Owner’s Manual
Table of Contents Product Introduction Page 3 Explanation of Warning Messages Page 4 Danger Warning Chemical Hazard Personal Injury Requirements for Detergents and Sanitizers Page 5 Detergents Sanitizers Factory Assistance Operating Instructions Pages 6-8 Filling The System Rinse Water Sanitizer Water Adding Detergents and Sanitizers Manual Dispensing Auto Dispensing Wash Cycle Controls & Features Pages 9-14 Starting and Stopping the Wash Action Introducing Pots and Pans to the Power Soak Prope
Table of Contents - Continued Preventive Maintenance Pages 15-16 Troubleshooting Pages 17-21 Routine Preventive Maintenance Daily Monthly Notes Facility Owner/Manager Section Authorized Service Agency Section Component Operation & Checks Pages 22-30 Parts List Pages 31-32 Electrical Schematic Page 33 Pump and Motor Assembly Pages 34-38 Installation Pages 39-40 Electrical Requirements Providing Proper Electrical Service Plumbing Requirements Notes 2
Product Introduction Thank you for purchasing a Power Soak ware washing system. Your new Power Soak pot, pan and utensil washing system will provide years of dependable, efficient and trouble-free service. As a Power Soak owner, you will benefit in numerous ways: • • • • • Your ware washing operation will be more efficient. Pots, pans and utensils will be cleaner. The overall level of sanitation in your scullery area will improve. Ware washing hours will decrease as employee morale increases.
Explanation of Warning Messages Be sure to 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 or 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.
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Requirements for Detergents and Sanitizers Detergents Remember, improper detergents may damage equipment! Use of the correct detergent in your Power Soak system is critical to its washing performance. If you are having problems with cleaning results, please contact the factory. Your new system requires a low-foaming, metal/aluminum-safe detergent that is safe for the hands. The detergent should have good grease cutting abilities but not have an excessively high pH level.
Operating Instructions 7
Preparing the System Filling the System At the beginning of each day or shift, fill the sinks with water that is metered to approximately the correct operating temperatures: • • • Wash sink (115°F / 48°C) Rinse sink (75°F / 24°C) Sanitizer sink (75°F / 24°C) All sinks should be filled to, but not above, the “waterline” marks. Fill the wash sink (the sink with the water jets) with water that is approximately 115°F / 48°C.
Adding Detergents & Sanitizers Manual Chemical Dispensing After the sinks have been filled with water, add the proper amount of detergent and sanitizer. The detergent goes into the wash sink (the sink with the water jets) and the sanitizer goes into the sanitizer sink (the last sink). Be sure to add the proper amount of chemicals to each sink. The amount to be used should be provided by your chemical supplier. Do not add the detergent or sanitizer to the sink prior to or during filling.
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Controls and Features Start Button (green) Starts the washing action and starts the timer. Your Power Soak sink will run for four hours after this button is pressed. Stop Button (red) Stops the washing action and resets the timer. Heat Switch (black on/off switch) Turns on power to the heat control. The heat control measures the water temperature and decides whether to heat the water more. Digital Display (heat control) Not visible on all models. Shows you the current temperature of the water.
Controls and Features - Continued Starting and stopping the wash action To start the wash action, press the green “START” button. A strong “rolling” wash action should be present. To stop the wash action, press the red “STOP” button. Introducing Pots and Pans to the PowerSoak Dirty pots and pans should be brought to the Power Soak in a timely manner. Do not allow items to sit and air dry.
Controls and Features - Continued Loading and Using the Wash Sink The Power Soak is a “random loading” system. This means that Power Soak items are not racked for washing. Instead, they are randomly loaded one at a time. As items are brought to the system and scrapped, they should be immediately dropped into the wash sink. If there is no movement of items in the wash sink, or if items are stationary above the waterline, the system has been overloaded and some items must be removed.
