SERVICE MANUAL PS-200 & PS-201
Table of Contents Explanation of Warning Messages......................................................................................... 1 Danger............................................................................................................................................ 1 Warning......................................................................................................................................... 1 Personal Injury Hazard.....................................................
Parts List ........................................................................................................................................ 10 Motor – Impeller – Pump Assembly ............................................................................... 10 Motor – Impeller- Pump Assembly................................................................................. 11 Motor – Impeller- Pump Assembly................................................................................. 11 Heater.......
Explanation of Warning Messages Read, understand and follow all DANGER, WARNING, and CAUTION messages located in this guide and on the equipment. Danger Personal Injury and Property Damage hazard. May result in serious injury of death. May cause extensive equipment damage. Warning Property Damage Hazard. May result in property or equipment damage. Personal Injury Hazard Hazard from sharp objects. May result in serious injury or death. Chemical Hazard May result in serious injury or death.
Preventive Maintenance Power Soak machines require minimal, routine preventive maintenance. As such, the following should be done on a routine basis to ensure that your system remains reliable: Daily Clean the liquid level sensors. These sensors are located on the side walls of the wash and sanitizer tanks. They are the white plastic discs with metal centers. Clean the sensor faces thoroughly. If cleaned regularly, a washcloth and soapy water are all that is required.
Troubleshooting Hazard to Untrained or Unauthorized Personnel. The following procedures are provided for use by an authorized service agency. No facility owner, manager, employee or other unauthorized person should attempt to perform any of these procedures. To obtain the name of a recommended service agent in your area, please call the Power Soak Service Department. 800-444-9624.
Pump does not work Look for 1 Slow flashing Green Light 2 Solid Blue Light 3 Error LED on UPM 4 Red, Green, Blue lights blinking together 5 No indicator lights at all Correction Clean Liquid Level Sensors. Fill sink with water to proper level. Tighten the External Wiring Harness on back of Control Panel. Clean Liquid Level Sensors. Drain sink and refill with proper water level.
No Power Look for 1 Incoming voltage between L1 and L2 (L1L2) (Also L1-L3, L2-L3 if 3 phase) 2 Less than 10 volts to UPM (leave UPM plugged in during check) Correction Check Heater and replace as necessary. Water too hot, above 135°F – empty sink and refill with 115°F water. Tighten the External Wiring Harness on back of Control Panel. Check transformer and replace as necessary. Check thermal cutoff for heater and replace as necessary. Check thermal cutoff for motor and replace as necessary.
2 ~~~** Temperature Sensor Error When the UPM receives a signal from the thermistor that is outside the range of the UPM programming, the temperature sensor error will actuate. The UPM will signal an error if it reads a resistance greater than 430 k and less than 15 k. Check and replace Thermistor as necessary.
Component Operation and Checks The following checks should only be performed by qualified technicians using extreme caution. Electrical hazard to untrained personnel may result in electrical shock, burns, or death. Liquid Level Sensors There are two Liquid Level Sensors (LLS) in the wash sink, and two more in the sanitize sink (if equipped with a sanitize sink). To check operation, first unplug the white connector from the UPM.
Heater Thermodisc (Hi-Limit or Cutoff Switch) The Heater Thermodisc is a protection device. If the temperature at the Thermodisc reaches 135°F, the disc opens, cutting off power to the UPM. To check operation, first shut off the circuit breaker to the sink. Next, unplug the connectors P9 and J10 form J9 and P10 for the Motor Thermodisc (reference schematic or “Motor Thermodisc” for location and description). Device should read less than one ohm when closed.
Triac (Thyristor or Solid-State Relay) The Triac is a three terminal semiconductor for controlling current in either direction. The Triac in the Power Soak is used similar to a contactor. When a gate voltage is applied from the UPM (similar to coil voltage on a mechanical Contactor Relay), the Triac conducts (closes) through the power terminals. On a single phase Control Panel, there are two Triacs, one for the Heater, the other for the Motor.
Parts List Motor – Impeller – Pump Assembly 60 Hz – Self-Draining HP Side Phase Volt Motor Impeller 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 3.0 3.0 5.0 5.0 5.0 5.
