ILS OPL - Seko Dosing Systems

ILS OPL - Seko Dosing Systems
ILS OPL
Installation and Operating Manual
TABLE OF CONTENTS
Preface ................................................................................. 2
Introduction ......................................................................... 2
Features and Benefits....................................................... 5
Chemical Feed Cycle Example........................................ 6
Specifications....................................................................... 7
Overall System................................................................. 7
Chemical Pumps .............................................................. 7
Transport Pumps.............................................................. 7
ILS OPL Pump Box......................................................... 7
Auxiliary Pump Housings................................................ 7
Transformer ..................................................................... 7
TR-7000-AC Trigger Module.......................................... 8
RS-3000 Formula Select Module..................................... 8
Account Planning................................................................. 8
Laundry Size/Dispenser Components.............................. 8
Washer Performance........................................................ 9
Chemical Compatibility................................................. 10
Equipment Installation....................................................... 10
Unpack Components...................................................... 10
Install the Dispenser Pump Box..................................... 10
Install One Additional Chemical and/or Transport Pump
Inside Pump Box............................................................ 11
Install Auxiliary Pump Housing(s) ................................ 12
Connect Water Supply ................................................... 13
Assign Chemicals to Pumps .......................................... 13
Install Transport Tube to Washers................................. 14
Install BetaLink ............................................................. 14
Install TR-7000-AC Trigger Module(s)......................... 14
Install the RS-3000 Formula Select Module.................. 16
Post Installation Checkup .............................................. 16
Pump and Washer Setup .................................................... 16
Screens........................................................................... 16
Front Panel..................................................................... 17
How to Access and Use the Screens .............................. 18
Pump Setup Mode.......................................................... 18
Washer Setup Mode....................................................... 22
System Checkout ............................................................... 26
Post Setup ...................................................................... 26
Interrogation Mode ........................................................ 27
Diagnostic Reports......................................................... 28
Status Messages ............................................................. 28
Diagnosing Problems......................................................... 29
Alarms ........................................................................... 29
Troubleshooting............................................................. 30
Error Messages .............................................................. 31
Advanced Troubleshooting............................................ 34
Reports............................................................................... 35
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
Reports Mode.................................................................35
System Setup Report......................................................36
Chemical Use Report .....................................................37
Pump Stored Strip Report ..............................................38
Pump Running Strip Report ...........................................39
Washer Activity Report ................................................. 40
Washer Load ID Setup Report .......................................41
Washer Trigger Setup Report.........................................43
Washer Running Strip Report ........................................46
Washer Stored Strip Report ...........................................47
Washer Cycle Record Report.........................................48
washer Error Cycle Report.............................................49
Washer Production Summary Report.............................50
Maintenance.......................................................................52
Replacements .................................................................52
Service ...........................................................................56
Appendix A. Feed Modes & TR-7000-AC Triggers.........58
Relay Mode....................................................................58
Enhanced Relay Mode ................................................... 58
Formula Mode................................................................59
Latched Formula Mode.................................................. 59
Miele Formula Mode ..................................................... 59
Automatic Mode (Strobed/Strobeless) ........................... 60
Machine On Signal......................................................... 61
Trigger Timing Limits ...................................................62
Appendix B. Pre-Dose Classification Identification ..........62
Introduction to PDCI...................................................... 62
Accumulating Triggers ..................................................62
PDCI Control Codes ...................................................... 63
PDCI Relay Mode..........................................................64
PDCI Formula Mode...................................................... 66
PDCI Automatic Mode ..................................................67
Trigger Timing Limits ...................................................68
Operation with Fewer Triggers ......................................68
Appendix C. Programming the Wash Wheel .....................68
Common (Return) Connections .....................................68
Microprocessor-Controlled Washers..............................68
PDCI Modes................................................................... 69
Relay Mode/Enhanced Relay Mode Washer
Connections....................................................................70
Card and Chart Controlled Washers...............................70
Appendix D. Assembly Drawings......................................71
Parts List & Assembly Drawings...................................71
Appendix E. ILS Max Emulation.......................................74
Notes ..................................................................................76
1
PREFACE
This manual describes how to install, set up, operate and maintain
the ILS OPL Laundry Dispenser. It corresponds to version 3.00 of
the ILS OPL internal software. Some features may be different or
may be absent in older versions of the software. The software
version number is displayed briefly when ILS OPL is first
switched on, and also appears at the bottom of printed reports.
Although every effort has been made to ensure the accuracy of
information conveyed in this document, no guarantee is made.
Material in this manual is subject to change without notice. Manual
revisions will be made on an as needed basis. Special
circumstances involving important design, operation or application
information will be released via Equipment Technical Bulletins.
© Copyright 1996, 1998 by Beta Technology
INTRODUCTION
Do not pump solvents of any kind through this
system without prior consultation with
Technical Services.
ILS OPL was designed to simplify the job of injecting liquid
chemicals into virtually any washer. The initial target application is
the small to medium sized washer and accounts (machines in the
15 to 100 Kg range) in on-premise laundries.
ILS OPL (hereafter called the dispenser) is a state-of-the-art
dispensing system designed to replace L-4000 and L-70000
equipment and target a similar market worldwide. It performs the
same functions as the older systems and provides these
enhancements:
•
Streamlined, smaller footprint at the customer site
•
Simplified washer trigger module (BetaLink) communication
structure
•
More efficient and accurate chemical dispensing
•
Added features for logging and reporting load and chemical
use statistics
•
Multiple washer chemical delivery
•
Flushed chemical capability
•
Modern modular components
•
Easier to install and maintain
•
Flexibility for cost-effective expansion
2
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
EQUIPMENT OVERVIEW
Figure 1. The Dispenser System
Pump Box
The Pump Box includes a break tank, four 0.6 liter/minute
(20 ounce/minute) SnapHead chemical pumps and two transport
pumps. This pump box is suitable for an account consisting of 4
chemicals and 2 washers. One additional chemical pump, and one
additional transport pump may be added to increase capacity to 5
chemicals and 3 washers.
of 8 and the number of washers which may be served to a
maximum of 6.
DF1MF03
Figure 3. Pump Box and 3 Auxiliary Pump Housings
System Capacity
DF1MF02
Figure 2. Pump Box
Auxiliary Pump Housing
Up to three Auxiliary Pump Housings may be connected to the
Pump Box. Each housing can then be fitted with one chemical
pump and/or one transport pump. This expansion option increases
the number of chemicals which may be dispensed to a maximum
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
To visualize the capacity of one dispenser system, refer to
Table 1. As you move down the left column and add
additional equipment, the system capacity increases as shown
in the last column. There is no requirement to add chemical
pumps and transport pumps in equal numbers. A system could
be configured to deliver eight chemicals to two washers, or
four chemicals to six washers.
3
RS-3000 Formula Select Module
The RS-3000 Formula Select Module provides a convenient
means of expanding the formula capability of mechanical
chart type washer controls. This module is mounted at the
washer and allows the operator to select one of 16 different
wash formulas. In addition, the module can provide a means
of cycle identification.
Table 1. Dispenser System Capacity
TR-7000-AC Trigger Module
The TR-7000-AC Trigger Module provides the signal interface
between the washer trigger signals and the dispenser pump box. It
provides high voltage signal isolation by converting the various
washer signals to a low voltage (BetaLink) serial message.
The TR-7000-AC Trigger Module has 7 fully isolated 24 to 240
VAC trigger inputs. The trigger inputs are connected to the module
via a 14-pin connector. A BetaLink cable connects to each
TR-7000-AC through a 5-pin Phoenix connector.
CH1
CH2
TR-7000-AC
+
-
INPUT
CH3
CH4
Figure 5. RS-3000 Formula Select Module
WHT
24
VAC
GRN
+
BETALINK
-
RED
BLK
GND
BRN
+5VDC
WHT
CH5
CH6
ALPHABUS
Tx
RED
Rx
BLK
GND
GRN
CH7
Tx
Rx
ADDRESS
SELECT
DF1MF04
Figure 4. TR-7000-AC Trigger Module
One or two TR-7000-AC Trigger Modules (mounted in a washer)
may be connected to the BetaLink, depending on the number of
chemical triggers needed and the amount of data logging desired.
The individual trigger modules are electronically differentiated via
their unique address switch setting.
4
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
FEATURES AND BENEFITS
Tables 2a and 2b highlights the dispenser features and benefits
and describes its technology.
Table 2a. Dispenser Features
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
5
Feature
Formula Triggering
Data Logging
Pre-Dose Classification
Identification (PDCI)
Printed Reports
Status and Error
Messages
Self Diagnostics
BetaLink
Feed Priority Setting
Description
Benefit
• Chemical Dosing Options
Suitable for All Washer Types
• System Diagnosis Information
• Management Use Information
• Simplified cycle logging
• System Diagnosis Records
• Laundry Management Records
Powerful triggering modes allow complete flexibility in
formula creation. Complex injections can be triggered
by single signals. Expands dosing capabilities for
machines with limited trigger options.
Depending on the configuration, options include load
counting, machine on time, turnaround and excess
time, total chemical use, cycle identification and
chemical use by classification.
Coded chemical triggers allow the washer to identify
wash classifications, for accurate cycle logging with
no need for a formula selector module or a machine
on signal.
Complete printouts of wash aisle activity for
management use, system setup, normal service and
troubleshooting.
A wide range of status and error messages keep the
operator informed of performance. Error messages
can activate an alarm and alert the operator to
problems such as an empty chemical drum.
• Uniform Quality
• Improved Wash Aisle
Performance
• Display of Alarm Conditions
The system continually monitors itself for malfunction
and immediately activates an alarm and displays an
error message if a problem occurs.
• Simple Installation
Communication between the remote pump box and
the washer and trigger modules is via an RS-485
5-wire BetaLink communication line. This greatly
simplifies wiring between the washers and pump box.
• Priority Chemical Delivery
One chemical can be high priority. Requests for this
chemical are answered first should other requests be
waiting. If a multiple-feed is in progress, it is
interrupted between chemical injections to allow the
high priority feed.
DF1MT02b
Table 2b. Dispenser Features
CHEMICAL FEED CYCLE EXAMPLE
4.
One chemical feed cycle is described below.
1.
Ready and Polling—The system is always ready to respond to
a chemical feed request from one of the washers. The pump
box continually polls each washer trigger module, monitoring
system status and waiting for a chemical request.
2.
Washer Chemical Request—Chemical supply triggers are
wired from the washer to the trigger module. When a washer
has a chemical feed request, its trigger module issues the
request to the pump box.
3.
Begin Feed Cycle—When the pump box accepts the chemical
feed request, it calculates the amount of chemical requested
based on the setup information for the requesting washer. At
this point, the pump box begins the feed cycle with the
preflush.
6
1208135
Transport flow calibration—The break tank is filled to
the upper limit. The transport pump is then turned on.
The time that it takes to lower the water level to the low
limit switch is measured. This determines the transport
flow baseline.
•
The break tank is refilled.
•
The chemical pump is turned on. The flow rate is
again measured by how long it takes to empty the
break tank. The difference between the two
measurements is computed as the chemical pump's
flow rate.
5.
Continue Feed—The remainder of the chemical is
dispensed.
6.
Reverse Pump—At the end of the chemical feed, the
chemical pump reverses. This draws water back into the
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
7.
8.
9.
chemical tube to reduce chemical attack on the pump tube and
avoid mixing of chemical in the manifold.
Uptake Tube Maximum Length
Monitor Flow—While the chemical pump runs, the Proof of
Flow (POF) cell monitors the conductivity in the manifold to
determine if chemical is actually being pumped. If no
chemical is detected, the chemical pump is run in Auto-prime
mode. If, after thirty seconds, no chemical is detected by the
POF, the Proof of Flow Failed error message is displayed on
the pump box screen. If chemical is detected during the thirty
seconds, the correct amount of chemical is fed.
TRANSPORT PUMPS
Water Flush—The chemical is transported to the washer and
the transport tube is flushed with water.
Ready Again—If there are no additional chemical requests to
this washer, the transport pump shuts off. The dispenser is
ready and polling for another chemical feed.
10. Multiple Chemical Requests from a Washer—If a washer
requests two or more chemicals at the same time, they are sent
through the transport tube separated by a section of water.
11. Multiple Washers Requesting Chemical—The dispenser
serves one washer at a time. If two washers request chemical
at the same time, the dispenser queues the request and will
promote a priority request. All other feeds are handled first-in
first-out (FIFO).
12. Error Messages—Throughout the feed cycle, the dispenser is
continually monitoring itself. If, for any reason, it is not able
to complete a chemical feed, an error message is displayed on
the pump box screen and the pump box alarm relay is set. The
error message tells the operator what corrective actions to
take.
SPECIFICATIONS
3 meters (10 feet)
Type
Diaphragm
Capacity
2.0 liters per minute (0.53 gallons per minute) @ 50 psi
Ambient Operating Temperature
0° - 50 °C (32° - 120 °F)
ILS OPL PUMP BOX
Size
Height
Width
33.02
13.0
55.88
22.0
22.75 cm
11.0 in
Enclosure
Type 304 stainless steel
Weight
16.3 Kg (36 lbs) with 5 chemical pumps and 3 transport
pumps
Power Requirements
24 VAC @ 5.0 Amperes
AUXILIARY PUMP HOUSINGS
Size
Height
Width
33.02
13.0
17.78
7.0
Depth
22.75 cm
11.0 in
Enclosure
OVERALL SYSTEM
Type 304 Stainless Steel
Washers Served
Weight
Up to 6
5.9 Kg (13 lbs)
Chemicals Delivered
Power Requirements
Up to 8
From Pump Box
Maximum Distance from Pump Box to
Washer
TRANSFORMER
Size
50 psi (approximately 61 meters/200 feet)
Height
18.8
7.38
Water Service
•
•
•
Depth
Width
15.6
6.13
Depth
10.8 cm
4.25 in
Enclosure
5 liters per minute (1.3 gallons per minute)
Tempered water may be required for some applications.
