OPERATING & MAINTENANCE MANUAL WASCOMAT FLEX-O-MATIC FL 125 WASCOMAT FLEX-O-MATIC FL 185 471 1562-68/02 96.01 Up to machine No. FL125 -96/28011 FL185 -96/13444 WARNING: ALL OPERATING AND MAINTENANCE PROCEDURES SHOWN ON THE NEXT PAGE OF THIS MANUAL MUST BE FOLLOWED DAILY FOR PROPER OPERATION OF YOUR WASCOMAT MACHINE. PLEASE ENTER THE FOLLOWING INFORMATION AS IT APPEARS ON THE MACHINE(S) DATA PLATE(S).
II NOTICE TO: OWNERS, OPERATORS AND DEALERS OF WASCOMAT MACHINES IMPROPER INSTALLATION AND INADEQUATE MAINTENANCE, POOR HOUSEKEEPING AND WILLFUL NEGLECT OR BYPASSING OF SAFETY DEVICES MAY RESULT IN SERIOUS ACCIDENTS OR INJURY. TO ASSURE THE SAFETY OF CUSTOMERS AND/OR OPERATORS OF YOUR MACHINE, THE FOLLOWING MAINTENANCE CHECKS MUST BE PERFORMED ON A DAILY BASIS. 1.
SAFETY AND WARNINGS SIGNS Replace If Missing Or Illegible One or more of these signs must be affixed on each machine as indicated, when not included as part of the front instruction panel. LOCATED ON THE OPERATING INSTRUCTION SIGN OF THE MACHINE: CAUTION PRECAUCION 1. Do not open washer door until cycle is completed, operating light is off, and wash cylinder has stopped rotating. 1.
FLEX-O-MATIC FL 125, FL 185 Contents Introduction ...................................................................... 1 Technical data .................................................................. 2 Installation ........................................................................ 5 Safety rules .................................................................... 16 Mechanical and electrical design ................................... 17 Procedure for use .........................................
Introduction 1 Introduction The Flex-O-Matic models washer/extractors have been developed to cover the heavy duty requirements of hotels, motels, nursing homes, hospitals, professional laundries, restaurants, airlines, ships, schools, colleges and all on-premises laundries where flexibility and quick formula variation coupled with high quality automatic washing are required. Fig.
2 Technical data Technical data FL 125 Dry load capacity up to 16 kg 35 lbs Overall dimensions Width Depth (at the top) Height Net weight Dyn force 745 mm 910 mm 1196 mm 210 kg 2.4 ± 4.8 kN 29 11/32 in 35 13/16 in 47 3/32 in 462 lbs 576 ± 1192 lbs force Crated dimensions Volume Weight 1,06 m3 222 kg 39 cu.ft 489 lbs Inner drum dimensions Diameter Depth Volume 620 mm 520 mm 157 litre 24 1/2 in 20 1/2 in 5.65 cu.ft Speed of rotation Wash Extraction 52 r.p.m. 500 r.p.m.
Technical data 3 Technical data FL 185 Dry load capacity up to 23 kg 51 lbs Overall dimensions Width Depth (at the top) Height Net weight Dyn force 827 mm 960 mm 1315 mm 264kg 3.1 ± 5.2 kN 32 5/8 in 37 13/16 ın 51 3/4 in 582 lbs 744 ± 1248 lbs force Crated dimensions Volume Weight 1,42 m3 275 kg 50.2 cu.ft. 606 lbs Inner drum Diameter Depth Volume 700 mm 600 mm 230 litre 27 9/16 in 23 5/8 in 8.1 cu.ft Speed of rotation Wash 45 r.p.m. Extraction 455 r.p.m.
Technical data 4 Outline and dimensions FL 125 mm FL 185 inches mm 1196 47 3/32 1315 51 3/4 B 691 C 465 D 600 E 775 F 995 G 60 H 508 J 58 K 205 L 160 M 1040 N 1055 O 100 P 270 R 281 S T U 1135 27 7/32 18 5/16 23 5/8 30 1/2 39 3/16 2 3/8 20 2 9/32 8 1/16 6 9/32 40 15/16 41 17/32 3 15/16 10 5/8 11 1/16 44 11/16 765 540 700 860 1085 60 600 58 205 160 1160 1177 100 260 236 295 1215 1255 30 1/8 21 1/4 27 9/16 33 27/32 42 11/16 2 3/8 23 5/8 2 9/32 8 1/16 6 9/32 45 5/8 46 5/16 3 15/16 10 3/8 9 7/16 1
Installation Installation 5 2 Machine foundation Fig. 2 Fig. 3 Fig. 4 The machines are designed to be bolted in position to a concrete floor or specially prepared concrete foundation. A template showing the size of the foundation and positioning of the foundation bolts is delivered with each machine. For installation on an existing concrete floor, the floor must be at least 8" thick and of good quality.
