Service Manual PS-225
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Table of Contents Introduction – Section 1 ............................................... 2 1.0 Product Introduction ....................................................................... 2 1.1 General Description ....................................................................... 2 Messages – Section 2.................................................. 3 2.0 Explanation of Warning Messages ................................................ 3 2.1 Danger ..................................................
Current Sensor Error ...................................................................... 11 Membrane Error ............................................................................. 12 Control Panel Components - Section 6 Authorized Personnel Only ........................................ 13 6.0 Universal Programming Module (UPM) ....................................... 14 6.1 Programming Interface ................................................................ 15 6.2 Communication Port ..............
8.4 Chemical Dispenser (Optional) .................................................... 34 Troubleshooting - Section 9 ....................................... 35 9.1 The pump will not start when the green “Start” button is pushed. 36 9.1a. Control panel Status (green) light is not on or flashing .......... 36 9.1b. Control panel Status (green) light is flashing and Wash Tank (blue) light is on. ................................................................... 36 9.1c.
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SECTIONS 1, 2 & 3 PS-225 1
Introduction – Section 1 1.0 Product Introduction The Power Soak pot, pan and utensil washing system will provide years of dependable, efficient and trouble-free service. Every system is manufactured to last, with only highquality, heavy-duty, 14 gauge stainless steel used in its construction. All electrical components used in a Power Soak system are of the highest quality. The faucets and drains are designed for quick filling and emptying of the system's tanks.
Messages – Section 2 2.0 Explanation of Warning Messages Be sure to read, understand and follow all DANGER, WARNING, and CAUTION messages located in this document and on the equipment. These messages are used to identify areas of the machine that are harmful. 2.1 Danger Personal Injury and Property Damage hazard. Will result in serious injury or death. Will cause extensive equipment damage 2.2 Warning Property Damage Hazard. Will result in property or equipment damage. 2.
Detergents and Sanitizer – Section 3 3.1 Detergents Power Soak machines require a low-foaming, metal/aluminum-safe detergent. The detergent should have good grease cutting abilities and pH level that is safe for human contact. Improper detergents may damage the equipment. Use of the correct detergent in the Power Soak PS-225 is critical to its washing performance. If there are problems with cleaning results, please contact Power Soak Systems (1-800-444-9624).
Preventative Maintenance - Section 4 PS-225 5
4.0 Maintenance Power Soak machines require minimal preventive maintenance. To ensure that the Power Soak PS-225 remains reliable, the following tasks should be completed at the intervals shown in this section. 4.1 Daily 4.1a Clean the liquid level sensors - The liquid level sensors are located on the side walls of the wash and sanitizer tanks (see section 7.4). They are white plastic discs with metal centers. The faces of the sensors need to be cleaned with a washcloth and soapy water.
Control Panel Lights - Section 5 PS-225 7
5.1 Control Panel Overlay The Control Panel Overlay is bonded to the surface of the enclosure door and conceals the membrane that contains the push buttons and lights. The panel lights are used to indicate conditions that have been detected by the operating program. The lights on the face of the control panel operate in conjunction with the Alert Light System located on the bottom surface of the control box (lights that shine on the floor).
5.2 Light Illumination Code 5.3 Green Status Light Off – Power to the machine is turned off or an over temperature situation has occurred. Slow Flashing – “POWER ON” – system is energized and ready to fill the wash tank. Solid Illumination – “OPERATING” – wash tank is full; START button has been pressed, the program is running.
5.4 Blue Wash Tank Light Solid Illumination – “CHANGE WASH SOLUTION” the wash cycle will be stopped until the wash tank is completely drained and refilled. Slow to Fast Flashing – wash solution life has expired, 15 minute warning prior to solid illumination. Flashing with Green Status light – occurs when tank is filling with water indicating near full, rapid flashing indicates that the tank is full (NOTE: the fill indication feature is an option that must be selected in the UPM settings.) 5.
5.7 Error Codes Certain conditions create errors in the program operation. The green “Status” light on the front of the control panel along with the error code light on the UPM will blink in patterns to indicate the source of the error. The definitions for the patterns are as follows: “_“ symbol represents a “long” flash “.” symbol represents a “short” flash 3 long & 1 short 3 long & 2 short 3 long & 3 short 3 long & 4 short 3 long & 5 short _ _ _ . = Liquid Level Error _ _ _ . .
Membrane Error – In the event that one of the control panel buttons sends a constant signal to the UPM, the program will recognize that the membrane is defective and display this error code (see Section 6.9 Push Button Membrane). Note: There are periods of unstable power from the incoming power source that can cause a false error. Turning the electrical power off and on can reset the program if it is a power source fluctuation that caused the error.
Control Panel Components - Section 6 Authorized Personnel Only PS-225 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 1-800-444-9624.
6.0 Universal Programming Module (UPM) The Universal Programming Module is located on the inside of the control panel door. To access the UPM, remove the two screws at the top of the control panel door and swing the door down toward the floor. The open door exposes high voltage terminals in the enclosure. DO NOT touch the electrical terminals with hands or tools. PROGRAMMING INTERFACE UPM The UPM has four indicator lights for troubleshooting: POWER ON Light is on when operating.