Inlet pressure between 0.7 and 5 bar (10 and 70 psi)
Painted Steel
Weight
CHEMICAL PUMPS
5.9 Kg (13 lbs)
Power Rating
Type
Peristaltic (dual roller, spring loaded rollers, self-priming and selfchecking)
0.15 KVA
Capacity
120/240 VAC, 50/60 Hz
0.6 liters per minute (20 ounces per minute)
Primary
Secondary
Pump Squeeze Tube Material
24 VAC
Silicone
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
7
TR-7000-AC TRIGGER MODULE
Size
Height
Width
12.1
4.75
17.2
6.75
Enclosure
Molded Plastic
Depth
Weight
3.8 cm
1.5 in
0.28 Kg (0.6 lbs)
Enclosure
Power Requirements
Molded Plastic
From BetaLink
24 VAC @ 0.05 Amps
Weight
0.3 Kg (0.68 lbs)
ACCOUNT PLANNING
Power Requirements
From BetaLink
24 VAC @ 0.05 Amps
This section gives you some tools in the form of tables to help
you decide which dispenser components to order for your
laundry accounts.
From Triggers
24 to 240 VAC
LAUNDRY SIZE/DISPENSER
COMPONENTS
Trigger Impedance
8.5 K ohms @ 60 Hz, 10.1 K ohms @ 50 Hz
RS-3000 FORMULA SELECT MODULE
Size
Height
12.1
4.75
Width
17.2
7.75
Component
Depth
Use Table 3 to determine the equipment components to order
depending on the size of the account (number of washers,
number of chemicals) and the capabilities needed. This list
does not include spares. Note that the shaded rows indicate
the minimum required components for a single system.
3.8 cm
1.5 in
Provides
Pump Box
4 chemical pumps and 2 transport pumps
Transformer
Voltage Stepdown from 120/240 to 24 VAC
Catalog#
1207746
092066 (U.S.)
Notes
One additional chemical pump
and one additional transport
pump can be added inside the
pump box
One per pump box
067260 (CE)
TR-7000-AC Trigger Module
Kit
See Table 4 for washer system type options
093600
Minimum one per washer
Standpipe Assembly
Tube stiffener for suction tube inside chemical drum
093624
One per chemical
Transport Tubing
Tube that carries chemical from pump box to washer
041778
Length required depends on
distance from washers to pump
box
BetaLink Cable
5-wire cable that connects pump box to the RS-3000
Formula Select Module and the TR-7000-AC Trigger
Module
094479
Length required depends on
distance from washers to pump
box
Chemical Supply Hose
Hose that carries chemical from the drums to the pumps
3/8” – 017256
1/2” – 041971
Length depends on no. of
chemicals and distance from
drums to pumps
RS-3000 Formula Select
Module Kit
See Table 4 for washer system type options
094488
Optional
Mounting Bracket for TR7000-AC Trigger Module
Stainless steel bracket that secures one or two TR-7000AC Trigger Modules
059728
Optional
Auxiliary Pump Housing
Housing for auxiliary chemical and/or transport pumps for
more than 3 washers or more than 5 chemicals
093245
3 maximum
Auxiliary Chemical Pump Kit
Additional chemicals beyond 4
093116
4 maximum
Auxiliary Transport Pump Kit
Additional washers beyond 2
097040
4 maximum
Table 3. Dispenser Components
8
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
WASHER PERFORMANCE
Use Table 4 to determine the modules to order for each washer,
depending on the chemical feed method and data logging desired
(available only if the washer has equivalent signals). In the last
column, the underlined term is the name of the washer system type
you will set during washer setup. Appendix A and Appendix B
describe chemical feed modes and the trigger functions available in
each.
Chemical Feed Method
Data Logging Provided
Wash System Type
(Modules to O rder per
Washer)
Formula Select Module
ILS Max
ILS Max
ILS Max
Formula Select Module
DF1MT04
Table 4. Washer Module Options
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
9
CHEMICAL COMPATIBILITY
7 IN
Although the dispenser accommodates a wide variety of common
and specialized laundry chemicals, there are several product types
that are fundamentally incompatible with flushed type systems.
RAIL 34 IN
PUMP BOX
Any product that thickens or gels when mixed with water may not
be usable. Depending on the degree of thickening, the use of warm
flush water or low chemical pump speeds may allow these
chemicals to be used. Products of this type are typically the
nonionic surfactants, and non-built detergents with anionic and
nonionic surfactants.
EQUIPMENT INSTALLATION
UNPACK COMPONENTS
Inspect the shipping containers for signs of damage and report any
damage to the carrier. All claims for apparent or concealed damage
should be filed with the carrier.
Some accessory components are packed separately. Unpack all the
cartons and verify the contents of the shipment against the packing
list to be sure the shipment is complete.
RAIL 34 IN
OR CUT OFF HERE
RAIL 34 IN
PUMP BOX
DF1MF06
Figure 6. Mounting Rail Configurations
If you are installing on masonry or wood walls, mount the
rails directly to the wall. Secure with 1¦4 inch lag bolts or
similar heavy duty fasteners.
If you are installing on sheetrock walls or irregular surfaces,
you should use a 2-foot strip of 3/4-inch CDX plywood as an
intermediate mounting surface for the pump box components.
Secure the plywood to the studs in at least six places with
1/4-inch or larger lag bolts or similar heavy duty fasteners.
Secure the mounting rail(s) to the plywood.
2.
Secure the mounting rails to the wall. The 34-inch mounting
rail is suitable for mounting any configuration of dispenser.
You may wish to cut off the unused portion of the rail, or
leave it extended for later expansion.
Hang the pump box on the mounting rails. Use the
mounting tabs at the bottom of the pump box to secure it
to the rail and firmly in place.
There is a front panel retaining screw
located inside the enclosure, just below the
lock. This screw must be retracted to allow
the front panel to swing open.
3.
Determine a location for the pump box where the chemical drums
can be easily serviced. For ease of setup and service, mount the
pump box such that the screen is at eye level or slightly higher if
possible.
1.
Connect the power transformer as follows:
•
Connect the transformer to the AC line as shown on
the transformer label.
•
Connect the 24 VAC output from the transformer to
the pump box (see Figure 7).
•
The pump box requires 24 Volts AC at 5 Amps,
provided by the separate 24 Volt stepdown
transformer. The transformer is suitable for 120 or
240 VAC, 50/60 Hz operation.
To avoid noise and reduce the possibility of inadvertent
power interruption, you should provide power to the pump
box from a dedicated, non-interruptible branch circuit. Wiring
must conform to all applicable code requirements. If you
hardwire the transformer to the branch circuit, you should
install a local service disconnect switch.
4.
Connect the POF cable to the POF connector. The cable
is loose below the pump box and the connector is
shipped plugged into the PCB at the lower leftmost
corner (J16).
•
10
1208135
MOUNTING
TABS
PUMP BOX
INSTALL THE DISPENSER PUMP
BOX
The dispenser Pump Box is designed for remote chemical feed and
can be mounted up to 200 feet from the most distant washer
serviced, with a maximum vertical rise of ten feet. Vertical rises
greater than ten feet may require a reduction in the distance
between the washer and pump box. Washers may also be located
below the pump box provided that siphoning of the break tank
does not occur. If siphoning does occur, a siphon breaker or spring
type check valve must be used in each transport line.
AUXILIARY PUMP AUXILIARY PUMP AUXILIARY PUMP
HOUSING
HOUSING
HOUSING
EXTEND EXTRA ON
EITHER SIDE AS SHOWN
Petroleum and solvent-based products are not compatible with the
materials used in the dispenser, and should not be used.
Products that have little or no conductivity may be used, but the
POF and auto-prime functions will not work. Products such as
hydrogen peroxide and mildewcide are among these types of
chemicals. Please see the POF/POD discussion in Pump Setup
Mode for more information.
2 IN
Feed the cable through the opening at the bottom of
the pump box.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
•
Each of the optional auxiliary chemical pumps, as well
as each of the auxiliary transport pump assemblies, are
provided with a modular segment of the manifold
system. Some installation-specific configuration of the
manifold may be necessary.
Remove the connector and attach the 4 colored wires in
the cable to the connector as follows:
Green to 1
Yellow to 2
Blue to 3
You must install the POF cell and filter assembly at the
rightmost end of the last auxiliary pump housing (or the
pump box if there are no auxiliary pump housings), and
plumb it between the last chemical pump and the first
transport pump.
Red to 4
Red and blue are conductivity; yellow and green are
temperature.
POF
CONNECTOR
1
2
3
4
GRN
YEL
BLU
RED
INSTALL ONE ADDITIONAL
CHEMICAL AND/OR TRANSPORT
PUMP INSIDE PUMP BOX
TEMP
COND
For the addition of one chemical and/or one washer to the
dispenser (so the system can dispense up to 5 chemicals to up
to 3 washers), no auxiliary pump housing is required. The
additional pump(s) are housed inside the pump box, as shown
in Figure 8.
DF1M01
•
Reinsert the POF connector into J16 on the PCB.
GR
EARTH
GROUND
POWER
INPUT
FROM
TRANSFORMER
WHT
BLK
POWER IN
ALARM
RELAY
BETALINK
CABLE
TO WASHERS
WHT
GRN
BRN
BLK
RED
CLOSED WHEN CLOSED ALARM
ALARM IS ON WHEN COMMON
OR POWER ALARM
IS OFF IS OFF
BETALINK
ALARM RELAY
TB1
DF1MF07
DF1 F08
Figure 7. Pump Box Terminal Block Connections
5.
6.
Connect external alarm. The pump box includes a Form C
relay that will trigger an external alarm. The relay coil is
energized in the non-alarm state. If power to the pump box
should fail, or any other failure occurs, the relay will switch
and trigger the alarm. This provides a fail-safe power
configuration.
•
Connect the alarm relay on the same barrier strip as the
BetaLink (see Figure 7).
•
Provide power to the alarm relay from an external
source.
To add either a single chemical and/or transport pump inside
the pump box, do one or both of the following procedures.
Use plastic tie wraps to secure all tubing
connections.
Add a Single Additional Chemical Pump
1.
Connect the manifold system after you have secured all pump
box components to the mounting rail. This will make it easier
to position the various components and to determine the
proper cut lengths for the manifold tubing.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Figure 8. Additional Chemical Pump and Transport Pump
(Inside Pump Box
1208135
Remove the plastic filler plate that covers the number 5,
rightmost pump position, and install the additional pump.
(The pump provided in the kit includes a manifold
section.)
11
2.
3.
AUXILIARY PUMP
HOUSING
Disconnect the existing manifold tube from the #4 pump
output tee and connect the manifold section from the new
pump (#5) to the #4 output tee fitting.
ADDITIONAL
TRANSPORT
PUMP
Unless auxiliary housings are to be installed, reconnect the
tube from the filter to the output of the #5 pump. (You may
wish to shorten the tube somewhat to provide for proper tube
routing.)
4.
If you are installing auxiliary housings, remove the POF cell
and filter assembly from the pump box and reinstall it in the
rightmost auxiliary housing.
5.
Wires for the #5 pump are included in the pump box wiring
harness. Connect the blue (common) wire to the lower
terminal of the motor (marked with a red dot), and the
white/brown wire to the upper motor terminal.
PROOF OF
FLOW CELL
ADDITIONAL
CHEMICAL PUMP
FILTER
Add a Single Additional Transport Pump
The Auxiliary Transport Pump Kit includes the pump, mounting
bracket, manifold tube and fittings.
1.
If you have not already done so, open the dropdown front
panel of the pump box.
2.
Disconnect manifold tube from the right side of the inlet tee
of pump #2.
3.
Secure the pump and bracket assembly to the studs located on
the back wall of the pump box using the provided hardware.
You will need a long shaft 1/4” nut driver or 1/4” socket
extension.
4.
Connect the manifold tube from the new pump #3 to the inlet
side of pump #2.
DF1MF09
5.
Unless auxiliary housings are to be installed, reconnect the
tube from the POF cell to the inlet of the #3 pump. (You may
wish to shorten the tube to provide for proper tube routing.)
6.
If you are installing auxiliary pump housings, remove the
POF cell and filter assembly from the pump box and reinstall
it in the rightmost auxiliary housing.
You may add up to three auxiliary pump housings (each of
which can house one auxiliary chemical pump and/or one
auxiliary transport pump).
7.
Wires for the #3 pump are included in the pump box wiring
harness. Connect the yellow wires to the transport pump
leads. Connect the wire with the black stripe to the black
transport pump lead.
The controls, wiring and electrical capacity in the pump box
can accommodate these expansions.
INSTALL AUXILIARY PUMP
HOUSING(S)
Figure 9. Additional Auxiliary Pump Housing
(Next to Pump Box)
Use plastic tie wraps to secure all tubing
connections.
1.
Remove the plugs on the auxiliary pump housing(s)
(except the right side of the rightmost housing) and the
right side of the pump box. Replace the plugs with
bushings.
2.
Hang the auxiliary pump housing(s) to the right of the
pump box on the mounting rail and secure the lower
edge with wall anchors.
3.
Open all auxiliary pump housings. Starting with the
rightmost auxiliary pump housing, thread the wire
harnesses to the pump box through the top bushings of
every auxiliary pump housing, working toward the left.
4.
Plug the wire harnesses into the connectors on the upper
right of the pump box’s PCB. The connection point
determines the pump number of the particular pump. Use
the following connections depending on whether you are
adding one, two or three auxiliary pump housings:
If your system requires more than 5 chemicals, or is serving more
than 3 washers, you will need to install auxiliary pump housings to
accommodate the additional pumps.
12
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
•
Plug the rightmost harness into EXP 3.
•
Plug the second harness (or last of two) into EXP 2.
•
Plug the first (or only) harness into EXP 1.
Connect the water supply to the 3/4” threaded hose fitting at
the pump box. Optionally, you can replace the 3/4” threaded
fitting with the available barb fitting if needed for the water
hose.
Relocate POF Cell and Filter
Water Filter
1.
If not done in a previous step, remove the POF cell and filter
assembly from the pump box and reinstall it in the last
(rightmost) auxiliary pump housing.
2.
Route the POF cable through the bushings along with the
motor wires.