Installation 6 Mechanical installation Fig. 5 5 • Place wide steel shims on the concrete foundation over the bolts. • Lift the machine and lower it in position. Never use the door or the door handle to lift or lower the machine. Fig. 6 Fig. 7 • Check that the machine is level front-to-rear and side-to-side and standing firmly on the six supporting points. Spacing washers must be mounted if one or more of these points is not resting against the floor/foundation.
Installation Electrical installation Fig. 8 7 8 Although the machines are fitted with a thermal overload in the motor windings and a separate fuse for the control circuit, a separate threephase common-trip circuit breaker must be installed for all three-phase machines. For proper overcurrent protection, check the data plate at the rear of the machine. Also consult local electrical code for special requirements. Fig. 9 Connect L1, L2, L3 and ground wires according to the markings of the terminal block.
Installation 8 Water connection 11 NOTE All plumbing must conform to national and local plumbing codes. Fig. 11 Fig. 12 Incoming water lines do not require non-return or back-suction valves, as the machine is already fitted with a siphon breaker. However, all incoming lines must be fitted with shut-off valves. • Water inlets are labelled for hot and cold water connection. • Flush the water system thoroughly and check that the filter at the machine inlet is fitted correctly. Fig.
Installation Steam connections 9 14 The steam supply to the machine should be fitted with manual shut-off valves and filters to facilitate installation and servicing. Fig. Fit the filter supplied to the manual cut-off valve. 14 The connection hose must be of type ISO/13071983 or equivalent. Connection size at filter: DN 15 (BSP 1/2''). Steam pressure required: • minimum: 10 psi (0.5 kp/cm2) • maximum: 115 psi (8 kp/cm2) Check there are no sharp angles or bends in the connection hose. Fig.
Installation 10 Drain connection Fig. 16 16 Connect a 3" (75 mm) flexible hose to the drain outlet of the machine. The drain hose must not have sharp bends and must slope from the machine to assure proper drainage. The outlet must open freely to the main drains. Do not reduce the size of the drain connection from the machine to the waste line. Start-up and safety checklist Before initial start-up of a Wascomat washerextractor, the following safety checks must be performed: Fig. 17 Fig.
Installation Connection of external liquid supply 11 19 Remove cover and cover support over the soap box. Fig. 19 Fig. 20 Fig. 21 Bend all the way back the metal plate in compartment 3. Pull the knobs up and forward. 1. Loosen both knobs so that one side of the metal fingers underneath can slide under the top lid of the machine, within the supply box. 2. Fit the supply injector into the supply box so that both sides are held securely in places by the metal fingers.
Installation 12 Fig. 22 1. Drop the knop into the larger opening in the supply injector lid. 22 2. Tighten securely. Do not overtighten! Do not use pliers or other tools to tighten the knobs! Fig. 23 1. Stretch the multi-rubber ring B and select the correct size ring which will fit snugly on the chemical tube you are using. Ring A is used for tubes with Ø1/3'' (8 mm). 2. Use scissors or a razor to carefully cut out the proper size rubber ring.
Installation Electrical connection Fig. 24 13 24 At the electrical connection of the machine is one quick connector. When using external supply, disconnect. Pump connection Fig. 25 On the right side of the terminal connection is the connection for pumps. Depending on the number of pumps to be connected, they shall be connected from 1-5 and C (common) on resp. connection. The pumps obtain signals from the program card via the connections.
Installation 14 Before the machine is operated, the door safety interlock must be checked for proper operation as follows: Fig. 26 Fig. 27 26 • When washer loading door is open, the machine must not start. Verify this by attempting to start washer with door open (see section ”Procedure”). • When washer is in operation, the loading door is locked and cannot be opened. Verify this by attempting to open the loading door when the machine is operating.