Motor – Impeller- Pump Assembly 60 Hz – Not Self-Draining HP Side Phase Volt Motor Impeller 1.5 LH 1 208/230 27590 2.0 LH 1 208/230 2.0 LH 3 230/460 3.0 LH 3 230/460 see above see above see above see above 27592 27592 27594 Motor – Impeller- Pump Assembly 50 Hz – European HP 1.5 1.5 1.5 1.5 2.0 2.0 3.0 3.0 5.0 5.
Pump Parts Common to all Part # 28920 27886 27047 27132 *27480 *27475 *27476 27477 *27478 *27479 27481 27483 28262 Description Seal Kit Thermodisc-motor-thermal cutoff Intake gasket Discharge gasket Mechanical Seal “O” ring – sleeve “O” ring – seal plate Key Impeller Bolt Fiber Washer Sleeve Cap Screw – seal plate Dowel Pin * These items are contained in seal kit 28920 12
Heater Part # 27743 27744 27839 29243 27930 29244 27939 27934 27702 27934 27702 27934 18797 27926 28454 27322 28928 29077 Description Element – 230 volt – rev. A – ribbon – rear mount Element – 460 volt – rev. A – ribbon – rear mount Gasket for Chromolex heater Element – 208 volt –rev. B – wire – bottom mount – not available yet Element – 230 volt – rev. B – wire – bottom mount Element – 380 volt –rev. B – wire – bottom mount – not available yet Element – 480 volt – rev.
Control Panel Parts # 27901 27902 27903 27171 27172 27920 27923 27924 27925 27928 28923 27927 27200 27922 Description Control Panel 220 volt single phase Control Panel 220 volt three phase Control Panel 480 volt three phase Contactor Transformer – 24 volt UPM – Programming Module Terminal Block Grounding Block Din Rail – mount for terminal blocks Triac – solid state relay Fuse Block Heatsink Overlay – start/stop membrane Wiring Harness – internal to control panel Miscellaneous Part # 23987 23988 27847 278
Optional Chemical Dispenser Dual Pump Chemical Dispenser Part # 28900 28370 29233 29230 29231 29232 29235 29234 28067 29236 29237 29238 29239 29240 29241 29242 28703 28704 103-014 27858 28557 28901 29145 28555 Description Chemical Dispenser – Dual Pump – Generic Chemical Dispenser – Dual Pump – Kay Chemical Timer – solidstate Button Guard – metal Switch – MOM – N/O – metal Rectifier – bridge Lock & Key Motor – 24 volt – 120 rpm Wiring Harness – soap dispenser Hook & Loop Screw - #8-32 x 1/2” flat phillips
Electrical Schematic 208-240 volt 60 Hz 1 phase 16
8-230 volt 60 Hz 3 phase 17
460 volt 60 Hz 3 phase 18
Electrical Schematic (European) 400 volt 50 Hz 3 phase 19
0 volt 50 Hz 3 phase 20
Motor and Pump Assembly Exploded View 21
Motor and Pump Assembly & Disassembly Procedures DISASSEMBLY PROCEDURE: 1 Remove (3) nuts from the back of the adaptor plate. Slide the pump end out from the volute. 2 Holding the impeller to keep it from turning, loosen the washer head cap screw, and remove the screw and gasket. 3 Slide the impeller off of the shaft and remove the key. 4 Remove the seal/sleeve as a unit by pulling it off of the shaft.
4 Coat the shaft sleeve lightly with lube. Install the mechanical seal on the shaft sleeve using your hand to push against the seal face. Make sure rubber seal bellows are seated against sleeve shoulder and carbon seal face is not scratched or chipped. 5 Slide the shaft sleeve onto the motor shaft and install the O-ring on the groove of the sleeve. Using lube or grease on the O-ring will help hold the ring in place temporarily until the impeller is secured.
Appendix A 24
Power Soak is a registered trademark of Cantrell Industries, Inc. The Power Soak Design and concept is fully patented. Power Soak Systems. Inc. 903 East 104th Street, Suite 130 Kansas City, MO 64131 Phone (816) 222-2400 Fax (816) 222-2419 (800) 444-9624 www.powersoak.