No water filter is required. However, the water supply should
be relatively free of sediment or large particles. High water
hardness or high TDS (total dissolved solids) may affect the
performance of the POF and optional POD functions. Should
these conditions exist, some water preconditioning may be
required for optimum performance.
3.
Reconnect the cable to the POF connector, J16.
Plumb the Auxiliary Chemical Pump
1.
Remove the plastic filler plate that covers the pump mounting
hole.
2.
Install the pump.
3.
Connect the manifold section from the new pump to the
output tee fitting of the previous pump.
4.
If this is the last (rightmost) chemical pump, connect the filter
inlet tube to the output of this pump.
5.
Wires for the pump are included in the auxiliary pump
housing wiring harness. Connect the blue (common) wire to
the lower terminal of the motor (marked with a red dot), and
the green wire to the upper motor terminal.
ASSIGN CHEMICALS TO PUMPS
Plumb the Auxiliary Transport Pump
1.
If not done in a previous step, remove the POF cell and filter
assembly from the pump box and reinstall it in the rightmost
auxiliary pump housing.
2.
Route the POF cable through the bushings along with the
motor wires.
3.
Disconnect the manifold tube from the right side of the inlet
tee of pump to the left of this position.
4.
Secure the pump and bracket assembly to the three studs
located on the back wall of the auxiliary pump housing.
5.
Connect the manifold tube from the new pump to the inlet
side of pump to the left.
6.
If you are not installing more auxiliary pump housings,
reconnect the tube from the POF cell to the inlet of the new
pump.
7.
Wires for the transport pump are included in the auxiliary
pump housing wiring harness. Connect the green and the
yellow wires to the transport pump leads. The yellow wire
connects to the black transport pump lead.
CONNECT WATER SUPPLY
The dispenser requires a water supply with a flow rate of at least 5
liters (1.3 gallons) per minute. Inlet pressure should be between 0.7
and 5 bar (10 and 70 psi). It may be necessary to reduce the inlet
pressure if excess splashing occurs at the break tank.
Normally a cold water supply (but not lower than 5 °C [41 °F]) is
sufficient. However, with some chemicals, a warm or tempered
water flush may be required. Should a warm flush be required,
install a water tempering valve to provide a 40 °C (104 °F) heated
water supply to the system.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Extremely hard water may cause minerals to precipitate on
the various elements of the transport system. This can include
buildup in the manifold, transport pump head, and transport
tube. If this problem persists, you should definitely use water
preconditioning.
1208135
There are no specific requirements for chemical assignment to
a given pump. There is, however, a general convention that
the chemicals be organized in a wash through finish left-toright plan, with the alkali in position 1, detergent in position
2, and so on.
A possible exception may be the location of the sour pump. In
extreme hard water situations, carbonates may precipitate out
in the manifold below certain chemical pumps. To reduce the
carbonate buildup, locate the sour pump at the number one
position, thus allowing the acid to dissolve any buildups.
Refer to the discussion on compatible
chemicals in Account Planning.
Chemical Uptake Lines
Drum Position
Place the chemical drums as close as possible to the pump
box.
Avoid uptake lines longer than 3 meters (10
feet). Greater lengths will prevent the
dispenser from fully auto-priming and
reduce pump tube life.
To avoid confusion and reduce the possibility of misplacing
replacement chemicals, arrange the chemical drums in the
same order as the pump assignment.
Keep the uptake line as short as possible when used with the
thicker products. This will help maximize pump tube life. If
long runs are unavoidable, it may be necessary to utilize a
section of 3/4-inch PVC pipe for segments of the chemical
uptake system.
See Advanced Troubleshooting for a method of manually
priming a new system with large uptake lines.
Standpipes
Optional tube stiffeners (standpipes) are recommended for
each chemical. The standpipe is made of 3¦4 inch PVC plastic
and is long enough to be used in a 205 liter (55 gallon) drum.
The standpipe may be cut to length for smaller drums if
13
desired. Cuts should be made at an angle to prevent suction
problems.
Also included in the standpipe kit are 2 bung caps suitable for use
in 205 liter (55 gallon) drums, and 25 liter (5 gallon) pails.
1.
Provide sufficient BetaLink cable within the washer to
allow for placement of the washer modules in convenient
locations near their respective signal sources.
3.
Select the proper bung cap for your container. Measure and
cut the standpipe to the proper length. (Refer to instructions
provided in the standpipe kit to determine proper length.)
2.
Slide the upper end of the pipe through the hole in the cap
until the cap rests against the plastic tie stop.
3.
Insert the chemical suction tube into the pipe until it protrudes
from the bottom.
4.
Secure the tube in place by tightening the hose clamp (do not
over tighten).
Route additional cable from this washer to subsequent
washers in a chain.
The actual routing may be either a serial
chain, a star distribution, or a combination
of the two. All components will be
connected to the same signals.
4.
To make the BetaLink connections, see Figure 10. Also
please refer to Figure 7 for information on the location
of the terminal block connections, and Table 5 for
washer module address assignments.
For proper shielding, the cable shields
should be connected together at each
module, but should not be connected to
any of the module terminals. The shield is
connected to chassis ground only at the
pump box.
Tubing Size
The chemical uptake suction tube should be 1/2-inch ID. Smaller
diameters will reduce chemical pumping rates and may reduce
pump tube life. Larger diameters may cause erroneous Out of
Chemical alarms due to long priming times, but in some cases may
be desirable if the chemical being pumped is particularly viscous.
INSTALL TRANSPORT TUBE TO
WASHERS
The transport tube should be polyflow LDPE 3/8-inch OD
(1/4-inch ID) for all transport lines. This will ensure that the
optimum transport velocity is maintained.
Use of other than specified tubing may
result in impaired system performance.
1.
Run the transport tube from each transport pump to the
washers.
The leftmost transport pump in the pump box is #1, the next
transport pump in line (left to right) is #2, and so on. Once
connected, washers are numbered the same as their respective
transport pumps. You must remember the washer numbers for
the purpose of assigning washer module addresses and
deciphering logged data and reports.
2.
Arrange the tubing in a safe manner. Do not run tube above
electrical connections and boxes. Provide adequate clearances
near steam pipes and other hot surfaces. Consult local codes
for exact requirements. Avoid sharp bends, as the tubing can
kink.
INSTALL BETALINK
The BetaLink 5-wire cable provides power and communication
throughout the dispenser. All the washers and washer modules are
connected to the BetaLink and, via the BetaLink, to the pump box.
You can connect the washers and modules in any sequence, but
you must observe polarity since the BetaLink is a polarized RS485 communication system.
1.
2.
14
Connect the BetaLink cable to the pump box terminal block
(see Figure 7). Be sure to provide strain relief for the cable
where it passes through the pump box.
Route the 22 gauge 5-conductor cable from the pump box to
the closest washer. Ground the shield at the pump box.
1208135
Figure 10. BetaLink Connections
INSTALL TR-7000-AC TRIGGER
MODULE(S)
One TR-7000-AC Trigger Module is installed at each washer
to provide a high-voltage interface for the chemical supply
triggers.
An optional second TR-7000-AC at a washer expands ILS
OPL’s capabilities to include:
•
Pumping more than 6 chemicals in the standard relay
mode.
•
More than one formula select bit.
•
Monitoring of washer control signals such as drain,
water fill and steam.
There are 7 trigger channels on the TR-7000-AC. These
inputs are electrically isolated from each other and from the
BetaLink.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
The function of each of the triggers (channels 1-7) depends on the
feed mode you select during setup. Appendix A and Appendix B
list the trigger functions for each chemical feed mode.
The dispenser can serve washers previously served by an
L-4000E or L-70000. You can use the Interface Wiring
Diagram Manual (IWDM) to find the triggers to connect
to the TR-7000-AC for Formula Mode. However, follow
the color code shown in Figure 11 instead of using the
terminal strip shown in the IWDM. Pairs 1-5 in Figure
11 equate to the machine triggers in the IWDM.
The TR-7000-AC enclosures are not sealed, so they should be
placed in an area not subjected to hose down or splashing. They
are designed to be mounted within the washer control enclosure, if
possible, but can be mounted externally if necessary.
1.
Install the TR-7000-AC in the washer control cabinet by
securing it to the cabinet side wall with double-sided tape,
Velcro straps or optional bracket. Optionally, mount the TR7000-AC externally using the NEMA enclosure.
TR-7000-AC
CH1
CH2
+
-
INPUT
CH3
CH4
GRN
+
-
CH5
CH6
WHT
24
VAC
BETALINK
RED
BLK
GND
BRN
+5VDC
WHT
Tx
RED
Rx
BLK
GND
GRN
ALPHABUS
CH7
2.
Set each TR-7000-AC address using Table 5. Set the address
with the 16-position switch located at one end of the TR7000-AC. Rotate the switch until the proper address appears
through the switch skirt. (Address 0 disables communication
to the TR-7000-AC.)
Tx
Each TR-7000-AC (and RS-3000) address
must be unique.
BLK
BRN
Washer
Number
TR-7000AC Trigger
Module
nd
Optional 2
TR-7000-AC
Optional RS3000 Formula
Select Module
1
1
2
1
2
3
4
2
3
5
6
3
4
7
8
4
5
9
A
5
6
B
C
6
RED
BLK
ORN
BLK
YEL
BLK
GRN
Alkali
Detergent
Bleach
Sour
Soft
1
2
3
4
5
PAIRS FROM MACHINE TRIGGERS AS IDENTIFIED IN THE
IWD MANUAL, SEE NOTE 1
BLK
BLU
BLK
VIO
Alternate
Formula
Trigger
SEE
NOTE 2
SEE
NOTE 3
Figure 11. TR-7000-AC Wire Harness and L-4000
Equivalents (Formula Mode only)
Note 1
It is not necessary to hardwire two or three
triggers together when using the dispenser
because triggers can be assigned to any pump
or pumps.
Note 2
If you use an alternate formula, connect the
trigger switch to the blue and black pair.
Note 3
If you use a machine on signal, connect the
washer source (which must be on without
interruption during the entire wash cycle) to
the violet and black pair.
0 (Common)
Brown Trigger Channel 1
Red
BLK
L-4000E
TERMINAL BLOCK
SHOWN FOR
REFERENCE
ONLY
Connect the primary TR-7000-AC (at each washer) to the
washer’s supply signal sources. Use the solid colored harness.
The wire colors in the harness correspond to the RETMA
color code, as follows:
Black
ADDRESS
SELECT
L-4000 Supply Trigger Signal Inputs
Table 5. Washer Module Address Assignment
3.
Rx
USE BLACK LEADS
WITH ADJACENT
COLOR LEADS AS A
PAIR TO CONNECT
TO TRIGGERS
Trigger Channel 2
6.
Green
Trigger Channel 5
Blue
Trigger Channel 6
If you are installing a second TR-7000-AC at a washer,
use the striped cable harness and connect the washer
supply signal sources as defined below, depending on
which signals you are using. These signals may require
isolated commons. The wires with the black stripe are
the commons.
Violet
Trigger Channel 7
Drain
Orange Trigger Channel 3
Yellow Trigger Channel 4
For additional information on how to make these connections,
depending on the mode to be used, please refer to Appendix
A and Appendix B.
4.
Tie the commons together as necessary.
5.
The following connection notes apply if you are going to be
using the Formula Mode (see Appendix A and Appendix B)
for this washer.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
Some washers are equipped with two drain
systems—reclaim drain and sewer drain.
Trigger channel 1 (brown stripe wire) is
used for sewer or main drain, and if
required, trigger channel 6 (blue wire) is
used for reuse drain. A chemical feed
request is ignored if the drain is open. If the
drain signal is not used, remember to set
the drain polarity to Normal. See Washer
Setup Mode.
15
DF1MF11
Cold Water Connect the cold water fill valve signal trigger
to channel 2 (red stripe wire). Because the cold
water signal may be used to monitor the actual
time that the water valve is open, make the
connection to a point in the washer circuit that
accurately reflects the status of the valve.
Hot Water Connect the hot water fill valve signal to trigger
channel 3 (orange stripe wire). Because the hot
water signal may be used to monitor the actual
time that the water valve is open, make the
connection to a point in the washer circuit that
accurately reflects the status of the valve.
Steam
Connect the steam valve signal to trigger
channel 4 (yellow stripe wire). Because the
steam signal may be used to monitor the actual
time that the steam valve is open, make the
connection to a point in the washer circuit that
accurately reflects the status of the steam valve.
Reuse Fill
7.
Connect the reuse fill valve signal (if used) to
channel 7 (violet stripe wire). Because the reuse
water signal may be used to monitor the actual
time that the water valve is open, make the
connection to a point in the washer circuit that
accurately reflects the status of the valve.
Verify the installation by exercising the individual functions.
Observe that the appropriate TR-7000-AC LED is on.
The RS-3000 includes an integral 5 meter (15 foot) BetaLink
cable. Secure the module to the washer in a location
convenient to the operator.
The RS-3000 is factory wired for BetaLink
applications. For other uses, consult
Appendix E.
2.
POST INSTALLATION CHECKUP
After completing the equipment installation, perform the
following procedure to check out the equipment prior to pump
and washer setup.
Power Up and Check Equipment
1.
Perform a visual check of all system connections.
2.
Turn on electrical power to the pump box (you may have
already done so in step 4). The LCD screen on the front
panel should initialize and then display the following run
screen:
3.
Check each system component’s function. If any part of
the system fails to operate properly, refer to Diagnosing
Problems to diagnose and fix the problem.
DF1MS01
The transport pumps may experience difficulty in priming
following installation if they have dried out internally during
storage and shipment. If the pumps are unable to prime when
dry, one of the chemical pumps may be used to inject water
into the manifold. This is best accomplished using the test
screens described under Advanced Troubleshooting.
PUMP AND WASHER SETUP
This section of the manual describes:
Connect the cable from the RS-3000 to the washer’s
TR-7000-AC BetaLink Phoenix connector. Please refer to
Figure 10.
3.
Refer to Table 5 to determine the address to use for this
RS-3000.
4.
Turn on electrical power to the pump box and set the
RS-3000’s address. The RS-3000 is supplied from the factory
set at address 0 (formula 16), which disables communication
to the module.