Identification of the UPM connector terminals is helpful for troubleshooting. Disconnecting the wiring harness connector and conducting voltage or ohm measurements on the terminals in the connector will help determine the condition of the components connected to the wiring harness. The pin numbers are identified on the schematic for determining the component connections. The 22 pin connector for the UPM is identified on the schematic as “J1”.
Tabs To separate the interface unit for mounting, squeeze the tabs on the end of the case and pull on the back edge of the mounting flange. Back edge of the mounting flange Separated for mounting 6.2 Communication Port A communication port (USB “A” style) is located on the bottom of the control panel enclosure and connected to the UPM by a cable. The connection port is protected by a cover that screws on to the body of the connector.
The Triac relays are connected to high voltage electricity. The power to the machine must be turned off at the circuit breaker in the wall mounted enclosure when working on the Triacs. Failure to turn off the power will result in serious injury and possibly death.
The wiring harness connectors for the Triac gates must be connected to the proper location. The connector location is matched to the gate connection by the location in the wiring harness. The first wire connector exiting the wiring harness will attach to the first gate connection on the heater control Triac. On a single phase machine or when a heating element is not used, the additional Triacs will not be installed and the connectors will be tied to the wiring harness.
6.6 Contactor A mechanical contactor is used to disconnect the high voltage electrical supply from the Triacs when the UPM detects a problem with the pump motor or wash tank heater. The contactor is located on the left side of the mounting plate in the control enclosure. The contactor is defective if there is 20vac-28vac across the coil and the contactor does not pull the center button into the core.
6.8 Fuse Holder, Terminal Blocks and Jumpers A fuse holder with a 1 amp fuse for the 24VAC contactor control circuit and chemical dispenser pump is nested with the terminal blocks. When this fuse is “blown” or not present, the contactor will not connect the high voltage electricity to the pump motor or heater. The fuse is accessed by pulling out on the tab at the top edge of the fuse holder. The electrical supply wires are to be connected to the terminal blocks.
6.9 Push Button Membrane The buttons and lights on the front of the control panel are made into a plastic membrane that is sandwiched between the plastic overlay and the sheet metal face of the enclosure cover. A “ribbon cable” with a connector on the end of the cable attaches to the buttons and lights. The ribbon cable fits through a slot in the sheet metal door on the control panel and pugs into the UPM to allow the buttons to signal the UPM for the start, stop and unload functions.
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Electrical Components - Section 7 Authorized Personnel Only PS-225 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 1-800-444-9624.
7.1 Pump Motor The pump motor is bolted to a mounting plate that is attached to the pump housing. The pump impeller is attached directly to the motor shaft. A rotary joint seal is used to separate the water containment area from the front of the motor (see section 8.1 for assembly instructions). The pump impeller and motor must rotate smoothly without “dragging” anywhere in the rotation.
connection. A “short to ground” from either side of the Thermo-disc indicates that the Thermo-disc is defective. These conditions will keep the UPM from operating correctly. On some motors, the Thermo-disc is built in to the motor, which is not replaceable. On other motor styles, it is located in the wiring box of the Motor, which is replaceable.
There are three heating coils within one element and each heating coil has two wires to connect the coil to the electrical circuit. The wires for a single coil are directly across from each other on the longest dimension of the mounting plate. Longest Dimension EXAMPLES OF HEATING ELEMENT STYLES These two wires are part of the same heating coil. The heating element in a Power Soak sink is rated at 7000 watts. Electrically, the Heater is considered as three separate elements, each rated at 2333 watts.
7.4 Heating Element Thermo-disc The Heater Thermo-disc is a devise used to detect a high temperature created by the heating element. If the temperature at the Thermo-disc reaches 135°F, the disc opens, turning off power to the UPM. The Thermo-disc is located close to the Heater, inside the Sensor Pad or on the mounting flange of the heating element. To check the operation of the thermo-disc, turn off the circuit breaker in the wall mounted enclosure that supplies electrical power to the control panel.
7.6 Liquid Level Sensors There are two Liquid Level Sensors in the side wall of the wash tank, and two in the side wall of the sanitize tank (if equipped with a sanitize tank). The sensor located at the bottom of the tank is used to detect when the tank has been drained and the sensor at the top of the tank is used to determine when the tank is full. To check operation, unplug the white connector from the UPM.
Assembly Procedures - Section 8 Authorized Personnel Only PS-225 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 1-800-444-9624.
8.1 Motor and Pump 8.1a Disassembly – Turn off the electrical power to the machine at the circuit breaker in the wall mounted enclosure and drain the wash tank. To service the pump or motor the wash tank must be empty. Refer to the illustration in Section 10.1for the following description: Remove the Nuts (15) holding the Adapter Plate (13) with a 9/16 wrench, and then slide the adapter plate and motor assembly off the studs.
8.1c Assembly – Refer to the illustration in Section 10.1for the following description: Apply a thin coating of light weight oil such as WD-40 to the outer surface of the Mechanical Seal base (10) and push the base into the Adapter Plate (13) with the white surface of the base oriented to the pump side.
