Service Manual PS-275
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Table of Contents Introduction – Section 1 ............................................... 2 1.0 Product Introduction .................................................................................2 1.1 General Description .................................................................................2 Messages – Section 2 ................................................. 3 2.0 Explanation of Warning Messages ...........................................................3 2.1 Danger ......................
5.6 Blue Wash Tank Light ............................................................................12 5.7 Red Sanitizer Tank Light ........................................................................12 5.8 Green Unload/Load Light .......................................................................13 5.9 Deep Cleaning Mode Lights ...................................................................13 5.9a High Wash Fluid Temperature ..............................................................13 5.
8.3a Disassembly .........................................................................................36 8.3b Inspection .............................................................................................36 8.3c Assembly ..............................................................................................36 8.4 Chemical Dispenser (Optional) ..............................................................36 Troubleshooting - Section 9....................................... 37 9.
COPYRIGHT © 2012 METCRAFT INC.
SECTIONS 1, 2 & 3 PS-275 1
Introduction – Section 1 1.0 Product Introduction The Power Soak pot, pan and utensil washing system will provide years of dependable, efficient and trouble-free service. Every system is manufactured to last, with only highquality, heavy-duty, 14 gauge stainless steel used in its construction. All electrical components used in a Power Soak system are of the highest quality. The faucets and drains are designed for quick filling and emptying of the system's tanks.
Messages – Section 2 2.0 Explanation of Warning Messages Be sure to read, understand and follow all DANGER, WARNING, and CAUTION messages located in this document and on the equipment. These messages are used to identify areas of the machine that are harmful. 2.1 Danger Personal Injury and Property Damage hazard. Will result in serious injury or death. Will cause extensive equipment damage 2.2 Warning Property Damage Hazard. Will result in property or equipment damage. 2.
Detergents and Sanitizer – Section 3 3.1 Detergents Power Soak machines require a low-foaming and recommend a metal/aluminum-safe detergent. The detergent should have good grease cutting abilities and pH level that is safe for human contact. Improper detergents may damage the equipment. Use of the correct detergent in the Power Soak PS-275 is critical to its washing performance. If there are problems with cleaning results, please contact Power Soak Systems (1-800444-9624).
Preventative Maintenance - Section 4 PS-275 5
4.0 Maintenance Power Soak machines require minimal preventive maintenance. To ensure that the Power Soak PS-275 remains reliable, the following tasks should be completed at the intervals shown in this section. 4.1 Daily 4.1a Clean the liquid level sensors - The liquid level sensors are located on the side walls of the wash and sanitizer tanks (see section 7.4). They are white plastic discs with metal centers. The faces of the sensors need to be cleaned with a washcloth and soapy water.
Control Panel Lights - Section 5 PS-275 7
5.1 Control Panel Overlay The Control Panel Overlay is bonded to the surface of the enclosure door and conceals the membrane that contains the push buttons and lights. The panel lights are used to indicate conditions that have been detected by the operating program. The lights on the face of the control panel operate in conjunction with the Alert Light System located on the bottom surface of the control box (lights that shine on the floor).
5.
5.3 Green Status Light Off – Power to the machine is turned off or an over temperature situation has occurred. Slow Flashing – “POWER ON” – system is energized and ready to fill the wash tank. Solid Illumination – “OPERATING” – wash tank is full; START button has been pressed, the program is running.
5.5a Error Codes Certain conditions create errors in the program operation. The purple ERROR light on the front of the control panel along with the ERROR CODE light on the UPM will blink in patterns to indicate the source of the error. The definitions for the patterns are as follows: “_“ symbol represents a “long” flash “.” symbol represents a “short” flash 3 long & 1 short 3 long & 2 short 3 long & 3 short 3 long & 4 short 3 long & 5 short _ _ _ . = Liquid Level Error _ _ _ . .
Membrane Error – In the event that one of the control panel buttons sends a constant signal to the UPM, the program will recognize that the membrane is defective and display this error code (see Section 6.9 Push Button Membrane). Please have the “Error Code” information and serial number of the machine available when calling Power Soak Systems for telephone assistance (1-800-444-9624). The machine serial number will be used to identify the configuration of the machine.