Pump Setup
Configuration of the pump box during initial installation and
whenever changes are necessary (such as changing chemical
costs).
Washer Setup
To change the address, simultaneously press and hold the 5
and 6 keys until one of the formula LED’s starts blinking
(approximately 4 seconds). Now press either the 5 or 6 key
until the LED corresponding to the desired address is
blinking. After about 4 seconds of no key activity, the
RS-3000 will accept the new address and revert to normal
operation.
16
The address will be remembered even when the power is off.
Pump Priming
INSTALL THE RS-3000 FORMULA
SELECT MODULE
1.
While you are changing its address,
the RS-3000 cannot communicate with
the pump box.
1208135
Configuration of each washer during initial setup and when
changes are necessary (such as wash formula changes).
When you have completed pump and washer setup, see the
post setup checkout procedure in System Checkout.
SCREENS
Figure 12 illustrates the dispenser screens you use to control
the system. This illustration is also located under the lid of the
pump box.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
SCREEN FLOWCHART
RUN
SCREEN
PRINT
REPORTS
(STARTUP)
INTERROGATION
Menu
SYSTEM TESTS OK
DATE
SELECT
NETWORK STATUS
PUMP STORED STRIP (LAST EVENT)
CHEMICAL USE
PRESS UP TO CLEAR
LANGUAGE & DISPENSER NAME
TIME & DATE
WASHER SIGNAL STATUS
PUMP SETUP
ALARM DISPLAY
PUMP SETUP
POF & TRANSPORT FLOW
Menu
PUMP STORED STRIP
GRAND TOTALS
SELECT REPORT TYPEPUMP RUNNING STRIP
PRESS DOWN TO
RETRY ABORTED FEEDS
WASHER ACTIVITY
LOAD ID SETUP
TRIGGER SETUP
ACCOUNT NAME & NETWORK ID
UNITS (METRIC/US)
SHIFT TIMES
Menu
CHEMICAL COST & NAME
FEED PRIORITY & POF/POD
(OFF/SENSITIVITY) & PUMP SPEED
MIN WATER TEMP
PUMP CALIBRATION
FLOW METER CAL & SYSTEM FLUSH
TUBE LIFE LOG
MOTOR LIFE LOG
TRANSPORT PUMP LIFE LOG
WASHER STORED STRIP
WASHER RUNNING STRIP
CYCLE RECORD
FLOAT SWITCH LIFE LOG
WATER VALVE LIFE LOG
ERROR CYCLE
PRODUCTION SUMMARY
WASHER SETUP
WASHER ON & SYSTEM TYPE &
WASHER NAME
Menu
TRANSPORT TIME
TRANSPORT RATE
LEGEND
TRIGGER MODE
PRESS BOTH CURSOR KEYS
TO CHANGE MENUS
USE TO SELECT OR
CHANGE DATA
USE TO SELECT OR
CHANGE FIELD
AUTOMATIC
RELAY
USE TO SCROLL THROUGH
SCREENS
AVAILABLE CHARACTERS
ABCDEFGHIJKLMNOPQRSTUVWXYZ
0123456789_!@#$%^&*()-+=/?.,' {space}
TRIGGER INPUT POLARITY
CYCLE NAME
CYCLE NAME
Menu
FORMULA
TRIGGER INPUT POLARITY
TRIGGER INPUT POLARITY
Menu
CYCLE QUALIFIER
FEED REQUEST RATE & TRIGGER
TIME LIMIT
CYCLE QUALIFIER
CYCLE NAME
Menu
CYCLE QUALIFIER
FUNCTION NAME
FORMULA NAME & LATCH RESET
CHEMICAL & DOSE AMOUNT
TRIGGER & DOSE AMOUNT
WASHER HOLD
STORED STRIP ENABLE
COPY WASHER SETUP
DF1MF12
Figure 12. Screen Flowchart
FRONT PANEL
Figure 13. Pump Box Front Panel
The front panel of the Pump Box is illustrated in Figure 13. Notice
the five modes. At power up, the following screens are the first that
appear in each mode. After you access the print, interrogation and
setup modes, the screen you were last using is displayed when you
re-enter the mode.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
17
•
Run
When entering alphanumeric information, the following
shortcuts may be useful.
If lowercase character is blinking, press 5 once to clear
the character. All uppercase character symbols and
numbers may be cleared by pressing the 5 and 6 keys
simultaneously.
Press and hold the 5 or 6 key to cause the selection to
scroll, first at a one-character rate, then at a 3-character
increment.
DF1MS01
Print
•
You can continue to cycle through all the screens in the
pump or washer setup mode until all the setup data is
correct.
•
When making setup changes, the changes are effective
immediately. Changing setups may adversely affect a
chemical delivery in progress, and so should only be
done when the wash aisle is idle.
•
When you are finished doing all pump and washer setup,
redisplay the run screen.
•
In illustrations of the screens in this manual, information
that you may change is in bold type.
DF1MS03
Interrogation
PUMP SETUP MODE
DF1MS04
The dispenser is supplied from the factory with all memory
cleared. However, if the system has been previously set up,
the RAM devices removed or the battery replaced, erroneous
setup information may exist. This will be evidenced by
strange, nonsensical data and characters being displayed in
some of the variable fields.
Pump Setup
In this case, clear the memory before beginning pump setup
(see Clear Memory in Maintenance).
Language and Dispenser Name
Washer Setup
HOW TO ACCESS AND USE THE
SCREENS
•
To enter pump or washer setup mode from the run screen
(normal operation), hold down the blue PROGRAM switch
on the PCB and firmly press the 5 and 6 keys
simultaneously. Each time you press these keys, you move to
one of the five modes. If you do not press the PROGRAM
switch, the setup modes are inaccessible, which restricts the
ability to change setups to those with a key to the pump box.
•
When in a mode, press the MENU key to scroll forward
through the screens or press the PRINT/INFO key to scroll
backward.
•
To change the data in a screen, press the 3 or 4 key to move
to a changeable field, and use the 5 and 6 keys to enter new
data or toggle to desired settings.
18
1208135
Select the language to be used for the screens and printed
reports. Also enter a 1-20 character model name for this unit.
This name is displayed on the run screen and at the top of the
printed reports. The name will be automatically centered, so
there is no need to add leading spaces.
The language selection is the first item in
the first setup screen, making it easy to
access even if set to a language you don’t
understand. Just turn the power off and on,
then follow the directions under FRONT
PANEL to access this screen.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Time and Date
Chemical Name and Cost
Use this screen to set the dispenser clock to the local time and
today’s date.
For each chemical pump in the system, enter the chemical
name and cost. Use unit cost of price/liter or price/gallon.
Cost per unit is not automatically converted if you change the
volume unit of measurement. Therefore, be sure that this data
reflects your chosen unit of measurement.
Account Name & Network ID
POF Sensitivity, Feed Priority and Pump
Speed
Enter a 1-20 character name for this laundry account. If the system
is to be connected to a supervisory computer, enter a unique
network ID number (01-99). Otherwise, set the network ID number
to 00.
Unit Select
Use this screen to set up the Proof of Flow conductivity
sensitivity, feed priority and delivery speed.
POF
Toggle between off, low, medium or high. This feature allows
you to select a POF/POD threshold that is best suited for the
chemical being pumped. Proper selection of this threshold
will ensure optimum performance of the Proof of Flow out of
chemical detection feature.
Select either liters or U.S. gallons/ounces as the volume unit of
measurement (the current selection flashes). The temperature
measurement units are changed automatically to correspond to the
volume unit of measurement. All report and display data is
presented in the currently selected unit of measurement.
All internal recordkeeping, calculations, and
dispensing are carried out in metric units. If
you set the system to U.S. units, all
requests, entries and outputs are converted
at the time of transmission or when
displayed. For this reason, a 10 -ounce
feed may be reported as 9.9 or 10.1
ounces. This does not affect accuracy.
Use the OFF setting to disable the POF/POD function. You
should disable POF/POD for nonconductive products such as
hydrogen peroxide and mildewcides. When POF/POD is
disabled, the auto-prime and out of chemical features do not
work.
Use the LOW setting for low conductivity chemicals, such as
softeners, anionic surfactants, starch, and non-built detergents.
This setting provides a threshold 150 microseimens above the
baseline conductivity.
Use the MEDIUM setting for chemicals in the mid range of
conductivity, such as built detergents, sour/softener
combinations and any other chemicals that are not quite as
conductive as the high conductivity products. This setting
provides a threshold 5,000 microseimens above the baseline.
Shift Start Times
Use the HIGH setting for highly conductive chemicals, such
as alkali, bleach, sour, and some built detergents. This setting
provides a threshold 30,000 microseimens above the baseline
water conductivity.
Set the three shift start times. These times are used in reports to
sort productivity and chemical usage data. You must set time in 24
hour format. Shift times must be sequenced in ascending order.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
To evaluate the performance and suitability of your selection,
observe the performance of the conductivity function by
viewing the POF Status/Flow Rate screen in interrogation
mode. Observe this screen during a chemical feed to
determine how close the chemical is to the detection
threshold. For best results, the minimum conductivity reading
during the feed should be at least 10% higher than the
threshold setting for the particular chemical.
19
Feed Priority
Toggle between normal and high priority for this chemical pump.
A single chemical may be designated as high priority. Requests for
this chemical will be promoted to the top of the feed stack and will
be serviced before any other pending requests. In addition, should
a multiple chemical feed be in progress, that feed will be broken
between the chemical feed segments, and the high priority feed
made. All chemical requests associated with a high priority feed
will be considered high priority. Selection of a chemical deselects
any previously selected chemical. This feature is useful in
situations where all washers may not have washer hold
capabilities, or where time-critical chemicals are injected.
Manual Calibration
Manual calibration allows you to perform a manual
calibration procedure on selected pumps. Selecting manual
tells the dispenser not to update the historical pump
calibration, but rather to use a manually-derived value. This
method is recommended if there will never be an injection
large enough for the dispenser to do auto-calibration. The
minimum injection amount for auto-calibration is 6.5 oz if
fast speed is selected and 3 oz if slow speed is selected.
View or Reset Calibration Values
Speed Select
Toggle between slow and fast.
Slow - The chemical pump runs at a reduced speed. Use slow
speed if the chemical is unusually thick, has nonlinear flow
characteristics or exhibits other unusual hydraulic characteristics.
If the chemical has a tendency to gel or thicken when mixed with
water (high-surfactant products), this feature allows you to
increase the mix ratio and thus reduce the gelling effect and the
transport pressure. Slow speed may also be used to allow autocalibration to occur for chemical doses too small to auto-calibrate
at fast speed. As a guideline, use slow speed with doses smaller
than 200 ml (6.5 oz).
To select the calibration mode for each chemical pump:
1.
Use the 5 and ukeys to set the pump number.
2.
Press the 4key to move the cursor to the calibration
mode field and use the 5 and 6 keys to toggle to
AUTO or MANUAL.
3.
If you select AUTO, this first screen only allows you to
view the current historical pump calibration values, or
reset the values to their default. To reset FAST and
SLOW values, press 4to highlight the value and then
press tto reset. Then press the 4to go back to the pump
field and select the next pump to calibrate, or the MENU
key to display the next pump setup screen.
4.
If you chose MANUAL, press the 4key. The message
Press UP to CALIBRT appears on the screen. Press the
5key to display the manual calibration screen (see
below).
Fast - The chemical pump runs at full speed (20 oz per minute).
Transport Water Temperature
Transport water temperature is critical when using certain
chemicals. If warm transport water is required, set the minimum
transport temperature on this screen for the appropriate chemical
pump. Toggle between minimum values of 5 °C and 24 °C (41 °F
and 75 °F). In both cases, the maximum is 70 °C (158 °F). If the
POF cell does not have a temperature sensor, the present
temperature will be blank, and you cannot set the minimum
temperature.
Chemical Pump Calibration
On a pump-by-pump basis, you can enable auto-calibration or
force the system to use a fixed, manually-derived pump rate.
Auto Calibration
If you select AUTO, you do not need to do anything. You may
wish to verify that the displayed values are either the default, or are
reasonable values for the chemical being pumped. Pumps you set
up as AUTO will, when possible, perform an automatic calibration
procedure at the beginning of each feed.
The AUTO procedure will continuously update the pump rates
shown on the calibration screen. This is the preferred mode of
calibration, as it compensates for tube wear, product viscosity
changes, suction head changes, and other factors that may affect
the chemical pumping rate.
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Manual Chemical Pump Calibration
This screen appears only when you are doing a manual
chemical pump calibration. Perform the following procedure
when the wash aisle is idle.
1.
Select pump to be calibrated (and its speed) from the
chemical pump calibration screen, then press the 5key
to go to this screen. For safety, the dispenser rejects all
feed requests while this screen is displayed.
2.
Disconnect the chemical pump outlet tube from the
manifold. Place the end of this tube into a measuring
container large enough to hold the amount indicated on
the screen.
3.
Press and hold the 5key until the indicated amount of
chemical has been pumped into the container. You can
stop and start the pump as required to “sneak up” on the
correct amount.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Pump Tube Life Reset
Raw chemicals are present. Handle with
care.
4.
When you have pumped the correct amount, press the 6 key
briefly to pull the chemical back through the pump.
5.
Reconnect the outlet tube to the manifold.
6.
Press the 4key to return to the chemical pump calibration
screen and view the new calibration. The dispenser does not
reject feed requests while this screen is displayed, so you
must reconnect the chemical pump outlet tube before
returning to this screen.
If you make a mistake during the manual calibration (you pump
too much chemical), and you are still displaying the manual
calibration screen, reconnect the chemical pump outlet tube to the
manifold. Then press the 4 key to discard the calibration and
return to the chemical pump calibration screen.
You can repeat this process as required to calibrate all chemical
pumps. Be sure to thoroughly wash the measuring container
between calibrations.
This screen displays the elapsed time that a chemical pump
tube has run (hours:minutes:seconds) and the date it was
installed. You can reset the elapsed time to zero after you
change a pump tube. To do so:
1.
Select the pump.