Wipe the faces of the mechanical seal parts so that they are free of debris and slide the shaft sleeve assembly onto the motor shaft so that the protruding ceramic face of the mechanical seal makes contact with the white face of the seal base. Place the Shaft Seal (8) into the groove on the end of the Shaft Sleeve (9). Insert the Impeller Key (7) into the motor shaft with the flat side of the key oriented toward the bottom of the motor keyway.
8.2c Assembly – Place the gasket on the bottom surface of the heating element mounting plate. Insert the heating element though the opening in the back wall of the wash tank. Push the wires through the center opening and align the studs with the mounting holes on the bottom surface of the tank. Install the nuts on outside surface of the tank to secure the heating element to the bottom of the tank.
8.3 Sensor Pad 8.3a Disassembly - To access the contents of the Sensor Pad, unbolt the mounting bracket that holds the sensor pad and remove the sensor pad from the back side of the wash tank. Lift the retainer plate out of the rubber pad and then remove the electrical components. Thermistor Heat sink compound is used on these faces Thermo-disc Retainer plate The sensor pad is located on the back side of the wash tank Sensor pad removed from wash tank. 8.
Troubleshooting - Section 9 PS-225 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 800-444-9624.
9.1 The pump will not start when the green “Start” button is pushed. 9.1a. Control panel Status (green) light is not on or flashing Possible Cause 1. The power supply to the machine is turned off. 2. The temperature in the wash tank or motor has exceeded the high temperature limit. 3. The transformer has failed. Solution 1. Restore power to the machine; check the circuit breaker in the wall mounted enclosure. 2.
9.1d. Control panel Status (green) light is blinking with a pattern of long and short flashes. Possible Cause A problem has been detected by the program and the UPM is signaling an error code. Solution See section 5.7 to determine the error message. 9.1e. All of the lights on the control panel and all of the Alert Lights are flashing. Possible Cause The transformer output voltage is below an acceptable level. Solution Check the voltage on the transformer (see section 6.5). 9.
9.3 Motor starts, but no water flows in the wash tank. Possible Cause 1. The pump impeller is broken or not connected to the motor shaft. 2. The motor is rotating the in the wrong direction (only occurs when motor is first installed or replaced). Solution 1. Turn off the power to the machine at the circuit breaker in the wall mounted electrical enclosure and remove the motor assembly (see sections 7.1 & 8.1). 2.
Solution 1. Clean the face of the sensor with a washcloth and soapy water. 2. Check the nut that secures the wire to the sensor on the outside of the tank. 9.6 The water gets too hot and stops the machine. Possible Cause The Triac has failed and is passing current to the heater when it is turned off. Solution With the machine operating, check the amperage on the heating element wires when the indicator light goes off. If the current does not go off when the indicator light is off, the Triac is defective.
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Parts Lists – Section 10 PS-225 41
10.1 Motor and Pump Assembly The part numbers for the Volute (1), Impeller (6) and Motor (16) are different for the different configurations of machines. Contact the Power Soak Service Department (1-800-444-9624) and provide the serial number of the machine for help with the part numbers. 10.
10.1b 60 Hz Motor and Impeller HP 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 3.0 3.0 Side LH RH LH RH LH RH LH RH LH/RH LH/RH Phase 1 1 1 1 3 3 3 3 3 3 Volt 208 208 230 230 208 208 230/460 230/460 208 230/460 Motor 29507 29507 29501 29501 29509 29509 29503 29503 29510 29504 Impeller 27592 27593 27592 27593 27592 27593 27592 27593 27594 27594 Motor 29513 29515 29516 29516 Impeller 27594 27594 27488 27489 10.1c 50 Hz Motor and Impeller HP 2.0 2.0 3.0 3.
10.
10.3 Control Panel TRANSFORMER JUMPER TERMINAL BLOCK GROUND BLOCK POWER FILTER (50 Hz ONLY) DIN RAIL FUSE HOLDER END STOP WIRING HARNESS CONTACTOR HEAT SINK USB PORT TRIAC ALERT LIGHT USB INTERFACE USB CABLE PROGRAMMING INTERFACE UPM OVERLAY (BACK SIDE SHOWING) The control panel is shown with door open and without the sheet metal enclosure for clarity. Some variations of the control assembly do not contain all of the components shown.
10.4 Decal Locations and Part Numbers. Some of the decals for a “left hand” unit will be different from a “right hand” unit. The information will be the same, only illustrated according to the direction of the work flow. The decals will also vary due to customer preferences; the part numbers for these decals may be obtained from the Power Soak service department (1-800- 444-9624). 10.
10.
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Appendix PS-225 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 800-444-9624.
Other PS225 Manuals and Related Component Manuals Description Part Number PS225 Operators Manual …………………………………………………. 33755 PS225 Installation Manual ………………………………………………… 34453 AWI (Advanced Wash Insert) Owner’s Manual Supplement ………….. 33754 Wall Chart AWI Installation Instructions …………………………………. 34293 PS225 UPM Programming Manual ……………………………………….
Electric Wiring Diagram – Single Phase 35157 51
Electric Wiring Diagram – 3 Phase 35158 52
AWI Insert Diagram 53
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.