5.8 Green Unload/Load Light Flashing – wash period is complete, time to unload the items from the wash tank (press the Load/Unload button to pause the unload timer). Solid – unload timer is paused (press the Load/Unload when the unloading is complete to restart the timer). (NOTE: Proper operation of the Load/Unload button according to the flashing of the green light along with keeping the wash tank continuously operating will extend the wash solution life.
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Control Panel Components - Section 6 Authorized Personnel Only PS-275 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 1-800-444-9624.
6.0 Universal Programming Module (UPM) The Universal Programming Module is located on the inside of the control panel door. To access the UPM, remove the two screws at the top of the control panel door and swing the door down toward the floor. The open door exposes high voltage terminals in the enclosure. DO NOT touch the electrical terminals with hands or tools. PROGRAMMING INTERFACE UPM The UPM has four indicator lights for troubleshooting: POWER ON Light is on when operating.
Identification of the UPM connector terminals is helpful for troubleshooting. Disconnecting the wiring harness connector and conducting voltage or ohm measurements on the terminals in the connector will help determine the condition of the components connected to the wiring harness. The pin numbers are identified on the schematic for determining the component connections. The 24 pin connector for the UPM is identified on the schematic as “J1”.
Tabs To separate the interface unit for mounting, squeeze the tabs on the end of the case and pull on the back edge of the mounting flange. Back edge of the mounting flange Separated for mounting 6.1b Membrane Encoder The membrane encoder is located next to the UPM and is used to translate inputs and outputs between the control panel overlay and the UPM. The ribbon cables from the overlay and a four pin connector routed from the UPM harness plug into the face of the encoder.
6.2 Communication Port A communication port (USB “A” style) is located on the bottom of the control panel enclosure and connected to the UPM by a cable. The connection port is protected by a cover that screws on to the body of the connector. The operating program is loaded into the UPM or copied from the UPM by using this port. Inserting a blank USB Flash Drive into this port will activate the programming module to copy the operating program to the flash drive.
Triacs for 3 phase Heater Control Triacs for 3 phase Motor Control High Voltage Power Connections Low Voltage Gate Connection The connectors are matched to the gate connection according to the location in the wiring harness and the location of the gate connection. Control Box with Triacs for 3 Phase Motor and Heater (Alert Lights are not shown for clarity) Gate Connections Alert Light Connections The unused signal connectors are tied to the wiring harness.
The wiring harness connectors for the Triac gates must be connected to the proper location. The connector location is matched to the gate connection by the location in the wiring harness. The first wire connector exiting the wiring harness will attach to the first gate connection on the heater control Triac. On a single phase machine or when a heating element is not used, the additional Triacs will not be installed and the connectors will be tied to the wiring harness.
6.6 Contactor A mechanical contactor is used to disconnect the high voltage electrical supply from the Triacs when the UPM detects a problem with the pump motor or wash tank heater. The contactor is located on the left side of the mounting plate in the control enclosure. The contactor is defective if there is 20vac-28vac across the coil and the contactor does not pull the center button into the core.
6.8 Fuse Holder, Terminal Blocks and Jumpers A fuse holder with a 1 amp fuse for the 24VAC contactor control circuit and chemical dispenser pump is nested with the terminal blocks. When this fuse is “blown” or not present, the contactor will not connect the high voltage electricity to the pump motor or heater. The fuse is accessed by pulling out on the tab at the top edge of the fuse holder. The electrical supply wires are to be connected to the terminal blocks.
6.9 Push Button Membrane The buttons and lights on the front of the control panel are made into a plastic membrane that is sandwiched between the plastic overlay and the sheet metal face of the enclosure cover. Multiple “ribbon cables” attach to the buttons and lights. The ribbon cables fit through a slot in the sheet metal door on the control panel and the cables pug into the Membrane Encoder (see section 6.1b) to allow the buttons to signal the UPM for the Start, Stop and Unload functions.
Electrical Components - Section 7 Authorized Personnel Only PS-275 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 1-800-444-9624.
