Effective Date: October 7, 2013 American Dish Service MODELS ADC44 & ADC66 CONVEYOR DISHWASHERS SERVICE MANUAL 900 Blake Street Edwardsville, Kansas 66111 (913)-422-3700
IMPORTANT: American Dish Service provides this information as a service to our customers. Keep all instructions for future reference. Although ADS will make every effort to make sure the information in this service manual is correct and up-to-date, ADS does not certify that this is the case, and should you decide to utilize this manual, you do so at your own risk. ADS reserves the right to alter or update this information at any time with out notice.
Table of Contents Page Description 4………........ NSF Data Plate 5………........ Installation Instructions 6………........ Dishtable Requirements 7………........ Dispensers 8………........ Machine Operation 9………........ Motors 9..……........ Motor Replacement 10………...... Hi Temp Design 11…............. Preventive Maintenance 21………...... Conveyor Basic Requirements 22…….......... Conveyor Warranty Statement 23…….......... Bulletins, “Most Common Problems” 36…............. Troubleshooting Guide ILLUSTRATIONS 45………......
ADC-44/-66 COMMERCIAL RACK CONVEYOR DISHMACHINE MANUFACTURED BY AMERICAN DISH SERVICE NSF DATA PLATE NSF Operational Requirements for MODEL ADC-44, Multi-tank, Rack Conveyor Dishmachine as Manufactured by AMERICAN DISH SERVICE Hot Water Sanitizing Final sanitizing rinse minimum temperature: 180° F Pumped rinse tank minimum temperature: 160° F Wash tank minimum temperature: 150° F Final rinse minimum pressure: 20 psi Maximum conveyor speed: 6.8 ft./min.
INSTALLATION INSTRUCTIONS SEE INSTALLATION MANUAL 5
TABLES The greatest source of service calls for conveyor accounts come from incorrect table application. Not all table types are suitable for conveyors. An existing conveyor may have improper tables. The conveyor has no doors and must operate with either side open. Tables are needed to control water flow. Water loss problems are due to improper tables and the placement of sinks and drains. 1. It is recommended that sinks and drains be a minimum of 20” from the edge of the table lip.
DISPENSERS 1. The final rinse manifold has two ports (1/8” IPS, female) provided in the mixing chamber chemical check-valves. The dispenser’s electrical connection points are provided in the control box. There are two signals. For the 44 3-phase, a 208/240v signal labeled RINSE and a 208/240v signal labeled DETERGENT. They are located in the lower left hand area of the control box, as you face the machine.
MACHINE OPERATION After the machine is operational and the tables are cleared, remove all packing material (heater supports) then wash out the tanks, give attention to any installation debris left over. Now, fill the machine by turning on the master switch. The Conveyor will automatically fill with water to an operational level. IMPORTANT: Adjustment of the water diverter plate is required to fill the tanks in proper sequence. It is found inside the hood on the back wall at the top.
MOTORS It is recommended that pump motors be replaced as a unit. This is classified as “pump motor complete, less cover.” The reasoning is as follows: conveyors are generally placed in high volume accounts, which have little space or time for major repairs. The simplest procedure is to remove the four housing bolts, disconnected the electrical connection and replace with a new unit. This can be accomplished without extensive service knowledge and down time for the restaurant.
A round wooden dowel works best for applying even pressure to seat the seal into the housing. The smooth surface will face out toward you; the grooved side will face the housing toward the motor end. Do not put grease or oil on the seal. Inspect the graphite section; make sure there are no cracks or chips on the face of the black graphite or white ceramic. Slide this black part onto the motor shaft (1.5” collar) and install the spring and retainer shield.
ADC-44/-66 Preventive Maintenance Schedule Three General areas must be inspected 1) Sequence switch mechanism in tray track 2) Water control mechanism 3) Conveyor system SEQUENCE SWITCH MECHANISM 1) Free moving 2) 1/16” clearance on pivot bolts 3) Magnet adjustment is approximately 1/16” from tank floor 4) Pump motor will activate only after 1/8-1/4” movement of sequence bar.
AMERICAN DISH SERVICE TECHNICAL SUPPORT MATERIAL Routine and Preventative Maintenance BURNED WIRES Burned wires on a high amperage circuit, occurs when that circuit experiences interference with the transfer of electrons across conductors, connections, points, or terminals. When it is difficult for electricity to pass over or through a material, that restricted flow will heat up the surrounding material.