2.
Push the 4 key until Press Up to Reset is flashing.
3.
Push the 5 key to reset to zero. The dispenser
automatically inserts the current date.
Pump Motor Life Reset
Flow Meter Calibration & System Flush
This screen displays the elapsed time that the chemical pump
motor has been in service (hours:minutes:seconds) and the
date it was changed. You can reset the elapsed time to zero
after you change a motor. To do so:
Use this screen to set the calibration volume or to manually run
(flush) and test the transport system.
1.
Select the pump.
Set Flow Meter Calibration
The calibration volume is measured at the factory and printed on a
tag mounted on the break tank bracket. Enter the number from the
tag for the calibration volume.
2.
Push the 4 key until Press Up to Reset is flashing.
3.
Push the 5 key to reset. The dispenser automatically
inserts the current date.
Transport Pump Life
Manual Flush to Test Transport System
A washer must be enabled (using the washer on/off screen
described in Washer Setup Mode) before you can do a manual
flush. To test the transport system, perform a manual flush as
follows:
1.
Select the desired washer. UP=RUN appears on the screen.
2.
Press 4until UP=RUN flashes.
3.
Press 5to begin the flush. During the manual flush, water is
sent to the selected washer.
This screen displays the elapsed time that the various
transport pumps have been in service and the date they were
changed. You can reset the elapsed time to zero after you
change a transport pump. To do so:
4.
The manual flush automatically stops after 2 minutes. To stop
it earlier, press the 6 key.
1.
Select the pump.
2.
Push the 4 key until Press Up to Reset is flashing.
3.
Push the 5 key to reset. The dispenser automatically
inserts the current date.
While a manual flush is in process, the screen displays the flow
rate of the transport pump, updated 4 to 5 times per minute. The
normal flow rate is about 2.0 liters per minute (0.53 GPM).
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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21
Float Switch Life
Basic + Formula Select
One TR-7000-AC
Trigger Module and
an RS-3000 Formula
Select Module.
Expanded (2 Trigger Modules) Two TR-7000-AC
Trigger Modules.
This screen displays the life of the float switches and the date of
their last replacement. The hi and lo numbers on the screen are the
number of times the corresponding switch has changed states (off
to on or on to off). The date is the service date. You can reset the
float switch life to zero when you change one. To do so:
1.
Push the 4 key to select one of the switches (hi or lo). The
selected switch flashes.
2.
Push the 5 key to reset life to zero and change the service
date to today’s date.
4.
Expanded + Formula Select
Two TR-7000-AC
Trigger Modules and
an RS-3000 Formula
Select Module.
Washer Interface
ILS Max emulation
mode in which a
Washer Interface
module is used for
communication and
POD functions.
Optionally, enter a 1-16 character name for the washer.
Water Valve Life
Transport Time
This screen displays the life of the inlet water valve and the date of
its last replacement. Cycles is the number of off to on actuations of
the valve since the last reset. The date is the service date. You can
reset the time to zero when you change the inlet water valve. To do
so:
Use this screen to set and clear the transport time to each
washer.
Push the 5 key to reset life to zero and change the service date to
today’s date.
WASHER SETUP MODE
Washer On/Off, Washer System Type and
Washer Name
The transport time is the amount of time it takes the dispenser
to transport the chemical from the pump box to the washer.
Having the correct transport time ensures that all pumped
chemical gets into the washer.
If the washer type supports Proof of Delivery (POD), then the
dispenser automatically measures the transport time and
displays it on this screen. You can change this automaticallyderived time if you think it is inaccurate. You may also reset
the time to zero to cause the dispenser to re-measure the time.
If the washer type does not support POD, you must measure
the transport time manually and enter the number on this
screen.
Whether entered manually or automaticallyderived, the displayed time will vary slightly
over time as the dispenser adjusts to
varying transport pump rates. If you copy
one washer setup to another (see Copy
Washer Setup), be aware that the transport
time is not copied to the new setup. You
must set up each washer individually. If
there is no transport time set up, the
dispenser uses the very long, default
preflush and postflush times.
Use this screen to enable or disable communication to the
individual washers, select a system type for each washer, and
optionally assign a name to the washer.
1.
Select the washer.
2.
Toggle the washer on or off. Only washers that are on will be
monitored by the pump box. Washers that are off will be
ignored. Nonexistent washers must be off.
3.
Select one of the following washer types. A different type
may be used for each washer.
Basic (1 Trigger Module)
22
One TR-7000-AC Trigger
Module.
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1.
Select the transport pump.
2.
Press 4 or 3 to select the digit to be changed, and use
the 5 or 6 keys to change the value.
3.
If the displayed time is other than zero, you may
continue to press 4 until Press UP to Reset appears.
Then press 5to set the time to zero.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Transport Rate
PDCI Automatic Mode
This screen displays the average transport pump rate for each
speed (slow and fast), and allows you to reset the rates to default
values if desired. You should reset the rates after you change a
transport pump or after major failures in the transport system.
1.
Select the washer.
2.
Press 4 to select the rate field.
3.
Press 5 to reset the rate to its default.
Similar to strobeless
automatic mode, but also
allows the washer to identify
wash cycles and load types.
When you select this mode,
another line appears so you
can set the trigger filtering
for use with either chart/card
or microprocessor controlled
washers.
Changing from one mode to another erases the previous mode
settings for the selected washer. To leave this screen without
making a mode change, press the MENU key.
Trigger Input Polarity
This screen appears for every chemical feed mode, although
the choices differ depending on the mode.
Chemical Feed Mode
Use this screen to set a chemical feed mode for each washer.
Appendix A and Appendix B provide detailed information about
each mode. The mode you select determines which subsequent
setup screens appear. Possible modes are:
Relay Mode
For microprocessor-controlled
washers, requires 1 trigger signal
per chemical.
Enhanced Relay Mode
Same as relay mode, for when you
have more chemicals than
available signals.
PDCI Relay Mode
Similar to enhanced relay mode,
but also allows the washer to
identify wash cycles and load
types.
Formula Mode
For washers with chart or card
controllers.
Latched Formula Mode
Same as formula mode but each
trigger can occur only once per
load.
Miele Formula Mode
For Miele washers.
PDCI Formula Mode
Similar to formula mode, but also
allows the washer to identify wash
cycles and load types.
Automatic Mode Strobed
For washers with chart or card
controllers, to trigger up to 32
injection groups.
Automatic Mode Strobeless
For fixed-cycle microprocessorcontrolled washers (rare), to
trigger up to 32 injection groups.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
Use this screen to select the signal logic (normal or reverse)
for the washer status signals connected to the TR-7000-AC
Trigger Module channels. The choices in the 4th line depend
on the selection you make in the 3rd line.
If you have not connected a machine on
signal and are not using a PDCI feed
mode, you must set the machine on logic to
reverse. (PDCI feed modes do not use the
machine on signal, so the polarity setting is
unused.) If you have not connected a drain
signal, you must set the drain logic to
normal.
The following chart lists the choices you can make. Module
#1 refers to the primary TR-7000-AC. Module #2 refers to the
second TR-7000-AC, if installed. Unless noted, the choices in
Line 4 apply to all feed modes.
23
Cycle Qualifier
This screen appears for every chemical feed mode, although
the choices differ depending on the mode.
Trigger Input Polarity Setup Screen
Line 3
MODULE #1, INPUT #7
Line 4
Machine On NORMAL
Machine On REVERSE
Machine On UNUSED (PDCI
Modes Only)
MODULE #2, INPUT #1
Sewer Drain NORMAL
If a non-PDCI feed mode is selected, this screen appears as
shown above. It is used to enter a unique qualifier for each
wash classification. The dispenser uses this information to
identify the wash cycle if it has no other way (such as an RS3000) to do so. If cycle identification is not required, you can
leave this screen unset. If an RS-3000 is being used to identify
the cycles, you only need to set the time and weight.
Sewer Drain REVERSE
MODULE #2, INPUT #2
Cold Fill NORMAL
Cold Fill REVERSE
MODULE #2, INPUT #3
Hot Fill NORMAL
Hot Fill REVERSE
MODULE #2, INPUT #4
In order for the dispenser to distinguish one classification
from another, each classification must have a unique qualifier.
The dispenser recognizes the classifications by the total
number of trigger signals in each wash load, and if connected,
the number of qualified drains. A qualified drain is any drain
signal that is longer than 5 seconds and was preceded by a
water fill signal.
Steam NORMAL
Steam REVERSE
MODULE #2, INPUT #6
Reuse Drain NORMAL
Reuse Drain REVERSE
Chemical #8 TRIGGER
(Relay Mode Only)
If you are not using the expanded triggering
mode that monitors drain signals, you must
leave the number of drains at zero (0).
Formula Select Channel 2
(Formula Mode Only)
MODULE #2, INPUT #7
Reuse Fill NORMAL
Trigger channels 1-5 on the first (per washer) TR-7000-AC
Trigger Module are always cycle qualifiers, regardless of
which pump they are set up to trigger.
Reuse Fill REVERSE
Formula Select Channel 3
(Formula Mode Only)
The time entry is the nominal length of the cycle. It is used
when calculating cycle excess times.
Table 6. Trigger Input Polarity Setup
1.
Verify that the correct washer number is flashing in the 1st
line.
2.
Press the 4 key to cause the 3rd line to flash.
3.
Press the 5 or 6 keys to select your choice in the 3rd line.
4.
Press the 4 key to cause the 4th line to flash.
5.
Press the 5 or 6 keys to select your choice in the 4th line.
The weight entry is the nominal load weight. It is used when
calculating chemical cost/weight. Unidentified loads will
automatically default to the weight set into cycle type 30.
Cycle Name
This screen appears for every chemical feed mode.
Use this screen to set up to 30 possible cycle names (load
classifications) for each washer. The cycle name may be 1-16
characters. Not needed if washer load identification is not required.
If a PDCI feed mode is selected, there is no need for cycle
qualifier information, so a simplified version of this screen
appears as shown here. The time and weight entries are the
same as described for non-PDCI feed mode. The add time
field is used to adjust the measured cycle duration to
compensate for washers that cannot generate the PDCI cycle
start and cycle end codes at the precise start and end of the
cycle, due to internal washer interlocks. The number you
enter here will be added to the interval between PDCI cycle
start and PDCI cycle end codes to determine the actual cycle
duration.
Relay Mode
For a definition of relay and enhanced relay modes, please
refer to Appendix A. For a definition of PDCI relay mode,
refer to Appendix B.
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Feed Request Rate and Time Limit
Function Name
Use this screen to set the feed request rate (chemical volume per
unit of trigger on time) and maximum trigger on time per load for
each washer. Maximum trigger on time is from 1-999 seconds. If
you enter 0, this feature is disabled, OFF is displayed and there is
no maximum cutoff time. If you are not using a machine on signal
or PDCI relay mode, you must disable this feature.
Use this screen to assign a name to each of the 32 possible
function names. The term function describes a chemical
injection group, such as Wash, Heavy Soil or Sour & Soft.
Each function can have up to 3 dose amounts of any chemical
you choose. The function name is optional, but will assist you
in subsequent setup steps.
If the washer processor chemical trigger signal were to fail on, the
dispenser will stop pumping chemical and will set the washer
alarm when the maximum trigger on time is exceeded. Once the
maximum time for any chemical is exceeded, the dispenser ignores
any more requests for that chemical until the next wash cycle
begins. Other chemical requests are processed as long as their
respective maximums have not been exceeded.
Chemical and Dose Amount
The units/second entry assigns the amount of chemical that will be
pumped for each second that the washer supply trigger signal is on
and should not be confused with the actual chemical pumping
rate of the pump in the pump box. For example, a 3
ounce/second rate entry with a 5 second trigger pulse will deliver
15 ounces of product. The call rate in metric units is from 0.010
liter/second to 0.990 liter/second in 10 milliliter increments. The
call rate in U.S. units is from 00.1 ounce/second to 99.9
ounces/second in 0.1 ounce increments.
The units/second value used will be a function of the smallest
chemical dose required for the particular washer. For example, if
the smallest feed required is 4 ounces, a 4 ounce/second rate would
be the largest rate usable because most processors cannot call
signals in fractions of seconds. Also note that the rate entered will
be the smallest increment of change that may be fed.
Use this screen to set the chemical type and amount for each
feed function. You can create up to three separate chemical
injections (chemical and amount) that will be fed upon
activation of the function trigger pattern described in
Appendix A and Appendix B. Enter the three separate
injections for DOSE #1, #2 and #3.
Formula Mode
For a definition of formula mode, see Appendix A. For a
definition of PDCI formula mode, see Appendix B. To
visualize the formula mode setup, print a Washer Trigger
Setup report (see Reports) and use the report layout as a
worksheet.
Formula Name and Latch Reset
If you choose rates less than the actual
pumping rates, the pump will get ahead of
the washer signal and have to wait before
finishing the chemical feed. This will result
in the pump starting and stopping during a
feed.
There is no trigger input debounce filter in relay mode. With a feed
request rate of 2 ounces/second, a 1-second signal will deliver 2
ounces of chemical. Refer to Trigger Timing Limits in Appendix A
and Appendix B.
Automatic Mode
For a definition of automatic mode, please refer to Appendix A.
For a definition of PDCI automatic mode, refer to Appendix B. To
visualize how to set up automatic mode, print a Washer Trigger
Setup report (see Reports) and use the report layout as a formula
development worksheet.
Use this screen to establish the formula names (classification)
for each washer. You may assign an optional 1-16 character
name to specific formulas. The formula name you enter here
is used by the RS-3000 Formula Select Module, if installed.
It is the cycle name, not the formula name,
that is used to identify wash loads in the
printed cycle reports. To avoid confusion,
the formula names and the cycle names
should be the same.
In the latched formula mode and Miele formula mode, you
can also select the latch reset trigger. You may use any of the
five triggers to reset the latch, or the machine on signal can
perform this function.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
25
In PDCI formula mode, this screen does not appear. Since the
cycle type and the formula are always the same in this mode, the
cycle name is also used as the formula name.