7.1 Pump Motor The pump motor is bolted to a mounting plate that is attached to the pump housing. The pump impeller is attached directly to the motor shaft. A rotary joint seal is used to separate the water containment area from the front of the motor (see section 8.1 for assembly instructions). The pump impeller and motor must rotate smoothly without “dragging” anywhere in the rotation.
extending out of conduit fitting). The device should read less than one ohm when closed. Check each wire for a “short” between the wire and the system ground connection. A “short to ground” from either side of the Thermo-disc indicates that the Thermo-disc is defective. These conditions will keep the UPM from operating correctly. On some motors, the Thermo-disc is built in to the motor, which is not replaceable. On other motor styles, it is located in the wiring box of the Motor, which is replaceable.
There are three heating coils within one element and each heating coil has two wires to connect the coil to the electrical circuit. The wires for a single coil are directly across from each other on the longest dimension of the mounting plate. Longest Dimension ROUND ROD STYLE HEATING ELEMENT FLAT BAR STYLE HEATING ELEMENT (Note: flat bar style has three elements inside the flat bar) These two wires are part of the same heating coil on both the round rod style and the flat bar style.
7.4 Heating Element Thermo-disc The Heater Thermo-disc is a devise used to detect a high temperature created by the heating element. If the temperature at the Thermo-disc reaches 135°F, the disc opens, turning off power to the UPM. The Thermo-disc is located close to the Heater, inside the Sensor Pad (see section 8.3 for Sensor Pad) or on the mounting flange of the heating element.
7.6 Liquid Level Sensors There are two Liquid Level Sensors in the side wall of the wash tank, and two in the side wall of the sanitize tank (if equipped with a sanitize tank). The sensor located at the bottom of the tank is used to detect when the tank has been drained and the sensor at the top of the tank is used to determine when the tank is full. To check operation, unplug the white connector from the UPM.
Assembly Procedures - Section 8 Authorized Personnel Only PS-275 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 1-800-444-9624.
8.1 Motor and Pump 8.1a Disassembly – Turn off the electrical power to the machine at the circuit breaker in the wall mounted enclosure and drain the wash tank. To service the pump or motor the wash tank must be empty. Refer to the illustration in Section 10.1for the following description: Remove the Nuts (15) holding the Adapter Plate (13) with a 9/16 wrench, and then slide the adapter plate and motor assembly off the studs.
8.1c Assembly – Refer to the illustration in Section 10.1for the following description: Apply a thin coating of light weight oil such as WD-40 to the outer surface of the Mechanical Seal base (10) and push the base into the Adapter Plate (13) with the white surface of the base oriented to the pump side.
Wipe the faces of the mechanical seal parts so that they are free of debris and slide the shaft sleeve assembly onto the motor shaft so that the protruding ceramic face of the mechanical seal makes contact with the white face of the seal base. Place the Shaft Seal (8) into the groove on the end of the Shaft Sleeve (9). Insert the Impeller Key (7) into the motor shaft with the flat side of the key oriented toward the bottom of the motor keyway.
8.2c Assembly – Place the gasket on the bottom surface of the heating element mounting plate. Insert the heating element though the opening in the back wall of the wash tank. Push the wires through the center opening and align the studs with the mounting holes on the bottom surface of the tank. Install the nuts on outside surface of the tank to secure the heating element to the bottom of the tank.
8.3 Sensor Pad 8.3a Disassembly - To access the contents of the Sensor Pad, unbolt the mounting bracket that holds the sensor pad and remove the sensor pad from the back side of the wash tank. Lift the retainer plate out of the rubber pad and then remove the electrical components. Thermistor Heat sink compound is used on these faces Thermo-disc Retainer plate The sensor pad is located on the back side of the wash tank Sensor pad removed from wash tank. 8.
Troubleshooting - Section 9 PS-275 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 800-444-9624.
9.1 The pump will not start when the green “START” button is pushed. 9.1a. Control panel white POWER light is not on. Possible Cause 1. The power supply to the machine is turned off. 2. The transformer has failed. Solution 1. Restore power to the machine; check the circuit breaker in the wall mounted enclosure. 2. Check the transformer output (see section 6.5) 9.1b. Control panel white POWER light is on. Possible Cause The Wash Tank is empty.
