before proceeding with the start-up of the unit, verify the following: WARM-UP CYCLES: For a typical daily start-up, it is recommended to run the machine through 3 cycles to ensure that all of the cold water is out of the system and to verify that the unit is operating correctly. To cycle the machine, ensure that the power is on and that the tub has filled to the correct level. Lift the doors and the cycle light will illuminate.
OVERVIEW OF OPERATION PRESSURE GAUGE VACUUM BREAKER REGULATOR FILL / RINSE SOLENOID T RINSE ARM CHECK VALVE RINSE TEMP >180 F CHECK VALVE WASH TANK WATER LEVEL PROBE WL THERMOSTAT TS WASH TANK COILS BOOSTER TANK T WASH TEMP 150-165 F ECO T-MID HEAT EXCHANGER BURNER ASSEMBLY RECIRCULATING PUMP MODULATING VALVE COMBINATION GAS CUTOFF VALVE The Tempstar GP heating system is designed to heat and maintain the wash tank water temperature at a minimum of 150 F as well as providing a constant 180
OVERVIEW OF OPERATION (CONTINUED) The operator may turn the power off at the ON/OFF switch for approximately 5 seconds, and then back on. This will also reset the ECB and the DSI. If flame is lost during normal burn, the DSI will attempt a reignition. The ECB monitors the 12vdc signal from the DSI to the combination gas cutoff valve. The software in the ECB also reads the temperature at the middle of the heat exchanger with the T-mid thermistor. After the 5.
THERMOSTAT ADJUSTMENT PROCEDURE 1) 2) 3) 4) 5) Start up unit Allow to fill, and start warm-up Turn thermostat trim screw Counter Clockwise (CCW) 2 full revolutions Allow wash temperature to reach 170LF on Wash Temperature Gauge Turn thermostat trim screw Clockwise (CW) until flashing Green LED on control board turns off. (The recirculating pump will also turn off).
AUTO-CALIBRATION PROCEDURE Model: TEMPSTAR GP, & TEMPSTAR TGP This procedure must be completed every time you replace either a control board or a modulating valve. AUTO - CALIBRATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Turn the unit OFF at the main power switch and let stand for one minute. Remove the lower front panel and set aside. Remove the cover of the rectangular control box. Locate the control board (see figure 1).
ELECTRONICS CONTROL BOARD (ECB) Testing and Setting the Set Point Temperature The Control Board regulates the temperature of the water in the heat exchanger system. This water is also used as the rinse water for the rinse cycle of the dishwasher. It does this by regulating the flame of the burner by increasing or decreasing the voltage to the modulating valve.
TESTING THE THERMISTORS There are two thermistors that are used in controlling the temperature of the water in the heat exchanger system. The T- in that samples the temperature of the water going into the heat exchanger and the T-Mid that samples the temperature halfway through the heat exchanger.
CONTROL BOARD LED LIGHT INDICATIONS The Electronic Control Board (ECB) has two LED light indicators that can be seen at its upper left hand corner. The following conditions for each light may be seen during operation of the unit. 1) Green LED is off. A) Dishmachine is turned off, therefore no power to ECB. B) Wash thermostat has cycled off, therefore breaking power to 12 volt transformer in the main control box. This will also disrupt power to the ECB. C) ECB may have never recieved an AUTO CALIBRATION.
TROUBLESHOOTING SECTION WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Symptom Dishmachine will not run. No power to the unit. Possible Cause Service breaker tripped. Action Reset breaker. If breaker trips again, immediately contact an electrician.
TROUBLESHOOTING SECTION WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Symptom Dishmachine fills continuously, only when the power is on. Dishmachine runs with the door open. Low wash water pressure. Possible Cause Action Faulty fill microswitch. Replace microswitch.
TROUBLESHOOTING SECTION WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Symptom Low wash water pressure. Water leak in the gas booster pack. Gas leak. CAUTION: WHEN CHECKING FOR GAS LEAKS DO NOT USE FLAME. Low rinse temperature/low wash temperature.
TROUBLESHOOTING SECTION WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Symptom Low rinse temperature/low wash temperature. Possible Cause Action Low inlet water temperature.
TROUBLESHOOTING SECTION WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Symptom High wash tank temperature. Possible Cause Defective thermostat. Action If wash tank temperature is greater than 170 F, back thermostat CCW one full turn and restart unit.
TROUBLESHOOTING SECTION WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Symptom Green LED flashes, but no ignition (igniter sparks, no gas). Possible Cause Gas flow interrupted. Action Check manual gas valve is open. Check regulated gas pressure. (7.0 -10.5 WCI for natural gas or 11.
TROUBLESHOOTING SECTION WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Symptom The unit ignites, but will to rise above ignition burn. Exhaust contains dark smoke. Possible Cause Action T-mid thermistor inoperative. Check T-mid thermistor readings at control board set points.
DIMENSIONS 19
TABLE DIMENSIONS TABLE DIMENSIONS CORNER INSTALLATION 2 1/4” 20 1/2” OPENING 4” MIN.