AMERICAN DISH SERVICE TECHNICAL SUPPORT MATERIAL Routine and Preventative Maintenance Motor Failure Items to inspect to determine the cause of a motor failure: The size wire feeding the machine, are there different sizes used in the distance to the machine. Size breaker for the machine, will it cycle on and off. Is it a new breaker. Is it a clean circuit, no other machines, lights, or motors on this dishmachine circuit.
AMERICAN DISH SERVICE TECHNICAL SUPPORT MATERIAL Routine and Preventative Maintenance POOR or NO HEATING OF WASH TANK ADC 44 Conveyor (11 gallon wash tank) The 12 kW, 208v wash heater in an ADC 44 would normally draw 34 amps on each leg. The factory setting of the thermostat is “on” at 161°F, “off” at 165°F. However, the NSF minimum temperature for the wash tank is 150°F on a multiple tank conveyor (ADC-44/66), so it is permitted to operate at 150°F in high temp sanitizing mode.
6. Curtains missing or open—replace curtains. Long curtains are placed on the ends. The conveyor is an open process because of the two openings; this allows greater disturbance to the energy transfer. 7. Racks washing large trays—trays will divert water out of its tank 8. Washing plastic trays—plastic will act as a heat absorber. Do not wash large plastic trays rack to rack, alternate with glasses, silverware racks so heat is not totally drained out of the water. 9.
AMERICAN DISH SERVICE TECHNICAL SUPPORT MATERIAL Preventative Maintenance QUESTIONS TO EVALUATE OPERATION OF CONVEYOR MACHINES 1. Will the machine fill with water when it is turned on for the first time during a new work period? If it does not fill, is the “ON” light illuminated when the master switch is turned on? If not, the machine will need electrical service. [SERVICE ITEM] 2.
7. If a surging sound is coming from the wash pump, check the pump filter and tank trays. They may be filled with debris. Clean the filters and trays, refill the machine. [OPERATOR ERROR] 8. When racks do not travel completely through the machine, examine the bottom of all the dishracks. If the “ladder” bars are missing or broken, the rack must not be used. The dishrack is part of the conveyor system and must be intact and complete. [OPERATOR ERROR] 9. Chemical supply is provided by the chemical company.
AMERICAN DISH SERVICE TECHNICAL SUPPORT MATERIAL Preventative Maintenance Replacement of ½” water solenoid diaphragm Solenoid valve assembly Remove screw and coil from tube Twist to remove top, RH threads, first close water pressure to valve then twist top Correct plunger placement, spring on top Coil will lift plunger in the tube.
Inspect the gasket in bottom of the plunger It must seal the top of the rivet shown here Turn over the diaphragm inspect near the rivet head A cut or indent would stop sealing on the center ring Remove the o-ring retainer, remove the screen Remove any material or debris from the body. Inspect the center ring for cuts or damage to the surface. If the stainless seat (center ring ) is rough or cut, the valve body must be replaced.
Failure modes Errors are returning a corroded diaphragm to service.
Conveyor Minimum Basic Requirements 1) Table with less then two racks “out” is not recommended. 2) A 90° curved table on the exit side is not recommended unless it is over five racks distance (100”) from the machine. 3) The minimum distance a sink or drain device can be to the entrance side (soil) of the conveyor is 20”. And no such device should be on the clean side. 4) Less then five racks out should have a limit switch installed on the exit table. 5) Incoming rinse water shall be rated 120F at 120 GPH.
AMERICAN DISH SERVICE Limited Warranty Parts and Labor American Dish Service warrants to the original purchaser that its products are free of defects in material and workmanship and agrees to repair or replace, at its option, any parts that prove to be defective within ninety (90) days from date of purchase. American Dish Service may require reasonable proof of your date of purchase. Therefore, you should retain your copy of the invoice or shipping document.
COMMON SERVICE PROBLEMS ADS BULLETIN #02-44 Effective Date 8/94 Rack travel and counting with a timer in CONVEYORS Rack-style conveyors move dishracks across the sprays by the reciprocation of articulating dogs. These dogs push in one direction and fold down in the return direction. They push against the “ladder” on the underside of the dishracks.
ADC-44 Conveyor 120V CONTROL CIR. GN L2 L1 MASTER SWITCH 120V TERM.
ADC-44 Conveyor for 3-phase, 208-240v power 120V CONTROL CIR. GN L3 L2 L1 MASTER SWITCH 120V TERM. BARS TRANSFORMER BLACK WHITE POWER CONNECTION FINAL RINSE RELAY DOOR SW 60 AMP, 6 AWG WIRES III PHASE, 60 HZ PURPLE CLEAN CIRCUIT REQ.
