200 SERIES UPRIGHT DOOR DISHMACHINES TECHNICAL MANUAL INSTALLATION MANUAL FOR EXPORT UNITS SERVICE MANUAL FOR DOMESTIC UNITS ELECTRICALLY HEATED MODELS: 200 200B 200LT STEAM HEATED MODELS: 200S April 19, 2007 P/N 7610-100-45-00 (Revision E) Jackson MSC, LLC. P.O. BOX 1060 HWY. 25E BARBOURVILLE, KY. 40906 PHONE (606) 523-9795 FAX (606) 523-9196 www.jacksonmsc.
REVISION REVISION DATE MADE APPLICABLE BY ECN C 10-30-2000 MAW 5709 Update to current design. D 01-12-2004 MAW 6946 Added 200S model. E 02-10-2006 MAW 7006, 7231 PG. 47 04-19-2007 MAW 7898 DETAILS Changed thermostat bracket from 05700-011-73-72 to 05700-01181-64. Change rinse thermostat from 05930-12-71-29 to 05930510-03-79. Delete thermostat mounting bracket and decal from booster tank assembly. Added False Panel Kit Option.
NOMENCLATURE FOR THE MODELS COVERED IN THIS MANUAL 200 NB 200 = Electrically heated, high temp, hot water sanitizing, no rinse booster, door-type dishmachine 200B = Electrically heated, high temp, hot water sanitizing, with booster heater, door-type dishmachine 200 LT = Electrically heated, low temp, chemical sanitizing, no rinse booster, door-type dishmachine 200 S = Steam heated, high temp, hot water sanitizing, door-type dishmachine Model: Serial No.: Installation Date: Service Rep. Name: Phone No.
TABLE OF CONTENTS SECTION I. DESCRIPTION PAGE SPECIFICATIONS Operating Capacities Dimensions Table Dimensions 2 3 4 INSTALLATION/OPERATION INSTRUCTIONS Installation Instructions Electrical Installation Instructions Detergent Control Operation Instructions 6 7 8 9 III. PREVENTATIVE MAINTENANCE 12 IV. TROUBLESHOOTING SECTION 14 V.
SECTION 1: SPECIFICATION INFORMATION 1
SECTION 1: SPECIFICATION INFORMATION OPERATING CAPACITIES PERFORMANCE/CAPABILITIES ELECTRICAL REQUIREMENTS OPERATING CAPACITY (RACKS/HOUR) WASH PUMP MOTOR HP RACKS PER HOUR DISHES PER HOUR GLASSES PER HOUR 57 1425 1425 NOTE: Typical Electrical Circuit is based upon (1) 125% of the full amperage load of the machine and (2) typical fixedtrip circuit breaker sizes as listed in the NEC 2002 Edition. Local codes may require more stringent protection than what is displayed here.
SECTION 1: SPECIFICATION INFORMATION DIMENSIONS LEGEND: A- Drain 1 1/2” NPT B- Water inlet 3/4” NPT C- Electrical connection D- Standard wall clearance, with dish table 4” E- Model 200B booster tank location D C C A 16 1/8” 40.9 cm 3 1/2” 32” D TOP VIEW CORNER CONVERSION TOP VIEW FRONT 30” 76.2 cm 25 1/4” (64.1 cm) 25 1/4” 64.1 cm 3 3/4” 9.5 cm 15 1/2” 39.4cm 21 1/8” 53.6 cm 75 1/2” 191.7 cm 56 3/4” 144.1 cm 25 1/2” 64.7cm 21 1/8” 53.7 cm 64” 162.6 cm 25 5/16” 64.3 cm E 34” 86.
SECTION 1: SPECIFICATION INFORMATION 4” (10.2 cm) MINIMUM 25 1/4” (64.1 cm) 20 1/2” (52.1 cm) OPENING 2 1/2” (6.4 cm) TABLE DIMENSIONS TABLE DIMENSIONS CORNER INSTALLATION 2 1/2” (6.4 cm) 20 1/2” (52.1 cm) OPENING 4” (10.2 cm) MINIMUM 25 1/4” (64.1 cm) 3/4” (1.9 cm) 1 1/2” (3.81 cm) ROLL TABLE DIMENSIONS CONNECTION TO DISHMACHINE 20 1/2” (52.1 cm) OPENING 25 1/4” (64.1 cm) 4” (10.2 cm) MINIMUM 2 1/2” (6.4 cm) 20 1/2” (52.1 cm) TABLE DIMENSIONS STRAIGHT THROUGH INSTALLATION 25 1/4” (64.