MAIN ASSEMBLY 01 08 02 09 03 04-NOT SHOWN 10 05 11 06 12 07-NOT SHOWN 13 NOT SHOWN 14 ITEM QTY 01 02 03 04 05 06 07 08a 08b 09 10 11 12 13 14 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 DESCRIPTION MFG NO.
CONTROL BOX ASSEMBLY - FRONT VIEW 01 ITEM QTY 01 02 03 04 05 06 07 08a 08b 09 10 11 12 1 1 1 1 1 1 1 1 1 1 1 8 1 02 03 04 05 06 DESCRIPTION 07 08 09 10 11 12 MFG NO.
CONTROL BOX ASSEMBLY - TOP VIEW 01 14 02 03 13 04 12 05 06 11 07 10 08 09 23
CONTROL BOX ASSEMBLY-TOP VIEW ITEM QTY 01 02 03 04 05a 05b 06a 06b 07a 07b 08 09a 09b 10a 10b 11a 11b 12 13 14 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 DESCRIPTION MFG NO.
HOOD ASSEMBLY 01 ITEM QTY 01 02 03 03 03 04 05 06 1 1 28 28 28 1 1 1 02 03 04 DESCRIPTION 05 06 MFG NO.
CANTILEVER ARM ASSEMBLY 01 12 11 02 03 10 09 04 ITEM QTY 01 02 03 04 05 06 07 07 08 09 10 11 12 1 1 1 2 2 1 4 4 6 2 2 2 1 05 06 07 DESCRIPTION 08 MFG NO.
TUB ASSEMBLY 01 02 ITEM QTY 01 02 02 03a 03b 04 05 06 07 08 09 10 11 12 13 1 2 2 1 1 1 1 3 2 1 1 1 2 1 1 03 04 05 06 07 08 09 DESCRIPTION 10 11 12 13 MFG NO.
BACK OF TUB, & DRAIN ASSEMBLY 14 01 13 02 12 11 03 10 04 05 09 06 07 ITEM QTY 01 02 03 04 05 06 07 08 09 10 11 12 13 14 1 1 1 1 1 1 1 2 2 2 1 2 2 1 DESCRIPTION 08 MFG NO.
LOWER ASSEMBLY (RIGHT SIDE) 01 ITEM QTY 01 02 03 04 05 06 07 08 09 10 11 12 13 14 1 1 1 1 1 6 1 1 1 1 2 1 1 1 02 03 04 05 06 DESCRIPTION 07 08 09 10 11 12 13 MFG NO.
INCOMING PLUMBING ASSEMBLY 26 25 24 23 22 21 01 02 03 20 04 19 05 18 06 07 17 08 09 16 15 14 13 12 10 11 30
INCOMING PLUMBING PARTS LISTS ITEM QTY 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 18 19 20 21 22 23 24 25a 25b 26 1 1 1 1 1 1 1 1 1 2 1 1 5 1 1 1 1 1 1 2 4 2 1 3 1 1 1 3 DESCRIPTION MFG NO.
GAS PACK ASSEMBLY 01 ITEM QTY 01 02 03 04a 04b 05 06a 06b 07 08a 08b 09 1 1 1 1 1 1 1 1 1 1 1 1 02 03 04 05 DESCRIPTION 06 07 08 MFG NO.
UPPER WASH, & RINSE ARM ASSEMBLY 01 02 ITEM QTY 01 02 03 04 05 06 07 08 09 10 11 12 2 1 1 1 2 2 1 1 8 2 1 2 03 04 05 06 DESCRIPTION 07 08 09 10 MFG NO.
LOWER WASH, & RINSE ARM ASSEMBLY 01 02 ITEM QTY 01 02 03 04 05 06 07 08 09 10 11 2 2 1 1 1 1 1 2 1 1 1 03 04 05 06 07 DESCRIPTION 08 09 10 11 MFG NO.
STEAM COIL ASSEMBLY 07 08 09 10 01 11 02 12 13 03 14 04 15 05 16 06 17 18 35
STEAM COIL ASSEMBLY (PARTS LISTS) ITEM QTY 01 02 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 1 4 4 1 1 1 1 1 1 4 1 2 1 1 1 1 1 1 1 DESCRIPTION MFG NO. Stand-D, Steam Coil Support Locknut, 1/4-20 s/s Hex w/Nylon Insert Washer, s/s 1/4 I.D.
RINSE TANK ASSEMBLY NOTE:THESE UNIONS ARE NOT INCLUDED WITH THIS ASSEMBLY. 07 01 08 02 03 09-NOT SHOWN 04 05 06 ITEM QTY 01 02 03 04 05 06 07 08 09 1 2 2 1 3 2 1 1 1 1 DESCRIPTION MFG NO.
ELECTRONIC CONTROL DRAWER COMPONENTS RED LED GREEN LED ITEM QTY 01 02 03 04 05 06 07 08 09 1 1 1 1 1 1 1 1 1 1 2 3 4 5 6 7 DESCRIPTION 8 9 MFG NO.
Tempstar GP ELECTRICAL DIAGRAM 110/120 VOLT - 60 HERTZ - 1 PHASE 39
Tempstar GP ELECTRICAL DIAGRAM 208/240 VOLT - 60 HERTZ - 1 PHASE 40