Installation Function control check-out list 15 28 In the machine cylinder, you will find the warranty registration card, a copy of the warranty policy, the bolt hole template and other pertinent materia. The warranty card should be completed and sent to Wascomat. All other items should be placed in a safe place for future reference. The machine should be cleaned when the installation is completed, and checked out as detailed below without loading the machine with fabrics: 1.
Safety rules 16 Safety rules • This machine is designed for water washing only. • All installation operations are to be carried out by qualified personnel. Licensed personnel are necessary for all electric power wiring. • The interlock of the door must be checked daily for proper operation and must not be bypassed. • All seepage in the system, due to faulty gaskets etc., must be repaired immediately.
Mechanical and electrical design General The door, card programmer, thermometer, thermostates (if heated), control lights and manual switches are located at the front of the machine. All control and indicating components, i.e. relays, level control, etc are assembled under the top cover, easily accessible from the top of the machine for simplified servicing. Main units Fig. 32 1. Control panel. 2. Card programmer for operating the machine through individually programmed cycles. 3.
Mechanical and electrical design 18 Machine construction Panels The machines are equipped with a top panel made of stainless steel. The front panel is available in different colors or in stainless steel. The colored panels are made of phosphatized steel plate. For servicing purposes, the panel can easily be removed. Outer shell Fig. 32 The outer shell is made of heavy gauge surgical steel and is attached to a heavy duty, rigid head casting (back gable).
Mechanical and electrical design 19 Rear gable and bearing Fig. 33 The rear gable and the bearing trunnion housing are constructed of a webbed heavy casting for extra rigidity. There are two neoprene seals to protect from filtration of water. The sleeve bearings are water protected. An intermediate safety outlet provides an escapement for any possible condensation.
Mechanical and electrical design 20 Door, description Fig. 34 The door consists of a backing frame (1), door (2), glass (3) and door gasket (4). The backing frame and door are both made of enameled aluminium. The backing frame is bolted directly to the outer shell of the washing machine.The door hinges are fastened on the outside of the backing frame and the door lock (5) on the inside.
Mechanical and electrical design 21 Control unit Fig. 36 The printed circuit board (1) with push-buttons (2) and control relays (3) are mounted just behind the control panel. The motor relays (4), level controls (5) and the reverser (6) are located at the top of the machine, easily accessible for service. Electrical connections to the components are made by quick-disconnect plugs.
Mechanical and electrical design 22 Relays Fig. 37 37 The Flex-O-Matic models employ four relays. The relays control: • the wash speed (1) • the extract speed (2 • the drain • the re-start 3 1 4 Construction 2 The body of the relay holding the stationary contacts is made of current-resistant plastic. A solenoid and a contact bank hold the moving contacts. The contacts are spring-loaded to assure the correct contact pressure.
Mechanical and electrical design Drive motor 23 39 Description in general Fig. 39 Fig. 40 The motor is mounted on an axle with rubber dampeners. The V-belt is tightened by turning the motor on the axle and locking it in place using the tensioner on the rear side of the motor. The motor and tensioner have vibration and noise dampening rubber suspensions. Construction in general The motor consists of stator, rotor and endshields with ball-bearings.
Mechanical and electrical design 24 Principal wiring and points of measuring on single-phase motors. Fig. 41 The numbers at the connection points refer to the terminal numbers at the motor connector plug. The numbers in circles indicate points of ampere measurements.
Mechanical and electrical design 25 41 FL185 208-240 V 60 Hz single-phase 1730
26 Mechanical and electrical design Motor connections Fig. 1, 2 and 3: wash speed (18-pole winding). 42 4, 5 and 6: extract speed (2-pole winding) 42 7 and 9: motor overload protector. Motor overload protector The motor is equipped with two self-resetting, thermal overload protectors, situated one in each of the windings of the stator. The protectors are connected in series and will trip at a temperature of 120°C (248°F) (3-phase) or 130°C (266°F) (single phase).
Mechanical and electrical design 27 Water level controls Fig. 44 One triple-level pressure switch controls the low and high water levels during various cycles of the washing program, and that there is water in the drum before flushing detergent starts. One double-level pressure switch checks that there is no water in the drum before the door can be opened and does not allow the machine to start extraction with water in the drum.