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS 5
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS VISUAL INSPECTION: Before installing the unit, check the container and machine for damage. A damaged container is an indicator that there may be some damage to the machine. If there is damage to both the container and machine, do not throw away the container. The dishmachine has been inspected and packed at the factory and is expected to arrive to you in new, undamaged condition.
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS INSTALLATION INSTRUCTIONS (CONTINUED) Mount all dispensing equipment at back of machine or on adjacent wall. Do not mount equipment on top or front of machine. A fuse block is provided and located at the rear of the control box for electrical power connection and will provide line voltage (208/230V) during sixty (60) second time cycle. Properly rated fuses must be installed into fuse block for power connection.
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS DETERGENT CONTROL Detergent usage and water hardness are two factors that contribute greatly to how efficient your dishmachine will operate. Using detergent in the proper amount can become, in time, a source of substantial savings. A qualified water treatment specialist can tell you what is needed for maximum efficiency from your detergent, but you should still know some basics so you’ll understand what they are talking about.
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS OPERATION INSTRUCTIONS PREPARATION: Before proceeding with the start-up of the unit, verify the following: 1. The pan strainers and pump suction strainer are in place and are clean. 2. The overflow tube and o-ring are installed. 3. That the wash and rinse arm assemblies are secured into place and that their endcaps are tight. The wash and rinse arm assemblies should rotate freely. POWER UP: To energize the unit, turn on the power at the service breaker.
SECTION 2: INSTALLATION/OPERATION INSTRUCTIONS OPERATION INSTRUCTIONS (CONTINUED) SHUTDOWN AND CLEANING: Secure steam flow to the machine in accordance with applicable codes and procedures. Steam flow must be secured prior to cleaning the inside of the machine. At the end of the workday, close the doors. When the unit completes the cycle, turn the power switch to the OFF position and open the doors.
SECTION 3: PREVENTATIVE MAINTENANCE 11
SECTION 3: PREVENTATIVE MAINTENANCE PREVENTATIVE MAINTENANCE The dishmachines covered in this manual are designed to operate with a minimum of interaction with the operator. However, this does not mean that some items will not wear out in time. Jackson highly recommends that any maintenance and repairs not specifically discussed in this manual should be performed by QUALIFIED SERVICE PERSONNEL ONLY.
SECTION 4: TROUBLESHOOTING SECTION 13
SECTION 4: TROUBLESHOOTING SECTION COMMON PROBLEMS WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Problem: Dishmachine will not run. No power to the unit. 1. Service breaker tripped. Reset breaker. If breaker trips again, immediately contact an electrician. 2.
SECTION 4: TROUBLESHOOTING SECTION COMMON PROBLEMS WARNING: Inspection, testing and repair of electrical equipment should only be performed by a qualified service technician. Many of the tests require that the unit have power to it and live electrical components be exposed. USE EXTREME CAUTION WHEN TESTING THE MACHINE. Problem: Water temperature is less than required. 1. Low incoming water temperature. Compare to data plate. 2. No power to heater. Check wiring, replace if necessary. 3.
SECTION 5: SERVICE PROCEDURES 16
SECTION 5: SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT These dishmachines are equipped with electrical solenoid valves to allow for automatic fill and rinse. These valves are designed to specific tolerances and design aspects that must be met in order to function properly.
SECTION 5: SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT (CONTINUED) Loosening the conduit nut 7. Using a pair of channel locks, gently loosen the conduit retaining ring for the conduit nut. Once it is loosened, use your fingers to unscrew and remove it. Prying open the coil wire cover 4. When replacing the coil, ensure that when removing the coil wire cover that care is taken not to damage the wires inside.
SECTION 5: SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT (CONTINUED) Removing the valve bonnet Removing the diaphragm 13. Slowly remove the valve bonnet. Note: The spring for the plunger is located directly under the bonnet and may come free if you are not careful. Remove the plunger, spring and valve bonnet and place to the side. 17. Remove the diaphragm retainer and then the diaphragm itself.