13 Controls & Features - Continued Loading and Washing Utensils Each Power Soak system comes with a utensil basket that hangs in the wash sink. All utensils and other small wares should be loaded into and washed inside this basket. Do not wash knives or other sharp objects in the Power Soak. Doing so may cause bodily injury. Unloading the Wash Sink The employee responsible for pot washing should routinely pass by the Power Soak and remove clean items from the wash sink.
14 Controls & Features - Continued Rinsing Pots and Pans Clean items that have been removed from the wash sink should be thoroughly rinsed. This is achieved by spraying them off or dipping them in the rinse sink (center). It is important that any remaining detergent residue is removed from the items prior to sanitizing. If items are rinsed by the "dipping" method, it is important to keep the water "fresh" by frequently draining and filling the rinse sink.
15 Controls & Features - Continued Deep Cleaning and "Night Washing" Extremely soiled items and pieces of cooking equipment that require regular, intensive cleaning can be washed in the Power Soak system overnight. Load the items to be deep cleaned into the Power Soak' s wash sink, turn the system on and leave it running overnight.
Preventive Maintenance Your system requires 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.
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Troubleshooting 19
Facility Owner/Manager Section The only troubleshooting procedure that the facility owner or manager can perform is listed immediately below. All other procedures must be performed by an authorized service agency. To obtain the name of a recommended service agent in your area, please call the Metcraft, Inc. Power Soak Service Department at 800-444-9624. Pump and Heater do not work Please perform the following in order: • Drain the sink. • Turn off the circuit breaker for your sink.
Authorized Service Agency Section Hazard to untrained or unauthorized personnel. The following procedures are provided for use only 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 Metcraft, Inc. Power Soak Service Department at 800-444-9624.
Authorized Service Agency Section - Continued Heater works – Pump does not work Look For Correction 1 Tripped OVERLOAD Push red RESET bar on OVERLOAD 2 Loose wires Tighten wires 3 Defective START or STOP switch Check and replace as necessary 4 Defective CONTACTOR/OVERLOAD Check and replace as necessary 5 TIMER settings incorrect Check – See page 24 6 Defective TIMER Check and replace as necessary 7 Defective PUMP MOTOR Check and replace as necessary Overload trips Look For 1 Low voltage to u
Authorized Service Agency Section - Continued Pump works – Heater does not work Look For Correction 1 Loose wires Tighten wires 2 Defective SWITCH Check and replace as necessary 3 Defective HEAT ELEMENT Check and replace as necessary 4 Defective HEAT CONTROL Check and replace as necessary 5 Defective THERMOCOUPLE Check and replace as necessary 6 Defective HEAT CONTACTOR Check and replace as necessary Intermittent running Look For 1 See 2,5,6,7 under Pump and Heater do not work 2 See 5, 6 under
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. Heater Contactor If there is 208v-230v across the coil and the contactor does not pull in, the contactor is defective. If there is 208v-230v across terminals L1 and L2 and the contactor is pulled in, but no voltage across terminals T1 and T2, the contactor is defective.
Component Operation and Checks Liquid Level Control and Sensor The liquid level control sends a trickle current (1/1000 amp) out terminal 5 to the liquid level sensor. If there is water in the wash sink, the current passes through it to the wash sink wall and back to the liquid level sensor to terminal 6. On some machines, the wire from terminal 6 is hooked up to a second probe instead of the wash sink wall. Reversing these 2 wires will not affect the operation.
Component Operation and Checks Timer The timer controls how long the pump will run after the "start" push button is pushed in. Two different timers have been used. They function the same but the settings differ. The timer settings should be as follows: MODE RANGE FACE NUMBERS DIAL SETTING ISSC Timer SF HRS 0 through 10 4 IDEC timer D 10H 0 through 1 4 When the "start" push button is pushed, the timer is activated and sends L1 power to terminal A1 on the motor starter/overload.