Trigger and Dose Amount
Use this screen to set up to 3 separate chemical injections
(chemical and amount) that will feed upon the activation of the
specific trigger and formula select setting. Each trigger signal can
have up to 3 dose amounts of any chemical you choose to specify.
Enter the 3 separate injections on this screen (DOSE1, DOSE2 and
DOSE3). Refer to Appendix A and Appendix B for the trigger
patterns for formula selection. Note that PDCI formula mode
allows up to 30 formulas, while the other formula modes allow up
to 16.
Washer Hold
This feature is used for diagnosing trigger timing and
relationship problems. The decision to enable or disable a
particular washer stored strip will depend on your
troubleshooting needs. If you are not experiencing problems
with any particular washer, then you should enable all
washers. This will provide a comprehensive, but relatively
short record, of all the washer trigger signals. This is
particularly helpful when setting up a new account.
Should you wish to diagnose problems associated with a
particular washer, disable some (or all) of the other stored
strips. This will allow a longer time period before the specific
washer’s stored strip record is overwritten in memory.
Copy Washer Setup
Use this screen to copy the washer setup information from
one washer to another.
1.
Select the source and target washer numbers.
2.
Press the 4 key until the Press Up to Copy message
flashes.
3.
Press and hold the 5 key until the Copy Complete
message appears.
Use this screen to control the dispenser’s washer hold function,
which is available only in ILS Max emulation configurations.
There are several washer hold options.
The entire washer setup image, except transport time, is
duplicated to the target washer. The copy function clears the
transport time of the target washer.
Normal
Activates the hold relay if the chemical delivery will be delayed
because an earlier chemical request is being processed.
Careful planning and layout of washer setups and formulas
can make this a very useful tool for system setup. By
progressively duplicating and editing washer setups, common
information can be duplicated and then edited at the
individual washers, thereby reducing much of the time needed
for highly repetitive data entry.
Hold Until POD
Activates the hold relay every time there is a chemical request, and
releases the relay at the end of the chemical feed sequence (POD).
Hold until POD may be useful as a delivery complete signal in
some interactive washer control systems.
Hold on Alarm
Causes the hold relay to be set any time there is a chemical feed
failure to the particular washer. This stops the washer timer until
the error is corrected and allows the wash aisle operator to refeed
using the last feed retry.
Enable Washer Stored Strip
Careful planning and a little creativity can save considerable
time.
SYSTEM CHECKOUT
POST SETUP
To ensure that your setups work properly, perform the
following procedure immediately after you complete pump
and washer setup. For hints on programming the wash
formulas at individual washers, see Appendix C.
Run a Test Load
Use this screen to activate the washer stored strip on a washer-bywasher basis. As long as it is active for a given washer, the stored
strip records a historical record of all the washer’s trigger signals.
The dispenser can save a maximum of 1400 lines of events for all
washers.
26
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1.
Connect the printer to the pump box and have the
running strip in operation during the wash load, or enable
the washer stored strip functions.
2.
During the wash, observe the washer status screen in the
interrogation mode (see Interrogation Mode in this
section) during the chemical feed. If connected, verify
that there is a valid machine on signal and that the drain
is closed.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
3.
Use the interrogation mode running strip screen to observe
any chemical request activity.
Temp indicates the current transport water temperature; if no
temperature sensor is installed, the temperature is blank.
4.
If the feed information is displayed, ensure that the
appropriate chemical and transport pump is running. Watch
for the chemical to enter the washer. If there is no POD cell at
the washer, you will need to measure the amount of time it
takes the leading edge of the chemical dose to reach the
washer, and enter this time in the transport time washer setup
screen.
FLOW is the current transport flow rate. It is updated three to
five times per minute when a transport pump is running.
5.
6.
After the load is complete, check for status messages and
check the Pump Running Strip report at the pump box. If the
running strip has recorded the feeds and there are no error
messages, then the system is functional. The washer is
receiving chemical.
Repeat for all washers in the system.
Review Pump Setups
Review the Pump Setup report. There should be a transport time
for each washer that is online. Confirm that the transport time
recorded is realistic. Assume a transport velocity of 1 meter (3
feet) per second.
Washer Status
This screen displays, washer by washer, the washer signal
status as monitored by the TR-7000-AC Trigger Module(s)
connected to the pump box. In this example, 1= indicates that
TR-7000-AC module 1 is online, and all signals are off. Each
dash (–) represents a trigger channel. The dash is replaced by
a number when the trigger signal is present. If a second TR7000-AC Trigger Module is present, it is indicated by a 2=
field.
The bottom line of this screen shows the:
INTERROGATION MODE
The dispenser provides a wide variety of diagnostic tools for
evaluating the performance of the system, and for troubleshooting
setup problems and operational failures.
The interrogation mode allows you to view various analytical
screens that display system performance in real time. To enter the
interrogation mode from the run screen, simultaneously press the
3 and 4 keys twice. One of the screens shown below will appear.
(Refer to the screen flowchart located under the top cover of the
pump box.)
•
Status of the Bleach Defeat control on TR-7000-AC
Trigger Module #1 (off or on). This control is not
presently used.
•
Current formula selected by the RS-3000 Formula Select
Module, if present (its 2-digit number)
•
Status of the Sequence Start light (off or on) on the RS3000. This control is not presently used.
ILS Max Emulation Systems
When you are finished viewing interrogation screens,
simultaneously press the 3 and 4 keys until the run screen is
displayed.
POF Status/Flow Rate
If the dispenser is connected to a Washer Interface Module,
the top line of the washer status screen shows the status of the
alarm and hold relays (+ = on, – = off). The second line
shows the conductivity and temperature readings from the
POD cell (+ = POD present, – = POD not present). POD
readings are only valid during a chemical feed.
This screen displays the conductivity and temperature of the
solution presently in the Proof of Flow (POF) cell, the POF
conductivity threshold that the system has calculated, and the
current flow rate. The THRESHOLD value will change during a
chemical feed depending on the threshold setting of the chemical
being pumped. When no chemical is being pumped, the lowest
threshold setting is used. The minus (–) to the right of the POF in
the top line changes to (+) when the POF conductivity exceeds the
POF threshold, indicating that chemical is present.
Network Status
This screen is used to evaluate your choice for POF threshold
(LOW, MED or HIGH), as described in Pump Setup Mode.
Observe this screen during a chemical feed to determine how close
the chemical is to the detection threshold. For best results, the
minimum conductivity reading during the feed should be at least
10% higher than the threshold setting for the particular chemical.
This screen indicates the BetaLink communication status of
the dispenser by showing which washers are enabled and/or
responding. The (+) indicates that the washer is selected and
responding. The minus (–) indicates that the particular washer
has been enabled during setup but that one or more of the
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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27
modules at the washer is not communicating. An (x) indicates that
the particular washer has not been enabled.
View Stored Strip/Running Strip
Washer Running Strip
The Washer Running Strip report is a real time diagnostic
report that records all washer signals connected to the system
(machine on, drain and all supply request signals). This report
is very useful in determining the reliability and timing of
washer signals that are used by the dispenser. The report also
shows chemical use totals and load identity when the load is
completed.
Washer Stored Strip
This screen displays the most recent event recorded by the
dispenser. It is updated as events occur, so is a real time view of
current status.
You can scroll through a stored list of past events using the 5 and
6 keys. The 5 key scrolls forward in time and the 6 key scrolls
back in time. The events are stored in chronological order with the
date and time displayed at the top line of the screen. The report
period selection does not affect this feature. The entire stored strip
is shown sequentially.
Press a key once to increment one record at a time, or hold the key
down to scroll at high speed through the records. Pressing 3 or 4
or exiting and reentering this screen returns to the most current
event, and returns the screen to the real time monitoring mode.
The Washer Stored Strip report is a logged version of the
Washer Running Strip report. This feature must be enabled
for each washer via the Washer Setup screen. This feature
may be used for catching the “every once in a while” washer
triggering or timing problem. It does not show chemical use
totals or load ID.
STATUS MESSAGES
During normal operation, the following messages may appear
on the run screen, on interrogation mode screens, and in Pump
Stored Strip or Pump Running Strip reports. These messages
are an indication of the current or most recent event the
dispenser performed.
Grand Totals
This screen displays the grand total volumes for flush water and
for each chemical. Press the 5 or 6 key to scroll through the
choices. These amounts are for total volume pumped and are not
resettable (except by a setup purge).
DIAGNOSTIC REPORTS
There are several reports that are helpful when troubleshooting the
overall system or individual washers. The strip or event type
reports have both a stored (logged in memory) and running (real
time) version. The strip reports are chronological data logs of all
system events or washer signals. The Pump Stored Strip report is
always enabled. You may enable one or more Washer Stored Strip
reports from the stored strip enable washer setup screen.
For more detailed explanations and illustrations of these reports,
refer to Reports.
Pump Stored Strip Report
You can use the Pump Stored Strip report to analyze individual
feeds to washers. It shows:
•
When and how much chemical was requested and delivered.
•
Each stage of the feed process.
•
Other logged events including loss and establishment of
system power, and aborted chemical feeds.
See Error Messages for a detailed list of error messages.
28
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Message
Meaning
Cycle Start
Cycle Stop
Using PDCI triggering, a washer has signaled the beginning or end of a wash cycle. The cycle type
is included with the start message.
Cycle Start Ignored
A Cycle Start code was received while a cycle was already running. This is normal with some chartdriven washers which have multiple start points for some cycles.
Feed Request Fixed Dose Mode
Feed Request Relay Mode
Feed Request from Network
The dispenser is acknowledging a chemical feed request. Messages include requesting washer,
amount and type of chemical.
Feed Request with Unknown
Cycle Type
A feed request has been received in a PDCI triggering mode when no cycle is running. The request
is honored anyway.
Proof of Flow Confirmed
Proof of Flow Assumed
Proof of Delivery Confirmed
Proof of Delivery Assumed
Indicate normal feed and delivery events that occur during all chemical feeds. An assumed
message indicates that the POF/POD feature is disabled for the indicated chemical, or that no POD
cell is present.
Feed Retry, Manual
A feed retry after a feed error is the source of the chemical request. The operator has pressed the
6 key to retry a failed feed and clear an alarm.
System Power On
System Power Off
These messages indicate the date and time power was turned off or on to the dispenser pump box.
Washer Hold Set
Washer Hold Released
These messages indicate when the specified washer was placed on hold or when the hold signal
was released.
Auto Cal Status
Manual Cal Status
Indicate when either manual or auto-calibration of a chemical pump has occurred.
Manual Memory Purge
Logged Data Cleared (or)
Setup Data Cleared
A memory purge occurred. Memory is purged at the factory before shipment. It may also be purged
at installation by trained service personnel.
Error Reset
The operator reset a system error by pressing the 5 or 6 keys.
Manual Flush Started
Manual Flush Stopped
Indicate when a manual transport flush occurs. The washer number is included in the message.
Washer Network Link Established
Indicates, at power up, that the selected washer networks are communicating with the pump box.
System Check OK
Normal status when power is turned on at the pump box.
Table 7. Status Messages
Clear Alarm Only
DIAGNOSING PROBLEMS
ALARMS
The dispenser continually monitors for correct system operation. If
a problem occurs, an error message is displayed on the screen and
logged in the Pump Stored Strip report. The alarm relay may also
be triggered.
Retry and Clear
This feature may be used only if the
dispenser is holding the washer because of
the error. Otherwise, feed retry is disabled
to prevent inappropriate feeds.
Be certain to correct the indicated problem
before clearing the alarm. Clearing the
alarm without correcting the reported
problem may result in local or system
performance degradation or missed
chemical feeds.
The alarm display register will record up to 10 error messages on a
first-in, first-out basis. These messages must be cleared
individually. If the alarm is reset and the condition that caused the
alarm has not been corrected, the alarm will be retriggered by the
next feed request. The alarm may be cleared (reset) in two ways–
clear alarm only or retry and clear, as described below.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
To reset the alarm, press the 5 key. This will turn off both
the dispenser and local washer (if present) alarms, and clear
the screen. Washer hold on alarm will be released if the hold
on alarm feature is activated. The alarm-cleared event is
logged in the Pump Stored Strip report.
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The Last Feed Retry feature allows you to tell the dispenser to
retry the last feed that had an error. If you determine, by
reviewing the error message, that an injection was probably
missed, press the 6 key to cause the dispenser to reinject the
missed feed. The washer hold will be released; the alarm will
be cleared; and hold release, alarm cleared and feed retry
messages will be logged in the Pump Stored Strip report.
29
TROUBLESHOOTING
Pump Fails to Auto-Prime
This section lists common problem symptoms and how to recover.
Pump Box LCD Screen Is Off
1.
Check main power to the stepdown transformer.
2.
Check the output of the transformer for 24 VAC.
3.
Check the power switch and circuit breaker. Reset the breaker
if necessary.
It is possible that a chemical pump will fail to auto-prime if
the chemical supply tube is too long. If the pump fails the first
time, it is best to wait for a second chemical call. If the pump
fails to auto-prime again:
1.
Check to see that POF for the pump is set on.
A chemical pump will not auto-prime if the
POF feature is off.
•
If the circuit breaker continues to trip, check system for a
short circuit in the 24 Volt distribution wiring.
2.
Check for air or air leaks in the uptake lines.
•
Check wiring to washer modules (BetaLink).
3.
Check for air leaks in the fittings from the break tank to
the chemical pump(s).
4.
Check for empty chemical drum.
5.
Too long a length or too large a diameter chemical
supply tube may require several prime attempts when
starting a new system.
6.
Pumps running at slow speed take longer to prime than
pumps running at fast speed.
4.
Check cable connections at the PCB.
5.
Check ribbon cable connection from the LCD display to the
PCB.
6.
Check DC voltages at the PCB.
Pump Box Screen Shows Bars
If the screen displays two lines of solid blocks, then the dispenser
is not booting (starting up) properly.
1.
Verify that the EPROM memory chip is installed properly on
the PCB (see Replacements).
2.
Check the ribbon cable to the LCD screen.
Washer(s) Not Receiving Chemical
If the dispenser appears to power up properly but is not pumping
chemicals to one or more washers, check the following.
