SI-100 I-208 I-240 I-480 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 Schematics Pages 33-41 Pump and Motor Assembly Pages 42-46 Installation Pages 47-48 Electrical Requirements Providing Proper Electrical Service Plumbing Requirements Warranty Pages 49-50 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.
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 6
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.
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) Not on all models. 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.
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.
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.
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.
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 17
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 Pump does not work – Heater works 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 does not work - Heater does not work 2
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 20-28v across the coil and the contactor does not pull in, the contactor is defective. If there is line voltage (208-240v, or 480v) between 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 X1 power to terminal A1 on the motor starter/overload.
Component Operation and Checks Pump Contactor/Overload Verify that the contactor/overload has the correct thermal units as shown on the wiring diagram for the horsepower and voltage. Always determine the horsepower from the data plate on the motor. The serial plate may not be correct. It is difficult to see the labeling on some of the terminals.
Component Operation and Checks Transformer Check the transformer as follows: 1. Make sure the wire from fuse 5 is connected to the proper terminal for the incoming voltage. • 208v – H2 • 240v – H3 • 480v – H6 2. Check voltage across terminals H1 and the terminal indicated in step 1. It should read the same as the incoming voltage. If no voltage, check the breaker, fuses, and wiring. Repair as necessary. 3. Check the voltage across terminals X1 and X2. It should be 20-28v.
Component Operation and Checks Heat Controller The 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. If the display is jumbled or incoherent, go to step 3. 3. Program the heat controller.
Component Operation and Checks Programming the Heat Controller Make sure the DIP switch is set correctly. To check the DIP switch, remove the control chassis from the case. Holding each side of the bezel, press in firmly on the side grips until the tabs release. You may have to rock the bezel back and forth several times to release the chassis. Pin 1 should be “OFF”, pin 2 should be “ON” To program, use the "up'and "down" arrows to change settings.
Component Operation and Checks Programming the Heater Controller – Continued ----------------------------------------------------------10 Push mode "100" on top "P L" on bottom ----------------------------------------------------------11 Push mode "nor" on top "dSP" on bottom ---------------------------------------------------------12 Push mode Actual temp on top Set temp on bottom ------------------------------------------------------------If an accurate reference thermometer is available, measure the te
Parts List Pump Parts RS1011 PUMP CLEANOUT PLUG 23503 MOTOR-BALDOR 2HP* 23504 MOTOR-BALDOR 3HP* 26572 FAN-BALDOR MOTOR 24463 SEAL KIT-PUMP (WORTHINGTON) 21356 FRAME ADAPTOR WITH WEAR RING -2HP (WORTHINGTON) 25977 FRAME ADAPTOR WITH WEAR RING -3HP (WORTHINGTON) 22446 SHAFT SLEEVE (WORTHINGTON) 25976 SNAP RING (WORTHINGTON) 21884 IMPELLER-2HP (WORTHINGTON) 5.
Parts List - Continued Control Parts 103-052 20540 RS1456 RS1457 RS1464 RS1465 RS1466 RS1472 RS1473 RS1475 21473 21472 19296 RS1471 20142 20281 RS1467 RS1468 20629 20635 20637 20642 17197 SCREW-CONTROL PANEL (2) GASKET-CONTROL PANEL START SWITCH STOP SWITCH MOTOR CONTACTOR/OVERLOAD TRANSFORMER HEATER CONTACTOR TIMER-PUMP SOCKET-TIMER LIQUID LEVEL CONTROL SOCKET-LIQUID LEVEL CONTROL HOLD DOWN CLIP-LIQUID LEVEL CONTROL QUENCH ARC GROUNDING BLOCK FUSE BLOCK-MAIN FUSE BLOCK-CONTROL CIRCUIT TERMINAL BLOCK (3) E
Electrical Schematic 32
Motor and Pump Assembly Exploded view Item 1 2 3 4 5 6 7 8 9 10 * * * * Description Motor 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 33
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.
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. The diagram shows the relative order of assembly, but also READ THE FOLLOWING INSTRUCTIONS. 1. Make sure all of the parts are clean and ready for assembly. This means no dirt or pieces of old gasket in the joints between the motor, adapter, and casing.
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.
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.
3-Year “NQA” Warranty The Power Soak 3 year “NQA” (No Questions Asked) Warranty is the most powerful in the industry. Every Power Soak system is fully covered for a full three years after shipping. General Warranty Information Metcraft, Inc., certifies that all Power Soak products are free from defects and/ or faulty workmanship. The following warranty and conditions are applicable: Parts & Labor Parts and labor are guaranteed three years from the date of shipment.
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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.
