K-TRONIC SERIES High Temperature Sanitizing Rack Conveyor Dishwashers (USA Version) OWNER’S INSTALLATION, OPERATION MAINTENANCE MANUAL AND Models: • K-200 • K-200 PW • K-200 LPW • K-400 • K-400 PW • K-400 LPW Meiko • 917 Airpark Center Drive • Nashville, TN 37217 • Phone: (615) 399-6600 • (800) 55-MEIKO • Fax: (615) 399-6620 Rev.
TABLE OF CONTENTS 1. INTRODUCTION ................................. 3 1.1 Overview of Equipment ............................. 3 1.2 General Safety Information........................ 3 2. TRANSPORT AND SHIPPING ............ 4 3. INSTALLATION .................................... 4 3.1 Overview of Installation ............................. 4 3.2 Requirements Before Installation .............. 5 3.3 Uncrating, Positioning and Leveling ............. 6 3.4 Tabling Attachment ....................................
SECTION 1 - INTRODUCTION 1 INTRODUCTION 1.1 Overview of Equipment Meiko K-Tronic series rack conveyors are commercial dishwashers designed for cleaning dishes, glassware, trays, cutlery and kitchen utensils with a minimum of employee intervention or supervision. A control keypad allows easy selection of three different conveyor speeds to accommodate different levels of soiling. A digital display permits easy monitoring of operation. Operation is fully automatic.
SECTION 2 - TRANSPORT AND SHIPPING 2 TRANSPORT AND SHIPPING IMPORTANT • Observe any notices on the crating material that pertain to shipping. • Use care when transporting the equipment. • As you unpack the equipment, check that all components shown on the shipping invoice are present and intact. Be sure to check for shipping damage. If shipping damage is present, call Meiko Customer Service at 1-800-868-3840, providing full details on the customer, serial number and extent of damage present.
SECTION 3 - INSTALLATION • • • • • • • • Routing the ventilation system in accordance with the factory-supplied engineering drawings and all applicable local and national codes. Connecting the water supply. Connecting the electrical supply. Connecting the steam supply line (for machines with steam heating). Connecting the steam condensate return line, and routing it to either a floor drain or a building condensate return line (for machines with steam heating).
SECTION 3 - INSTALLATION 3.3 Uncrating, Positioning and Leveling IMPORTANT Most K-Tronic series machines are shipped in a single section, with wiring and plumbing connections already in place from the factory. The Installation section of this manual describes the installation of these preassembled machines. Due to space limitations at some installation sites, it may be necessary for the machine to be shipped in sections. If this is the case, assembling the sections is outside the scope of this Manual.
SECTION 3 - INSTALLATION Figure 3-2: Removing the end cowling (if required) With cowling removed, set machine into place between tables Gasket Cowling Replace cowling Threaded studs on back of cowling Qty. 16 Reach through rack opening to access acorn nuts and washers 10. Using a spirit level on the conveyor track, check that the appliance is level in both directions (front-to-back AND side-toside).
SECTION 3 - INSTALLATION 3.4 Tabling Attachment • 1. Position the table lip-in at both ends of the machine, as shown in Figure 3-4. Be sure to seat the lip-in against the inner face of the sidewall of the dishwasher. Figure 3-4: Tabling attachment Table lip-in Sidewall of dishwasher 2. Position the dishwasher and tables as follows: • Check that the centerline at the opening of each table is aligned with the centerline of the rack track of the dishwasher.
SECTION 3 - INSTALLATION 3.6 Vent Connection IMPORTANT In some cases, local codes dictate that ventilation connections be made only by a certified HVAC professional. CAUTION All aspects of the ventilation system must be corrosion-resistant, frost-free and protected against freezing temperatures (32°F/0°C or lower). Freezing temperatures inhibit proper operation and can damage internal components. Meiko K-Tronic series warewashers are designed for use with a single-point, indirect ventilation connection.
SECTION 3 - INSTALLATION 3.7 Main Electrical Supply Connection • WARNING! Check that the circuit breaker/fused disconnect is in the OFF position and that the unit is switched off before making the electrical utility connections. IMPORTANT In some cases, local codes dictate that electrical supply connections be made only by a certified professional. 1. Refer to Figure 3-7.
SECTION 3 - INSTALLATION 2. Check that the incoming power leads are of sufficient rating for the appliance’s current draw. Amperage and minimum supply wire specifications are shown on the wiring diagram, the serial plate and the electrical information label(s) next to each terminal block. 3. Remove the top access panel from the control compartment as shown in Figure 3-7. 4. Fit seal-tight fittings or strain reliefs into the holes in the access panel for the electrical supply wires as necessary.
SECTION 3 - INSTALLATION 3.9 Installing an External Solid or Liquid Detergent System 1. Locate the detergent line connection at the load end of the machine. See Figure 3-8. 2. Route the detergent supply line to the opening, completely down the raceway and into the wash tank. Page 12 CAUTION Make sure that the detergent line runs completely down the raceway to the wash tank. The raceway is NOT watertight, and is NOT intended to be a tube for chemicals! 3. Fasten the line in place and seal the connection.
SECTION 3 - INSTALLATION 3.11 Wiring External Chemical Dispensing Systems IMPORTANT Some local codes dictate that electrical connections be made only by a certified professional. 1. Locate the chemical dispenser circuit breakers inside the control box of the machine. See Figure 3-10. 2. Thread the incoming leads from the chemical pumps into the control box and to the chemical dispenser circuit breakers. 3.