Component Operation and Checks Pump Contactor The thermal overload can be checked as follows: 1. If there is 208-230v across the coil (terminals A1 and A2) and the contactor does not pull in, the contactor is defective. 2. TURN POWER OFF AT BREAKER PANEL. 3. Remove the wires from terminals T1 and T3 on the thermal overload. 4. Push the contactor closed manually and check for continuity across pump contactor terminals L1 and T1, L2 and T2, L3 and T3.
Component Operation and Checks Heater Controller The heat controller controls the wash tank temperature. On some models, this display is not visible. If the display is visible, the Heat Control is made by either Watlow, or RKC. They function similarly, but are visually different. If the display is not visible, the Heat Control is made by RKC.
Component Operation and Checks Watlow Heater Controller - Continued The Watlow heat controller can be checked as follows: 1. Make sure the heat controller is wired as indicated above. Turn heater on/off selector switch to "on". 2. If the heat controller is displaying any of the above error messages, take the recommended action. If there is no display, go to step 4. If the heat controller is displaying the actual and set temperature, go to step 7. 3. Program the heat controller. See programming on page 28.
Component Operation and Checks Programming the Watlow Heat Controller 1. Push "up" and "down" arrows simultaneously for 5 seconds. The display should read "CnF9”. If not, push the “down” arrow repeatedly until it does. 2. Push and hold the “set” button. The display will read “no”. Change to “YES” by pushing the “up” arrow. Release the “set” button. 3. The display should read "tA9”. If not, push the “up” arrow repeatedly until it does. Push and hold the “set” button.
Component Operation and Checks Programming the Watlow Heat Controller 12. Press the “down” arrow. The display will read "AhY5”. Push and hold the “set” button. The display should read “1”. If not, adjust by pushing the “up” arrow. Release the “set” button. 13. Press the “down” arrow. The display will read "LAT”. Push and hold the “set” button. The display should read “no”. If not, adjust by pushing the “up” arrow. Release the “set” button. 14. Press the “down” arrow. The display will read "5 IL”.
Component Operation and Checks Programming the Watlow Heat Controller 21. Press the “down” arrow. The display will read "P,d”. It may also flash “LO” or “hI”. Push and hold the “set” button. The display should read “no”. If not, adjust by pushing the “up” or “down” arrow. Release the “set” button. 22. Press the “down” arrow. The display will read "Pb h”. It may also flash “LO” or “hI”. Push and hold the “set” button. The display should read “0”. If not, adjust by pushing the “down” arrow.
Component Operation and Checks RKC Heater Controller The set temperature will be shown in the red illuminated display on the top right corner. The actual temperature will be shown in the green illuminated display in the center. The set temperature will then start blinking. You then push the "arrow up" or "arrow down" button to the temperature setting you would like. When finished, press the “set” button again. The range of adjustment is typically 114 to 120 degrees. The RKC heat control is pre-programmed.
Parts List Pump Parts 29501 29507 26572 29743 21356 22446 25976 21884 25975 19345 24463 RS1011 MOTOR-LEESON 2HP 230V MOTOR-LEESON 2HP 208V FAN-BALDOR MOTOR PUMP WITH MOTOR, IMPELLER AND CASING GASKET (W/B 2HP) FRAME ADAPTOR WITH WEAR RING SHAFT SLEEVE SNAP RING IMPELLER IMPELLER KEY GASKET-PUMP CASING (W) SEAL KIT-PUMP PUMP CLEANOUT PLUG Heater Parts 23985 24181 24179 24849 24848 24847 28925 28926 21457 23727 CB1327 21203 18797 23983 23987 23988 GASKET-HEATER BOX ( SERIAL #’S 1000-1349 ) HEATER BOX RIGHT
Parts List - Continued Control Panel Parts 103-052 23949 23894 23895 23896 23727 21458 29444 17394 24223 24224 19885 21473 21472 23579 23580 RS1471 20281 20637 20280 29939 27833 103-020 103-014 SCREW-CONTROL PANEL (2) GASKET-CONTROL PANEL START SWITCH-PUSH BUTTON STOP SWITCH-PUSH BUTTON SWITCH BLOCK-STOP SWITCH BLOCK-START ( SERIAL #S 1026 AND ABOVE ) SWITCH BLOCK-START ( SERIAL #S 1000-1025 ) CONTACTOR-PUMP CONTACTOR-HEATER TIMER SOCKET, TIMER LIQUID LEVEL CONTROL SOCKET, LIQUID LEVEL CONTROL HOLD DOWN CL
Electrical Schematic This schematic reflects the wiring for a RKC heat control, which replaces the Watlow heat control.