9.1d. Control panel STATUS light and ERROR are blinking with a pattern of long and short flashes. Possible Cause A problem has been detected by the program and the UPM is signaling an error code. Solution See section 5.5a to determine the error message. 9.1e. All of the lights on the control panel and all of the Alert Lights are flashing. Possible Cause The transformer output voltage is below an acceptable level. Solution 1. Check the voltage on the transformer (see section 6.5). 2.
9.3 Motor starts, but no water flows in the wash tank. Possible Cause 1. The key that drives the impeller has fallen out of the motor shaft keyway. 2. The pump impeller is broken or not connected to the motor shaft. 3. The motor is rotating the in the wrong direction (only occurs when motor is first installed or replaced). Solution 1.& 2. Turn off the power to the machine at the circuit breaker in the wall mounted electrical enclosure and remove the motor assembly (see sections 7.1 & 8.1). 3.
9.6 The water gets too hot and stops the machine. Possible Cause 1. Incorrect soap is creating too much foam. (Foam causes excess heat by reducing the efficiency of the pump and it insulates the top of the tank which holds in heat). 2. The Triac has failed and is passing current to the heater when it is turned off. Solution 1. Change the wash solution and use a low foaming soap designed for continuous ware washing or reduce the quantity of low foaming soap that is added to the water. 2.
Parts Lists – Section 10 PS-275 42
10.1 Motor and Pump Assembly The part numbers for the Volute (1), Impeller (6) and Motor (16) are different for the different configurations of machines. Contact the Power Soak Service Department (1-800-444-9624) and provide the serial number of the machine for help with the part numbers. 10.
10.1b 60 Hz Motor and Impeller HP 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 3.0 3.0 Side LH RH LH RH LH RH LH RH LH/RH LH/RH Phase 1 1 1 1 3 3 3 3 3 3 Volt 208 208 230 230 208 208 230/460 230/460 208 230/460 Motor 29507 29507 29501 29501 29509 29509 29503 29503 29510 29504 Impeller 27592 27593 27592 27593 27592 27593 27592 27593 27594 27594 Motor 29513 29515 29516 29516 Impeller 27594 27594 27488 27489 10.1c 50 Hz Motor and Impeller HP 2.0 2.0 3.0 3.
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JUMPER 10.3 Control Panel TERMINAL BLOCK TRANSFORMER GROUND BLOCK FUSE HOLDER DIN RAIL CONTACTOR END STOP USB PORT WIRING HARNESS HEAT SINK ALERT LIGHT TRIAC USB CABLE PROGRAMMING INTERFACE UPM USB INTERFACE MEMBRANE ENCODER The control panel is shown without the sheet metal enclosure for clarity. Some variations of the control assembly do not contain all of the components shown.
10.4 Decal Locations and Part Numbers. Some of the decals for a “left hand” unit will be different from a “right hand” unit. The information will be the same, only illustrated according to the direction of the work flow. The decals will also vary due to customer preferences; the part numbers for these decals may be obtained from the Power Soak service department (1-800- 444-9624). 10.
10.
Appendix PS-275 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel. DO NOT attempt to do these procedures without proper training. To obtain information for a recommended service agent, please call the Power Soak Service Department at 800-444-9624.
Other PS-275 Manuals and Related Component Manuals Description Part Number PS-275 Operators Manual …………………………………………………. 36212 PS-225 & PS-275 Installation Manual …………….……………………… 34453 AWI (Advanced Wash Insert) Owner’s Manual Supplement ……….….. 33754 Wall Chart AWI Installation Instructions ………………………….………. 34293 PS-275 UPM Programming Manual ………………………..…….……….
Electric Wiring Diagram – Single Phase 51
Electric Wiring Diagram – 3 Phase 52
AWI Insert Diagram 53
Power Soak is a registered trademark of Cantrell Industries, Inc. The Power Soak Design and concept is fully patented. Power Soak Systems. Inc. 903 East 104th Street, Suite 130 Kansas City, MO 64131 Phone (816) 222-2400 Fax (816) 222-2419 (800) 444-9624 www.powersoak.