SECTION 3 - INSTALLATION 1. Check that iron or other metal particles cannot contaminate the fresh water supplied to the dishwasher. 2. Check the incoming water temperature. • The final rinse line should be approximately 50°F for optimal operation. This water is circulated through the machine’s waste air heat recovery system and routed to the internal booster heater for the final rise to 180°F. • The tank fill line should be 110-140°F to reduce the machine’s preheat time. 3.
SECTION 3 - INSTALLATION 3.15 Drain Connection IMPORTANT In some cases, local codes dictate that drain connections be made only by a certified professional. The machine is equipped with a 2-15/16” (75mm) OD vertical, gravity-fed drain. The machine requires a 4” or larger floor drain. See Figure 3-13. 1. In some cases, a grease trap (supplied by others) must be fitted into the waste water line. If a trap is required for your installation, check that it is present. 2.
SECTION 3 - INSTALLATION 11. As the racks move through the machine, check that they move smoothly without binding and that the wash and rinse arms activate properly. 12. Prime the detergent and rinse aid pumps according to the manufacturer ’s instructions. The chemical installer should check for correct chemical concentration at this time. 13. Allow all racks to exit the machine. 14. Press to shut off the machine. Switch the master circuit breaker/fused disconnect to the OFF position. 15.
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SECTION 4 - OPERATION 4 OPERATION 4.1 Location and Description of Controls The dishwasher controls are on the control box. See Figure 4-1.
SECTION 4 - OPERATION A - POWER ON button Switches the machine on and begins the filling and heating process. B - START OPERATION button Starts the conveyor drive and wash pumps in operation. This button also begins to circulate water through the machine to allow the Waste Air Heat Recovery System to operate. I - LCD Display Provides information about the dishwasher, including operating status, tank temperatures, etc.
SECTION 4 - OPERATION 4.2 Startup Check the level of the external detergent and rinse aid dispensers. If necessary, replace or refill the dispensers. IMPORTANT Note that while the tanks are heated, the final sanitizing rinse (FR) has not yet heated to the correct temperature (180°F minimum). Check that the wash arm manifolds, scrap screens, curtains, and all other removable components are correctly installed in the machine. Press the START OPERATION button to start the wash pumps.
SECTION 4 - OPERATION 4.3 Loading The loading guidelines shown here will lead to faster, more efficient cleaning of your dishware. Ware such as trays, plates and bowls should be loaded into the racks facing front or rear so that the edges enter the machine first. If they are loaded facing the sides (so that the large front or rear faces enter the machine first), they may bind on the curtains or shift in the racks as they touch the curtains. Items should not extend past the edges of the rack.
SECTION 4 - OPERATION 4.4 Operation Operation of the dishwasher is fully automatic. Simply push a rack into the entrance end of the dishwasher until the rack conveyor drive engages. The dishwasher features three conveyor speeds to accommodate varying levels of soiling.
SECTION 4 - OPERATION 4.6 Clearing Jams Under normal operating conditions, racks will not jam as they move through the machine. However, improper loading or improper curtain installation may cause a rack to jam. If the conveyor jams, the ERROR light will begin flashing and the machine will stop operating. To clear a jam: Press the ERROR button to acknowledge the error. The flashing light above the button should turn off. 4.7 Shutdown Check that the last rack has exited the machine.
SECTION 5 - CLEANING 5 CLEANING WARNING! Before ANY cleaning, check that the circuit breaker/fused disconnect is in the OFF position and that the unit is switched off. WARNING! When the front access doors are opened after operation, steam will escape the interior of the machine. WARNING! For your safety, allow the interior of the machine to cool before cleaning. IMPORTANT The headings Daily Cleaning and Weekly Cleaning in this section are general recommendations based on typical soiling.
SECTION 5 - CLEANING Figure 5-1: Daily cleaning disassembly Page 25
SECTION 5 - CLEANING 5.2 Weekly Cleaning (or as required) Once per week, or as required, perform the following steps: • With the scrap screens removed from the machine, remove the wash arm manifolds See Figure 5-2. If the machine is equipped with a prewash section, the arms and manifolds can also be removed at this time. IMPORTANT Upper and lower manifolds are NOT interchangeable. However, some machines may have prewash manifolds that are identical to the wash arm manifolds.
SECTION 5 - CLEANING Figure 5-2: Arm removal Upper manifolds Lower manifolds Push lever up to release manifold Pull manifold out To reinstall, seat the water inlet at the back of the manifold firmly onto the water supply tube. Then, push the front of the manifold up until it snaps into place.
SECTION 5 - CLEANING 5.4 Deliming (as required) Lime scale deposits will occur over time on the interior of the dishwasher if it is operated using a hard water supply. Meiko recommends a hardness of 4 grains per U.S. gallon (7 DH German hardness). A deliming or de-scaling process can be used to remove these deposits, as well as any accumulated food residue. When deliming the interior, be sure to follow these guidelines: • Use deliming agents designed for use with commercial dishwashers.
SECTION 6 - TROUBLESHOOTING 6 TROUBLESHOOTING If the dishwasher encounters a problem, check this Troubleshooting Guide. Some simple problems can be quickly resolved, allowing the dishwasher to be returned to operation faster than placing a service call. Problem Action Machine does not fill • • • • Check that all drain filters are correctly installed and that the drain handles are in the DRAIN CLOSED position. Check that the water supply is turned on.
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If you need service... Meiko warewashers are designed for solid reliability as much as for outstanding ware-cleaning ability. With proper care, your warewasher should provide years of trouble-free operation. If service is necessary, contact your local Meiko Authorized Service Agent. With factory training, OEM parts and direct support from the factory, Meiko’s nationwide service network is highly qualified to quickly restore your warewasher to regular operation.