One Washer Not Receiving Chemical
1. At the washer, verify that each washer module has the correct
address setting.
2.
Verify that the washer is enabled. Check washer setup.
3.
Verify washer system type. Check washer setup.
4.
Verify that the machine on and drain logic settings
(normal/reverse) are appropriate for the particular washer.
Remember, if you have not connected a machine on signal at
this washer, you must set the washer’s trigger input polarity to
reverse logic, except when using PDCI triggering modes (see
Washer Setup Mode).
Water Supply/Transport System
Problems
Adequate transport water flow is essential for proper system
performance. The dispenser continuously monitors the
transport water flow before, during, and after the chemical
pumps inject chemical into the transport system for delivery
to the washer.
Transport System Problem
A low transport flow rate problem is indicated by the message
Transport System Error. This indicates that the level in the
break tank did not go from the upper to lower level (float
switch setpoints) within the specified maximum time. If the
inflow to the break tank is too low, the message may also say
Water Supply Problem.
1.
Check that the transport pump is operating and that there
are no flow restrictions in the transport tubing.
2.
Check the manifold filter. Clean if necessary.
3.
Check the BetaLink connections between the pump box and
each washer module.
Check for air leaks in the suction side of the transport
pump.
4.
Check the entire manifold for suction leaks.
6.
Recheck the washer controller and trigger wiring. Observe
that the appropriate trigger module LEDs illuminate when the
chemical triggers are active.
No Flow to All Washers
The level of water in the break tank varies during operation.
However, it should not go below the lower float switch.
7.
Trigger time limit exceeded (relay mode only). Check washer
setup.
1.
8.
No established chemical amount. Check washer setup.
5.
All Washers Not Receiving Chemicals
If none of the washers are receiving chemical, a pump box or
BetaLink problem may exist.
1.
Check BetaLink communication status (using Network Status
interrogation screen).
2.
Check 24 VAC supply to washer modules.
3.
Check washer system type setup.
30
•
Water source turned off.
•
Stuck/misadjusted float switch.
•
Solenoid valve inoperative/failed.
- Check solenoid valve.
- Check filter built in to the solenoid valve.
- Check circuit board connections and solenoid
drive.
2.
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If break tank is empty, check for:
If break tank is full, check for:
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
•
Stuck/misadjusted float switch.
•
Failed chemical pump tube. Check for cracks or leaks.
•
Clogged manifold filter. Check and Clean if necessary
•
Broken manifold. Check for cracks or leaks.
ERROR MESSAGES
Diagnosing a Water Supply Problem Alarm
1. You can run the transport pump and break tank manually
using the following pump setup mode screen:
Table 8 lists the dispenser error messages that may appear on
the screen or in the Pump Stored Strip or Pump Running Strip
reports. These messages indicate an abnormal condition, or
that a chemical feed may not have been successfully
completed.
By analyzing these messages, you can troubleshoot many
chemical injection problems. Some messages are dependent
on the dispenser configuration, and may not apply to all
accounts. Additional information on these error conditions is
provided after the table.
Help Information on Error Messages
2.
To test the transport system, perform a manual flush. Select
the desired washer, press 4 to cause UP=RUN to flash, then
press 5.
3.
To stop the flush, press the 6 key.
4.
If water flows into the break tank and the tank fills to the
upper level within 15 seconds, then all elements upstream of
the tank (solenoid valve and external water source) are OK
and the problem is most likely with the transport pump.
5.
If there is no water flow:
6.
•
Check the electrical connections to the solenoid valve.
•
Check the operation of the solenoid valve.
•
Check the external water source.
Each time an error message is displayed, you can press the
Print/Info key to see a help screen relevant to the error
condition. Press Print/Info again to scroll through additional
help screens (if any) associated with the error.
After you take the appropriate corrective action, you can press
5 to clear the error message, or 6 to clear the error message
and retry the feed.
If there is very low water flow into the tank:
•
Check the inlet filter of the solenoid valve.
•
Check the inlet water supply pressure.
No Flow to One Washer
1. If motor runs but there is no transport flow:
2.
•
Check for blocked transport system. Look for kinks or
obstructions.
•
Check for manifold suction leaks.
•
Repair or replace transport pump head.
If motor does not run:
•
Check pump wiring.
•
Check whether pump motor failed.
•
Check motor drive circuit.
Communication Errors
This is indicated on the washer status interrogation screen or by
repeated Communication Link error alarms. Check for duplicate
module addresses or loose BetaLink connections on the affected
washer.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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31
Message
Meaning
Action Required
Proof of Flow Failure
Chemical not detected at pump box
Check supply drums for chemical level. Check suction tube,
uptake hose and pump tube for air leaks and blockage.
Proof of Delivery Failed
Chemical not detected at washer.
Applies only to ILS Max emulation
systems.
Check transport tube for leaks or breaks. Check POD cell for
air. Clean POD cell.
Relay Mode Trigger Time
Limited Exceeded
Too much chemical requested.
Check washer control and washer setup.
Feed Rejected High Water
Temperature
Water temperature is > 150°F or 70°C.
Check cold water supply and temperature valve setting.
Delivery: Transport System
Error
Transport system flow rate below
limits after a chemical feed.
Check transport tube for air leaks and blockage. Check the
manifold filter and transport pump.
Delivery: Water Supply
Problem
Transport water flow failed or the
break tank is empty after a chemical
feed.
Check break tank, water supply pressure, float switches, inlet
valve and filter.
Feed Rejected
Pump Box Offline
The pump box will not feed chemicals
during a manual chemical pump
calibration.
Do not perform a manual calibration while the wash aisle is
active.
Feed Rejected
Washer Drain Open
Drain status has changed.
Check washer setup drain polarity.
Feed Rejected
Washer Off
Washer status has changed.
Check washer setup machine on polarity.
Feed Rejected
Washer Not Selected
Network error.
Check pump setup.
Feed Rejected
Data Link Erratic
Unreliable communication to washer
Check BetaLink cable and washer module connections.
Feed Rejected
Transport Pump Error
Pump did not run, or current is too
high.
Check pump motor, PCB, wiring and connections.
Feed Rejected
Transport System Error
Transport system flow rate is below
limits prior to a chemical feed.
Check the transport tube for blockage or air leaks.
Feed Rejected
Unknown Formula
A chemical request has been received
in PDCI formula mode, but the
dispenser doesn’t know what type of
cycle is running.
Check washer setup. May be caused by operator error or power
outage.
Feed Rejected
Low Water Temperature
The water supply is too cold for the
selected chemical.
Check the hot water supply temperature valve setting and
temperature probe at POF.
Feed Rejected
Water Supply Problem
Transport water flow failed or the
break tank is empty during a chemical
feed.
Check the break tank, water supply pressure, float switches,
inlet valve, filter, transport pump, motors and chemical pumps.
Feed Aborted
Water Supply Problem
Transport water flow failed or the
break tank is empty during a chemical
feed.
Check the break tank, water supply pressure, float switches,
inlet valve and filter.
Feed Aborted
Transport System Error
Transport system flow rate below
limits during chemical feed.
Check transport tube for blockage or air leaks. Check manifold
filter and transport pump.
Feed Aborted
Chemical Pump Error
Pump did not run, or current is too
high.
Check pump motor, PC board, wiring and connections.
Worn Chemical Pump Tube
Caution only.
Replace pinch tube and reset date changed.
Washer Network Link Lost
Unable to communicate with washer.
Check BetaLink wires, remote modules, connections, network
and setup.
Incompatible Setup Data
Format
Bad PCB backup battery or
connection to batteries altered.
Check battery voltage. If under 3.2 volts, replace. Ensure good
connections at battery holder. Also refer to ETB #14360. You
will need to perform a setup and logger purge to reset error.
Table 8. Error Messages
32
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Proof of Flow Messages
in the washer formula mode setup. This is an advisory
message; no alarm is set.
The three most common error messages are:
Proof of Flow Failure
Proof of Delivery Failure
Proof of Delivery Not Detected
Proof of Flow Failure
The Proof of Flow failure message indicates that the dispenser was
unable to detect the presence of chemical during a feed. The most
common reason for this alarm is an out of chemical condition.
Check the following components:
1.
Check the chemical drum for adequate chemical supply.
2.
Check the standpipe to be sure that the end is immersed in
chemical.
3.
Check the uptake hose and standpipe for obvious leaks.
4.
If the uptake line is full of chemical, there are additional
possible causes for this failure:
•
Pump tube is worn and unable to pump chemical at a
high enough rate.
•
Proof of Flow cell is dirty and unable to detect chemical.
•
Chemical conductivity is too low or the feed amount is
too small to be detected by POF cell.
If you have checked all of these conditions and the problem
persists with a particular chemical, it is likely that the conductivity
of the chemical is too low. If the POF threshold for that chemical is
medium or high, lower it by one level. If the POF threshold is low,
disable the POF feature by setting the threshold to OFF. See Pump
Setup Mode.
The POF error may also initially be the result of an excessively
long uptake tube. The 30-second timer (fast speed) or 60-second
timer (slow speed) elapsed before the uptake line was primed.
Proof of Delivery Failure
This message appears only in ILS Max emulation systems. It
indicates that the dispenser was unable to detect a sufficient
conductivity change in the POD cell at the washer. The difference
between the failure message and the Not Detected message is that
the failure term indicates that the chemical was highly conductive
and under normal circumstances should have been detectable by
the POD system. This condition will set the alarm.
Proof of Delivery Not Detected
This message appears only in ILS Max emulation systems. It
indicates that the chemical was marginally conductive at the POF
cell and the dispenser was unable to detect a sufficient conductivity
change in the POD cell at the washer. This condition is not
necessarily critical, as the dispenser has already proved there was
chemical injected (POF) and has verified that there is transport
flow. This is an advisory message; no alarm is set.
Feed Rejected Messages
Feed rejected messages indicate that the feed was not started. The
dispenser has detected some condition that was inconsistent with
chemical delivery requirements.
Feed Rejected: Request Amount = 0
Although the message does not indicate a true error, it may
indicate that a setup problem exists. Check the injection amounts
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
The following error messages indicate that the washer status
has changed since the dispenser accepted the chemical
request. The dispenser will not deliver chemical to a washer
with an open drain, or to a washer that is off.
Feed Rejected: Washer Drain Open
Feed Rejected: Washer Off
The term washer off refers to the signal used
by the dispenser to determine that a wash
cycle is in progress. This signal may in fact
be a reverse logic signal.
If the problems persist, check the washer setup to verify that
the logic settings have not been altered. Also check the
integrity of all washer trigger signals.
The dispenser is in constant communication with the washer
modules, monitoring the washer status during the feed
sequence. The following message indicates that the dispenser
could not properly communicate with the washer modules to
determine the washer status just prior to commencing a feed.
Check the integrity of all BetaLink connections to the various
washer modules. Because it is a common installation practice
to daisy chain the BetaLink cable from one washer to another,
be sure to check all intervening connections.
Feed Rejected: Data Link Erratic
General System Operation Errors
Other error messages may be encountered from time to time.
The following is a maintenance warning. The dispenser has
determined that the indicated chemical pump’s pumping rate
has fallen below 50% of its initial starting rate. The pinch tube
should be replaced as soon as practical to optimize system
performance. This does not mean that the dispenser accuracy
has been compromised, as the auto-calibration feature is still
ensuring accurate chemical metering. (See Replacements for
tube replacement procedures.)
Before changing the pump tubes, check the
chemical uptake system for blockages such
as a pinched or kinked hose. After
changing a pump tube, be sure to reset the
pump tube life and pump calibration (see
Pump Setup Mode). It is necessary to do
this because this establishes a new
baseline reference for the worn tube
calculation.
Selecting manual calibration of the chemical pump will
prevent the worn tube feature from functioning.
Worn Chemical Pump Tube
The following message appears in relay mode only and states
that the indicated chemical trigger has exceeded the maximum
trigger time programmed in the washer setup file. The
dispenser will not deliver any more of this particular chemical
to this particular wash load. Check the wash formulation in
the washer controller, and trigger time setting in the washer
setup. Also verify the proper performance of the washer
controller supply outputs.
Relay Mode Trigger Time Limit Exceeded
33
The dispenser is in constant communication with the washer
modules, monitoring the washer status. The following message
indicates that the dispenser has lost, or cannot establish,
communication with at least one of the washer modules. Check the
integrity of all BetaLink connections to the various washer
modules.
As it is a common installation practice to
daisy chain the BetaLink cable from one
washer to another, check all intervening
connections as well as the indicated washer.
Screen # 2: Pump Box Outputs
Use this screen to individually control the alarm relay and the
water inlet solenoid valve.
Check that only the desired washers are enabled in the setup, and
verify the proper address settings of the washer interface module.
Screen # 3: Pump Box Inputs
Washer Network Link Lost
ADVANCED TROUBLESHOOTING
This procedure must be done only when the dispenser is not
dispensing chemicals. It allows you to initiate and monitor various
individual inputs or outputs free of any interactive controls.
Use this screen to monitor the state of the pump box inputs.
POF and TEMP are the readings from the POF cell. WATER
LEVEL measures the water level in the break tank (low, ok or
high) and may be used to check operation of the float
switches. FLOW INPUT is not used.
Only experienced technical personnel should
use this procedure since you are not
automatically prevented (as in other modes)
from doing harm to the dispenser .
To access the test screens:
Screen # 4: Transport Pump Control
1.
Turn off electrical power to the pump box.
2.
Hold down the blue PROGRAM switch on the PCB as you
turn on electrical power to the pump box. Continue to hold the
switch until the first test screen appears.
3.
Use the MENU key to cycle through the screens, which are
numbered in the upper right corner (1 through 8).
4.
To exit this testing mode, turn off electrical power, wait for 5
seconds, then reapply power. The run screen will appear.
Screen # 1: Chemical Pump Control
Use this screen to control the individual chemical pump drives.
SPD is the pump motor’s speed and CURNT is the pump motor’s
current, both in arbitrary units. Typical speeds are 80-90 at fast,
and 20-30 at slow. Typical currents under light load conditions are
5-15 at fast, and 2-6 at slow.