SECTION 5: SERVICE PROCEDURES RINSE SOLENOID VALVE REPAIR PARTS KIT (CONTINUED) 21. With the mesh screen removed, look down into the valve and verify it is not clogged. Remove any foreign objects from the valve body that would obstruct flow. 22. Reassemble the valve, reversing the steps needed to take it apart. Replace defective replacement parts with new parts from ordered kits. Ensure that components are sufficiently tightened to prevent leakage.
SECTION 5: SERVICE PROCEDURES VACUUM BREAKER REPAIR PARTS KIT These dishmachines are equipped with vacuum breakers to serve as back-flow prevention devices. ASSE requirements specify what type of back-flow prevention is necessary on dishmachines. Vacuum breakers, unlike air gaps, have certain parts that have specific tolerances and design aspects that must be met in order to function properly.
SECTION 5: SERVICE PROCEDURES VACUUM BREAKER REPAIR PARTS KIT (CONTINUED) 9. Pick up the cap and examine it. With a soft towel, remove any grit, grime or debris that may have gotten caught in the threads of both the cap retainer or the vacuum breaker body. There is an O-ring that should be present on the cap retainer as well. Regardless of the condition of the plunger, this O-ring should be replaced once the cap is removed. Using a small flathead screwdriver, remove the old O-ring. 10.
SECTION 5: SERVICE PROCEDURES RINSE REGULATING THERMOSTAT REPLACEMENT Many dishmachines comes with integral booster tanks to ensure proper temperature of the final rinse. Jackson has predominantly used two manufacturers of thermostats, EGO and Stemco. These instructions are for use with kit 06401-003-13-94, which is to replace an EGO rinse regulating thermostat with a Stemco brand. Jackson offers all of the repair parts necessary for performing this task.
SECTION 5: SERVICE PROCEDURES RINSE REGULATING THERMOSTAT REPLACEMENT Attaching the jumper wires. 5. Attach the jumper wires to the wires that you removed from the old thermostat. Removing the imperial brass fitting. Sliding imperial fitting onto new thermostat. Pulling the thermostat probe and fitting from the well. 6. Slide the new imperial brass fitting from your kit onto the new thermostat. Putting the new thermostat in the well. Removing the wires from the thermostat.
SECTION 5: SERVICE PROCEDURES RINSE REGULATING THERMOSTAT REPLACEMENT 7. Insert the new thermostat/brass fitting combination into the well and tighten down the brass fitting by hand. Removing the thermostat screws. 10. Use the phillipshead screwdriver to remove the attachment screws on the thermostat for the NORMALLY CLOSED and COMMON points. Tightening the brass fitting. 8.
SECTION 5: SERVICE PROCEDURES RINSE REGULATING THERMOSTAT REPLACEMENT 12. Once both wires are attached, ensure that there is no excess hanging out where it could become pinched by any cover or such. Jackson MSC Inc. provides technical support for all of the dishmachines detailed in this manual. We strongly recommend that you refer to this manual before making a call to our technical support staff.
SECTION 6: PARTS SECTION 27
SECTION 6: PARTS SECTION CONTROL BOX ASSEMBLY 35 25 34 28, 5 USE COPPER 26, 27 22 GND L 3 L 2 L 1 CONDUCTORS ONLY 20, 18 29, 30 21, 23, 24 17 15 2, 25 7, 6 16 14 1 19 3, 4 WASH/RINSE TEMPERATURE 8 10 9 11 12 13 WASH °F 31 Jackson 200 SERIES WASH AUTO OFF OFF RINSE MANUAL MODE MANUAL CYCLE MODE 200 Series Technical Manual 7610-100-45-00 Rev.
SECTION 6: PARTS SECTION CONTROL BOX ASSEMBLY (CONTINUED) ITEM QTY DESCRIPTION Mfg. No.
SECTION 6: PARTS SECTION HOOD ASSEMBLY (SINGLE PIECE WELDMENT) 5 3 2 5 1 6 7, 8 8 4 9 7, 8 6 9 Magnetic Reed Switch 5930-002-36-80 ITEM QTY DESCRIPTION Mfg. No. 1 2 3 4 5 6 7 8 9 1 2 6 1 2 2 2 4 6 Hood, Weldment Bracket, Cantilever Support Wear Button 1/2” Dia.