ADC-66 Conveyor for 3-phase, 208-240v power 120V CONTROL CIR. GN L3 L2 L1 MASTER SWITCH 120V TERM. BARS BLACK FINAL RINSE RELAY WHITE POWER CONNECTION 90 AMP, 3 AWG WIRES III PHASE, 60 HZ CLEAN CIRCUIT REQ.
Frequently Asked Questions (ADS Conveyor & High Temp Dishmachines) “What is the dishmachine’s operation—how does it work?” Operation: Be sure all the screen filters, drain stoppers, spray arms, and curtains are put in their correct place. Turn on the master switch located on the side of the control box. The machine will fill automatically. Prepare a rack of soiled dishes and push the rack into the machine.
“Why does the circuit breaker keep tripping after the machine runs for a while?” Circuit breakers become weaker as they are repeatedly tripped or if they are hit by an unusually strong short. Consequently, a breaker can begin ‘nuisance tripping’ and should be replaced. Another cause can be a motor or heater that is getting ready to fail. Wires that have melted and allow current carrying load to come close to the neutral or other phase will trip a breaker. (To verify, take the wires out and separate them.
That is the correct operation for the “water-curtain” pump. The only purpose of the lower spray arm is to rinse off the bottom of the rack so final rinsing can take place more easily. If the lower arm of the water curtain were to spray with higher pressures, the water would layover the top of the tank divider and pump out the water in the rinse tank. This would cause the machine to re-fill, which turns off the heater and takes away the final rinse pressure.
“The conveyor can’t seem to keep up the tank temperatures, can it be fixed?” EVERYTHING TAKES HEAT AWAY. The only thing that will sustain the water temperature in a tank of water being sprayed into the air is the kW in the element itself. All of the following cause cooling of the tank temperatures.
If there is a fault, repairs consist of #1 replacement of the ADS switch (P/N 291-3014 only, similar looking switches will not work), #2 replace the “float” or #3 removing anything that interferes with the rod holding the weight—like buildup inside the protecting tube. With the machine full, test by flipping the lever that pushes against the switch button 5-10 times, should never stick on. If it does, refer to the three repairs above.
When a tap is opened or a valve is opened, it is like taking the knot out of the balloon and all the air is forced out under pressure. This is called flow pressure, the force the balloon can expel when opened. The flow pressure is always lower than the static pressure (when the knot is closed). The larger the opening, the lower the flow pressure.
If the magnets are hanging freely at the 6:00 position and about 1/16” off the bottom, the problem will be a faulty REED SWITCH or misalignment of both magnet and switch. Test by using a large magnet (one strong enough to pick up a screwdriver). Put it up to the reed located on the underneath side of the wash or rinse tanks near the front corners of the machine. If the machine turns off, the switch is okay and the problem will be alignment of the inside magnet and the switch mounted outside.
LEAKS “Why is water leaking out of the pump next to the motor?” It is because of a failed pump shaft seal. The next question is “But I just put a new one in.” It may have been put in dirty, facing the wrong way, or seated improperly in the housing. The seal may have been cracked or chipped prior to or during installation. Use some liquid dish soap to re-assemble, do not use grease or oil. “Why is water spraying out of the door or on to entrance and exit tables?” Check for missing or open spray arm end caps.
“How often do I have to clean out the pump filters, spray arms, or scrap box tray?” They should be cleaned after every meal period “Does the machine need to be turned off at night?” Yes. Always turn off electrical equipment when not in use or when the facility is closed. “Can they wash their floor mats in the dishmachine?” No. The floor mats carry floor bacteria and soils into the dishmachine. This should never be done in a machine used for cleaning public eating utensils.
“Why are black marks showing up on the plates?” There is nothing in the machine that makes black. Carbon black is the source of black specs and comes from grill or hood filter parts. There are professional services that clean these kinds of parts. They should never be clean in a dishwasher. Once the carbon black is inside of the machine, it is costly to remove it. Cleaning hood filters or stove parts in a dishmachine is prohibited by FDA Food Code section 6-501.15.
Unfortunately, you are talking about making a square rack go through a round hole (or bend, it is the same physics). And that one account you’ve seen or heard about will not help you here. It is a matter of the rack turning in the diamond shape when the next rack pushes against it. That is when everything bunches up and comes to a stop—approximately ¾ of the way into the arc.
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American Dish Service Manufacturer of low and high temperature Commercial Dishwashers and Glasswashers 900 Blake Street Edwardsville, Kansas 66111 Ph:(913) 422-3700 Fax:(913) 422-6630 75