28 Mechanical and electrical design Rotation guard The rotation guard checks that the drum is completely at a standstill before the door can be opened. When the drum has been still for approx. 2 seconds the coil in the door lock is activated and the lock can be opened (providing the water has emptied and the programmer has reset). This guard also checks that the drum is actually rotating when the wash or extraction relays are operating. Fig.
Mechanical and electrical desing 29 Rotation guard for machines without auxiliary transformer When the machine has halted, the rotation guard relay K1 is closed which means that the door lock coil Y4 will be energised an the door can be opened. Since the wash and extraction relays are not closed, relay K3 is not energised. Fig. 46 When the machine starts and pulses are received from the pulse generator, relay K1 will switch immediately and it will not be possible to open the door.
Mechanical and electrical design 30 Inlet valves 47 Construction Fig. 47 The valve has a single-inlet with either one, two or three outlets, each with its own solenoid. The body is made of heat-resistant polyamid plastic and the solenoids encased in water-tight plastic. A filter screen on the inlet side prevents dirt from entering the valve. Flow restrictors can be placed at either the inlet or any of the outlets. Operation Fig.
Mechanical and electrical design Maintenance instructions 31 49 Limescale can block the hole in the valve diaphragm and interfere with the function of the valve. Fig. 49 It is therefore advisable to dismantle and clean the valve at certain regular intervals. The frequency depends on operating conditions and the level of contamination in the water. Trouble shooting If the valve does not open ventilating hole pilot valve • Check that power is supplied to the coil.
Mechanical and electrical design 32 Inlet valve for FL185 Fig. 53 52 The water inlets have brass bodies with larger cross section of t˛e outlet in order to achieve a shorter filling time for the machine. Construction The valve housing is made of pressed brass. The spring-loaded plunger is made of stain-less steel and located at its lower end is a rubber gasket for the pilot valve.
Mechanical and electrical design 33 Soap supply box Fig. 55 The three-compartment soap supply box is located at the top of the machine. Viewed from the front, the compartments marked with figures 1, 2 and 3 are used as follows: Compartment 1 This compartment is used for adding detergent to the wash at the start of the Soak cycle. Compartment 2 This compartment is used for adding supplies to the wash at the beginning of the Wash cycle. The insert is used to help prevent oversudsing.
Mechanical and electrical design 34 Drain valve 56 Description Fig. 56 The drain valve is operated by using the pressure in the cold water intake. A tube (1) is connected between the cold water intake and a solenoid valve (2). When the solenoid valve is activated, it opens and allows water to flow into the feeder tube (3). The water presses up a piston (4), which uses the pressure lid (5) to close the drain valve rubber membrane.
Procedure for use 35 Procedure for use 57 1728 Control panel Fig. 57 Switches and dials for various functions are located on the control panel whether the machine is controlled manually or via a program card. 1. Switch for manual flushing of detergent from compartment 1. (Powder supply) 2. Switch for cold water filling. 3. Switch for hot water filling. 4. Drain open switch. 5. Switch used to select GENTLE action instead of NORMAL action. Drum stops when the machine is draining and filling. 6.
Procedure for use 36 Preparations 58 NOTE! To be able to open the door, the ON-OFF switch must be in the ON position and the knob on the card programmer in the position O. Sort the laundry according to the categories listed on the control panel. Check washing instructions on garment tags. Empty pockets and close zippers. Press the ON-OFF switch to ON and turn the programmer knob to position O. 0256 59 Open door, put laundry in the machine and close door. Fig.
Procedure for use Soak Fig. 61 37 61 The knob of the card programmer shall be in position O. Fill water manually by pressing the button for cold water until requested level is reached. Programmed stop If ''Stop with signal'' has been programmed, the machine will stop, a buzzer will sound and a light on the RESTART button will come on. Fig. 62 The machine is started again by pressing RESTART. Finishing Fig. 1736 62 Turn the control on the programmer to O.
Procedure for use 38 Manual washing 65 Caution! Fig. 65 To obtain a closed drain during manual washing, an unprogrammed card must be inserted in to the programmer and the control turned to I. Water, filling with detergent and drain Fig. 66 Fill with water by pressing COLD WATER and/or HOT WATER. Use FLUSHING DOWN DETERGENT to flush down the detergent from compartment 1 (pre-wash). Water is drained from the machine with DRAIN. 1740 Extraction 66 A card must be programmed to provide this function.