SECTION 6: PARTS SECTION CANTILEVER ARM/DOOR ASSEMBLIES 2 10, 11, 21 3 1 4 13 18, 23 14 9 11 12 19 20 18, 22 6 15, 16 7 8 18, 24 17, 28, 12 10, 11, 12, 13 3d 3e 3a 3c 3b 3f 200 Series Technical Manual 7610-100-45-00 Rev.
SECTION 6: PARTS SECTION CANTILEVER ARM/DOOR ASSEMBLIES (CONTINUED) ITEM QTY DESCRIPTION Mfg. No.
SECTION 6: PARTS SECTION TUB ASSEMBLY 2a 2 3 5, 10 1* 6 7 8 9, 6 10 2b 29 2c 3 30* 28* 27 26* 18 11 25 12 24* 22, 23 32 13 SEE PAGE ENTITLED “MOTOR ASSEMBLY” 14 15, 16 17 31* 19, 20 21 *SEE PAGE ENTITLED “WASH HEATERS/RINSE HEATERS”. For the 200S, the steam coil assembly replaces the Heater and Gasket. To order the Complete Steam Coil Assembly, use part number 05700-002-08-62. * Take note of quantities/use on 200S units. 200 Series Technical Manual 7610-100-45-00 Rev.
SECTION 6: PARTS SECTION TUB ASSEMBLY (CONTINUED) ITEM QTY DESCRIPTION Mfg. No.
SECTION 6: PARTS SECTION RINSE TANK ASSEMBLY (200B) 2, 3 5 4 6 10 11 1 SEE PAGE ENTITLED “WASH/RINSE HEATERS”. 9 12 8, 7 ITEM QTY DESCRIPTION Mfg. No. 1 2 3 4 5 6 7 8 9 10 11 12 1 2 2 1 1 6 4 4 1 6 1 1 Booster Tank Weldment Locknut, 10-24 with Nylon Insert Washer, #10 S/S Flat Decal, Warning - Disconnect Power Booster Tank Cover Weldment Nut, Hex, 5/16"-18 Washer, 1/4" ID, S/S, Flat Locknut, 1/4"-20 with Nylon Insert Thermostat, Rinse Washer, 5/16” I.D.
SECTION 6: PARTS SECTION WASH HEATERS/RINSE HEATERS The 200 models covered in this manual come supplied with various heaters, depending on the characteristics of the machine.
SECTION 6: PARTS SECTION MOTOR ASSEMBLY The 200 models covered in this manual come supplied with various wash motor assemblies (a wash motor assembly includes the wash motor and the pump end), depending on the characteristics of the machine.
SECTION 6: PARTS SECTION FRAME ASSEMBLY Frame Weldment 05700-001-25-46 Front Panel Assembly with Mounting Hardware 05700-001-25-80 Bullet Foot 05340-108-02-06 Bullet Foot (Option) 05340-002-01-15 200 Series Technical Manual 7610-100-45-00 Rev.
SECTION 6: PARTS SECTION INCOMING FILL PLUMBING/OUTLET PLUMBING 200B INCOMING FILL PLUMBING 200B OUTLET PLUMBING 12 7 10 7 5 8 9 6 200/200LT INCOMING FILL PLUMBING 8 2 11 7 12 3 15 4 1 5 16 When servicing plumbing components, take care not to damage the threads of each individual item. Damaged threads can cause leaks and loss of pressure, which could adversely effect the performance of the Tempstar dishmachine.
SECTION 6: PARTS SECTION INCOMING FILL PLUMBING/OUTLET PLUMBING (CONTINUED) ITEM QTY DESCRIPTION Mfg. No.
SECTION 6: PARTS SECTION 3/4” SOLENOID VALVE & 3/4” NPT VACUUM BREAKER REPAIR PARTS KITS Screw Cap Screw Data Plate Coil & Housing Data Plate Cap Valve Bonnet Spring 06401-003-07-40 Plunger 06401-003-07-40 Diaphragm Retainer Cap Retainer O-Ring O-Ring 06401-003-07-42 Plunger Diaphragm 06401-003-07-42 Components of Repair Kit 06401-003-06-24 Body Screen Retainer Mesh Screen Valve Body Complete Vacuum Breaker Assembly 04820-002-53-77 Complete 24 Volt Solenoid Valve Assembly 04820-100-01-40 Coil
SECTION 6: PARTS SECTION COIL ASSEMBLY (200S) Complete Steam Coil Assembly 05700-002-08-62 Steam Coil Weldment 05700-021-41-38 Stand C, Steam Coil Support 05700-002-08-52 Stand D, Steam Coil Support 05700-002-08-53 Stand B, Steam Coil Support 05700-002-08-51 Stand A, Steam Coil Support 05700-002-08-50 Gasket, Steam Coil 4 per assembly 05700-001-17-86 Washer, Steam Coil 2 per assembly 05700-001-17-87 Adapter, Steam Coil Nut 2 per assembly 05700-011-17-85 200 Series Technical Manual 7610-100-45-00 Rev
SECTION 6: PARTS SECTION INCOMING STEAM PLUMBING ASSEMBLY (200S) To order this complete assembly, use part number 05700-041-42-73.