Motor and Pump Assembly Exploded view Item 1 2 3 4 5 6 7 8 9 10 * * * * Description Motor, 2 HP, 50 Hz, 1 Ph, 230V Sleeve O-ring Black adapter with wear ring Seat O-ring Shaft sleeve Retaining ring Sleeve gasket Impeller Casing gasket Screw Item 11 12 13 14 15 16 17 18 19 * * * * * * Description Adapter ring Seal seat Sleeve subassembly Impeller key Impeller washer gasket Impeller washer Impeller screw seal Impeller screw Casing * indicates parts included in the seal kit 37
Motor and Pump Assembly Disassembly Procedure 1. Remove casing cap screws, which hold adapter to casing. 2. Pry adapter from casing with pry bar or large screwdriver and remove adapter and motor from casing. 3. Using a suitable holder to keep impeller from turning, remove impeller cap screw washer and gaskets. Be careful not to damage precision surfaces of impeller. 4. Remove impeller and impeller key from shaft. 5.
Motor and Pump Assembly Inspection and Repair of Components With pump wet end disassembled, clean all parts and check for worn or damaged areas. It is seldom economical on these pumps to repair damaged or worn parts. Therefore, when a part is found unusable, it should be replaced. Casing Clean and inspect gasket surfaces for damaged areas that would cause leaks. Check wearing ring surfaces for excessive wear.
seal. Anything beyond this will require repairs to the motor, which are beyond the scope of these instructions. Check motor fan and shroud for damage and clean, if necessary. Motor and Pump Assembly Assembly Procedure The PowerSoak pumps are easy to put together. The hardest part, requiring the most care, is installation of the mechanical seal parts. Study the exploded diagram and become familiar with the name of each part.
9. Carefully remove any particles from the lapped face of the carbon washer (part of the mechanical seal) and coat it with clean SAE 10 or SAE 20 oil. DO NOT USE GREASE.
Motor and Pump Assembly Assembly Procedure - Continued 10. Install the mechanical seal on the shaft sleeve by hand. A twisting motion may be needed to make it ride smoothly over the shoulders on the sleeve. Push it by hand until it contacts the seat, make sure the spring and spring holder line up properly. *(see note) 11. Install the snap ring using one hand to hold the snap ring pliers and the other hand to compress the spring.
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Installation Guide The installation and initial operational check of your new system must be performed only by licensed and certified plumbers and electricians. Be sure to follow all applicable national and local electrical codes when installing the electrical supply and/or a new breaker. DO NOT connect the system using a power cord and plug or an extension cord of any kind. Please refer to the detailed installation instructions that were sent with your Power Soak system.
Providing Proper Electrical Service The system is completely pre-wired and tested at the factory, and a hard-wired connection from an appropriate power source junction box is all that is required. The installer is to provide a disconnect that should be incorporated in the fixed wiring. Properly sized watertight conduit, fittings and parts are required, as well as the appropriate gauge wire.
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Power Soak is a registered trademark of Cantrell Industries, Inc. The Power Soak design and concept is fully patented. 13910 Kessler Drive, Grandview, MO 64030 Phone: (816) 761-3250 Fax: (816) 761-0544 (800) 444-9624 www.powersoak.