Card programming Card programming 39 67 General Fig. 67 Programmable cards are used to control the various sequences in a washing cycle. These have 16 ribs with pegs which act on the programmer integral micro-switches. Each rib has its own function. The card is fed through the programmer using mechanically transferred impules from the programmer motor. A function is selected by punching out one or more pegs depending on the amount of time desired. The rib are marked A through Q.
Card programming 40 I - Flushing conditioner from compartment 3. See rib A for programming. If external liquid supply is used, signal is given to connection 5. 68 K - Drain. Punched for either 30 or 60 seconds duration. If followed by extraction, cut for minimum 30 seconds prior to extraction and through the period of extraction. L - Spare M - STOP. Programmed if a signal is desired after completed wash or when it is desirable to stop in mid-cycle for some reason. N - High water level.
Card programming When Cool down is programmed (rib P) the machine is filled with cold water. The amount of time chosen depends on the temperature desired. The cooling rate is approximately 3-4°C/min. Fig. 70 41 70 Extraction Drain before and during extraction Programming Extraction (rib marked H) shall always be preceded by Drain (rib marked K). This shall also be programmed during the entire extract cycle. A. Detergent, (1) B. Heating C. Detergent, (2) D. Heating E. Extern supply F. Extern supply G.
Card programming 42 Main wash Fig. 72 The main wash lasts for approximately 8 minutes and begins by filling with hot water and detergent dispensing from compartment 2 (peg no. 8 in rib C cut away). 72 Draining Washing { The program stops the card at peg no. 8 until the water level is reached. Rib Q is cut away for the entire main wash to ensure that the water level are maintained during the entire wash procedure. The running time once the required level have been reached is 6 minutes (peg nos.
Card programming Rinse cycle 4 Fig. 74 Rinse cycle 4 lasts for 8 minutes and begins with Filling water to high water level and dispensing of fabric conditioner from compartment 3 (peg no. 33 in ribs N, I and O removed). The program stops the card at peg 33 until the water level has been reached. The running time once the water level has been reached is 2 minutes (peg nos. 33 to 36 in ribs N and O cut away). Rinse cycle 4 is concluded with Drain for 6 minutes (peg nos. 37-50 in rib K cut away).
Maintenance 44 Maintenance 75 Preventive maintenance has been reduced to a minimum by the careful design of reliable components and material. However, the following measures should be taken at regular intervals and in proportion to the hours of service. IMPORTANT! Make certain that all electrical power to the machine is shut off before removing top or rear panels. Daily • Check the door lock and interlock before starting operations.
Trouble shooting Trouble shooting 45 77 If the machine does not start Fig. 77 A Check circuit breaker in the power feed line to the machine. B Check the door safety switches. B C Check the glass cartridge fuses. D Check electrical auxiliary contact on extract relay. A C If water does not drain Fig. 78 A Check the drain valve and drain solenoid for proper operation. B Disconnect the drain hose connected to drain line. If full flow of water comes out, the problem is in the main waste line.
Trouble shooting 46 If machine does not extract Fig. 79 79 A Check extract relay and relay coil for proper operation. If motor does not operate at wash speed Fig. 80 A Check wash relay. B Check motor and V-belt. A C Review procedures outlined under section ”If machine does not start” above.
Trouble shooting If machine runs slowly on wash speed or there is a slapping or thumping noise. Fig. 81 47 81 A Replace V-belts If a metallic noise can be heard at rear of machine Fig. 82 A Tighten pulley on motor shaft If the door is leaking Fig. 83 A Check the door gasket. If the gasket is in good condition, install a 4-7 mm rubber O-ring around the entire gasket, using the slits provided.
48 Trouble shooting If there is a leaking around the glass Fig. 84 84 A Replace door gasket if worn. If water does not enter the machine. A Check the valve coils on inlet valves. Fig. B Check wires leading to valve coils. 85 C Be sure manual shut-off valves are in open position.
Trouble shooting If water continues to fill without stopping. Fig. 86 49 86 A Check hose attached to level control unit. B Check inlet valves for dirt underneath the valve diaphragm. To localize, shut off power. If water continues to flow, inlet valves have foreign material in them and should be thoroughly cleaned. A If water continues to flow without filling machine. Fig. A Check seating of drain valve.
Trouble shooting 50 If machine vibrates excessively. Fig. 88 Tighten mounting bolts.