SECTION 6: PARTS SECTION WASH & RINSE ARM/MANIFOLD ASSEMBLIES Hose, Rinse Manifold Hose 05700-001-26-50 Connects with 2 of the following: Clamp, Hose, 11/16” - 1 1/4” 04730-002-18-40 Hose, Top Manifold Pump 05700-001-22-93 Connects with 1 of the following: Clamp, Hose, 1-5/16” - 2-1/4” 04730-719-01-37 Bottom Wash & Rinse Manifold Assembly 05700-001-25-53 Top Wash & Rinse Manifold Assembly 05700-001-25-52 Manifold Gasket 2 per 05330-500-18-00 Manifold Spanner Nut 05700-001-22-56 200 Series Technical Man
SECTION 6: PARTS SECTION WASH & RINSE ARM/MANIFOLD ASSEMBLIES (CONTINUED) Plunger, Ball 1 per manifold assembly 05315-707-02-00 O-Ring, Rinse Manifold 05330-400-16-00 Wash & RInse Spindle Assembly 05700-031-42-01 EXPLODED VIEW OF WASH & RINSE SPINDLE ASSEMBLY E-Ring External 05340-011-44-76 Rinse Arm Assembly 05700-021-41-98 Wash Head Cap 05700-021-41-92 Qty. 11 Ball Bearing, 1/4” S/S 03110-100-03-24 Qty. 17 Rinse Spindle, Machined 05700-031-41-98 Qty. 26 Qty.
SECTION 6: PARTS SECTION SAFETY DOOR INTERLOCK (SDI) OPTION Safety Door Interlock Box Bottom 05700-001-21-26 Safety Door Interlock Box Cover 05700-001-21-27 Other Safety Door Interlock (SDI) components (not shown): Pipe Clamp (found on the side of the machine) Solenoid, Electrical Interlock Option Relay 05700-000-35-05 04810-100-61-33 05945-109-03-09 200 Series Technical Manual 7610-100-45-00 Rev.
SECTION 6: PARTS SECTION EXHAUST FAN CONTROL OPTION 2” Din Rail 05700-002-36-09 Terminal Board 05940-011-84-41 FAN LOAD ON TIMER OUTPUT 5A, 1/4HP, 240 V AC MAX Kit, Exhaust Fan Control 05700-002-01-74 Decal, Fan Load 09905-003-32-20 Delay Timer 05945-011-65-44 200 Series Technical Manual 7610-100-45-00 Rev.
SECTION 6: PARTS SECTION FALSE PANEL INSTALLATION Front False Panel 05700-001-29-39 Rack rail removed & repositioned for a corner operation. Front False Panel Kit with Hardware 05700-021-30-39 False panel positioned in unit. 1. Loosen the rack assembly from the unit. 2. False panel will mount to the rack; inside the dishmachine. 3. Position panel in unit on side to be closed. 4. Hold panel against side of dishmachine and push up. 5. Panel will clip inside the unit under the edge of the hood. 6.
SECTION 7: ELECTRICAL SCHEMATICS 49
SECTION 7: ELECTRICALSCHEMATICS 200/200B/200LT 208-230-460V, 50/60 HZ, SINGLE & THREE PHASE Dashed White/Blue wire is added for Sani-sure Option. Sani-sure can only be installed on machines with booster option. 9905-105-01-12 200 Series Technical Manual 7610-100-45-00 Rev.
SECTION 7: ELECTRICALSCHEMATICS 200S 208-230-460V, 50/60 HZ, SINGLE & THREE PHASE 200 Series Technical Manual 7610-100-45-00 Rev.