This screen controls the individual transport pumps. The
selected pump runs at the selected speed as long as you hold
down the 4 or 3 key. The break tank operates to provide
water.
FLOW is the current flow rate, updated 3 to 5 times per
minute. SPD is the pump motor’s speed, and CURNT is the
pump motor’s current, both in arbitrary units. Typical speeds
are 35-45 at fast, and 25-35 at slow. Typical currents under
light load conditions are 4-6 at fast, and 2-4 at slow. Pressing
both 4 and 3 keys runs the selected pump at an extra-fast
speed, which may be useful when priming the pump.
Screen # 5: Washer Output Control
This screen varies depending on whether the selected washer
is connected to a ILS Max emulation system.
The selected pump remains on, in the direction selected, as long as
you hold down the appropriate key. This function may be useful in
manual priming of unusually long or large chemical supply hoses.
Use caution when running the pumps in this
mode, as the transport system is not
running. As such, once the pump is primed,
further running of the chemical pump may
cause concentrated chemical to be pumped
into the manifold and transport system.
34
1208135
•
Use the screen to control the washer modules as follows:
Press 4 and 3 to increment formula set on RS-3000.
Current formula is shown.
•
Press 4 to turn the sequence running light on (RS3000).
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
•
Press 3 to turn the bleach defeat light on (first TR-7000-AC)
ILS Max Emulation
Use this screen to exercise the serial ports of the PCB. You
can set the transmit output of the selected port to 0 or 1.
NETWORK toggles between the network port and the printer
port.
REPORTS
The dispenser produces a range of reports that provide
management, maintenance and troubleshooting information.
The available reports are:
Use the screen to control the Washer Interface Module as follows:
•
Pump (System) Setup
•
Press 4 and 3 to turn the POD light on.
•
Chemical Use
•
Press 4 to turn the alarm relay on.
•
Pump Stored Strip
•
Press 3 to turn the hold relay on.
•
Pump Running Strip
•
Washer Activity
•
Washer Load ID Setup
•
Washer Trigger Setup
•
Washer Stored Strip
•
Washer Running Strip
Screen # 6: Washer Interface Input Read
For ILS Max emulation systems only. Use this screen to monitor
the state of the two trigger inputs, and the POD cell of the selected
washer interface.
Screen # 7: Washer Module Input Read
Washer Cycle Record
•
Washer Error Cycle
•
Washer Production Summary
REPORTS MODE
To print reports from the pump box with the briefcase printer:
Use this screen to view the trigger status of all modules connected
to the selected washer. The top line at the right displays
BETALINK or ALPHABUS, depending on the type of trigger
modules in use.
1= or 2=
•
1.
Plug the printer cable into the pump box printer port on
the PCB inside the pump box, and into the printer data
input plug.
2.
Turn the printer power switch on. Make sure the printer
is online and press form feed until the paper is at the top
of a page. If the online light is off, press the On Line
switch on the printer.
3.
Simultaneously press the 5 and 6 keys until you see:
4.
To set the report period, press the MENU key. This may
be done at any time from any report screen. You can
report on the last 01 to 99 days as shown in the top
screen below, or you can set the days to 00 and set
starting and ending dates, as shown in the bottom screen
below.
is the status of the trigger inputs on the TR-7000-AC
Trigger Modules (1 or 2).
BCH DFT is the status of the bleach defeat input on the
TR-7000-AC.
FORM
is the current formula on the RS-3000 Formula Select
Module.
SEQ
is the status of the start button on the RS-3000.
SEQ TRIG is the status of the trigger input on the RS-3000
(unused).
Screen # 8: Serial Port Test
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
35
SYSTEM SETUP REPORT
5.
To print a report, display the report type screen and press the
PRINT key to start printing the report. When the printing is
complete, unplug the printer cable from the system. You can
halt printing while it is occurring by pressing the Print key.
This report is a hard copy of setup information. It contains
present chemical pump calibrations, service life and
replacement date for the pump tubes, pump motors, and
transport pump, washer flow rates and transport times. Print
this report at each service call or whenever you change setups.
It is possible to exit the print screen while
the print mode is still active (for example,
while printing a Washer Running Strip
report). To do so, press the 3 and 4 keys
to advance to the next mode (interrogation).
All menu and setup functions are available
while the printer is active. When desired, or
when printing is complete, return to the
Print menu and turn off the print function.
Figure 14. System Setup Report
36
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
CHEMICAL USE REPORT
This report gives the total amount of chemical pumped by the
dispenser during the report period. The memory storage capacity
for chemical use totals is the last 3100 wash cycles. Usage is
shown in shift and period totals.
Figure 15. Chemical Use Report
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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37
PUMP STORED STRIP REPORT
The Pump Stored Strip report is a chronological log of all pump
box activity for the period selected or the last 2700 records. This is
a very helpful diagnostic tool for reconstructing wash aisle feed
events. This is the same information that is presented by the
interrogation mode stored strip screen.
To select the report start point, press the Menu key. The screen
displays a section of the Pump Stored Strip report. Select the
desired starting point by pressing 5 or 6 to scroll up or down
(holding the key down increases the speed of the scroll, and
pressing 3 or 4 returns to the most recent event). Press
Menu again to exit the Date Select mode, and then press Print.
The Pump Stored Strip report records every feed request and
all subsequent information about that feed, as well as a
complete record of system status. This will include such
things as BetaLink status, water flow problems, and loss and
establishment of line power to the pump box (with the
appropriate date and time stamp).
DF1MF16
Figure 16. Pump Stored Strip Report
38
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
PUMP RUNNING STRIP REPORT
This is a real time version of the Pump Stored Strip. Pump events
are printed as they occur. This is useful when tracking pump box
activity while the wash aisle runs.
Figure 17. Pump Running Strip Report
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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39
WASHER ACTIVITY REPORT
This report gives information on efficiency — how many chemical
feeds each washer received and total hold time for each washer if
the washer supports holds. Memory capacity for this data is the last
3100 wash cycles. This information is valuable for deciding how
many washers the dispenser can efficiently service.
DF1MF18
Figure 18. Washer Activity Report
40
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
WASHER LOAD ID SETUP REPORT
that occurred during a load. This information is not required
in PDCI modes, and so is not listed.
This report is the primary washer setup report. It shows all of the
classification (wash cycle) names, and other cycle-related
information. The data reported changes when the washer is
utilizing a PDCI triggering mode.
In all trigger modes, the cycle time forms the basis for the
excess run time calculation in washer reports, and weight is
used as part of the cost calculations. The machine control
logic settings (normal/reverse) are also shown.
In non-PDCI modes, the report shows the cycle qualification drain
and trigger counts. The dispenser uses this information to identify
wash loads based on a match of the qualifiers, and those events
In PDCI modes, the cycle-add time is listed. It is used to
adjust the measured cycle duration to equal the actual cycle
duration.
DF1MF19
Figure 19. Washer Load ID Setup Report - Non-PDCI Triggering Mode
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
41
DF1MF20
Figure 20. Washer Load ID Setup Report - PDCI Triggering Mode
42
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
WASHER TRIGGER SETUP REPORT
This report shows a washer’s trigger configuration and setup. The
data varies depending on trigger mode setting (relay, automatic or
formula). The report shows call rate or injection amounts,
depending on trigger mode. The relay mode version shows call rate
of the chemical pumps, and maximum trigger time setting. Call
rate is the amount of chemical that will be dispensed by the pump
for each second of trigger on time.
DF1MF21
Figure 21. Washer Trigger Setup Report (Relay Mode
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
43
Both the formula and the automatic mode Washer Trigger Setup
reports show the dispensing matrix that the system will follow in
response to a given trigger pattern. There are 30 formulas available
in PDCI formula mode (report requires four pages), and 16
formulas in the other formula modes (report requires two pages).
DF1MF22
Figure 22. Washer Trigger Setup Report (Formula Mode)
44
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Automatic mode has 32 functions available.
DF1MF23
Figure 23. Washer Trigger Setup (Automatic Mode)
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
45
WASHER RUNNING STRIP REPORT
of asterisks is printed, followed by a cycle summary. Input
changes that occur between cycles are not shown.
This report is a diagnostic tool for verifying status and timing of
the washer and chemical trigger signals. Each time a channel
changes state, the report logs the event. This report is also useful to
diagnose washer problems such as leaking drain valves (indicated
by repeated water fills during a bath) or low water temperature
(indicated by excessive steaming).
The Hold and Alarm columns reflect the status of the Washer
Interface Module in a ILS Max emulation system. Alarm does
not reflect the status of the alarm relay in the pump box. The
Accum Trig. column is on in PDCI triggering modes while
triggers are being accumulated. When the accumulation
process ends, another line is printed with Accum Trig. off,
and with the composite accumulated trigger code. It is the
trigger code, at this time, that is seen by the feed triggering
logic.
When this report is started while a wash cycle is running, all events
from the beginning of the cycle to the present time will be printed
before real time printing begins. At the conclusion of a cycle, a line
DF1MF24
Figure 24. Washer Running Strip Report
46
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
WASHER STORED STRIP REPORT
events for all washers. Therefore, with fewer washers enabled
for logging, more records can be captured per washer.
This report is a logged version of the Washer Running Strip. The
logging feature must be enabled in washer setup. This allows you
to diagnose multiple washers at the same time, or have the stored
strip running during normal operation of the wash aisle to catch a
“once in a while” event. The report can include 1400 lines of
Unlike the running strip report, the stored strip report does
report events that occurred between wash cycles. This
includes the accumulation of the cycle start code in PDCI
triggering modes. These between cycle events may be
recognized by the blank cycle time. This report does not
generate cycle summary information.
DF1MF25
Figure 25. Washer Stored Strip Report
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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47
WASHER CYCLE RECORD REPORT
This report is a representation of all valid cycle data stored in
memory on the performance of the individual washers. All other
historical reports are based on the information contained in this
file. This record is a total of 3100 cycles maximum for all washers
served. You can print the cycle record for any or all cycle
classifications, or all washers, during the selected time period. This
is a valuable historical document for evaluation of wash aisle and
machine performance as well as verifying chemical injections for
individual loads. Unidentifiable loads may be diagnosed and
resolved, usually by combining with adjacent unidentified loads, as
they are usually the result of broken or interrupted cycles (that is,
an extract imbalance or addition of dry chemical).
The chemical usage may be 0 even though
a qualifier trigger is shown. This may be the
result of a 0 amount being called (check the
setup report) or an aborted chemical feed
(feed rejected because drain was open or
the Machine On signal was off) or the
channel was not assigned. Check the pump
and washer running strip reports for
detailed analysis.
For a cycle to be recorded, it must be a valid cycle—at least
five minutes in duration, with a qualified drain. However, any
cycle with a chemical injection will be reported, regardless of
cycle length. The (*) in the column between cycle start time
and cycle name indicates that there was a chemical feed
irregularity in the load.
DF1MF26
Figure 26. Washer Cycle Record Report (All Cycles
48
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
WASHER ERROR CYCLE REPORT
A variation of the Washer Cycle Record, this report lists cycles
that had an error in the feed within the specified date range, and
reports which chemical feed had the error. An error does not
indicate whether chemical was delivered, just that the
dispenser detected something abnormal about the reported
feed. Refer to the stored strips for analysis and
troubleshooting.
DF1MF27
Figure 27. Washer Error Cycle Report
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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49
WASHER PRODUCTION SUMMARY
REPORT
This report provides summary data of load count and average
chemical cost (per 100 lb or 100 Kg) by classification or by
washer. When an individual washer is selected, the totals are by
classification, by shift. The weight used to calculate the cost per
100 weight for unidentified loads is the weight of classification
#30. The report also provides washer efficiency data such as
total machine on time, average turnaround time and average
excess time. Excess time is the time in excess of the cycle run
time programmed in the cycle ID setup. Large excess times
are usually the result of excessive steam up times or long
water fill times. The average turnaround time is calculated on
a per shift basis. Load changes that occur across a shift
boundary are not used in the calculation.
DF1MF28
Figure 28. Production Summary Report (By Washer
50
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
When All Washers is selected, the totals are for all classifications
run by washer, by shift.
DF1MF29
Figure 29. Production Summary Report (All Washers)
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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51
MAINTENANCE
REPLACEMENTS
5.
Unplug cable and remove LCD display.
6.
Reinstall in the reverse order.
7.
Turn on electrical power to the pump box.
When reinstalling LCD display, ensure that
the four standoffs remain on the LCD
mounting studs.
Always disconnect power to the pump box
before beginning service. The system can
trigger automatically and cause severe injury
if the power is not disconnected.
PROM (Software)
PCB
When servicing or replacing the PCB, use
extreme caution to prevent shorting the RAM
devices. These devices are under power at
all times, even with the board completely
removed from the system, since they have
battery backup power.
At times, a new PROM (Programmable Read-Only Memory)
with updated software will be issued for the pump box.
Do not place the PCB on any conductive
surface, such as the lid of the adjacent
auxiliary pump modules or a metal
workbench. Failure to observe this caution
may result in the loss of all stored data, and
possibly result in destruction of the PCB.
Procedure
1. Turn off electrical power to the pump box.
Tools Required
•
Phillips head screwdriver
•
Tools Required
•
Phillips head screwdriver
Integrated circuit (IC) removal tool (PLCC style)
2.
Loosen the 2 screws that fasten top lid.
3.
Unlock and open top lid.
4.
Locate the PROM socket on the PCB.
Older versions of the PCB have the PROM
socket oriented differently. Verify the location
of the beveled corner of the socket before
proceeding.
Procedure
1. Turn off electrical power to the pump box.
5.
To remove the PROM IC from the socket, insert the IC
removal tool into the space at the upper left and lower
right corners of the socket and lift the IC out of the
socket. If you don’t have an IC removal tool, you can
push the PROM out of its socket by pushing with a small
rod from the back side of the PCB. Exercise caution
when removing the device, as the pins may be easily
bent.
6.
Place the new PROM, illustrated below, in socket with
the bevel in the lower left corner. Check that the pins
align properly and press in firmly to seat the PROM.
Procedure
1. Turn off electrical power to the pump box.
7.
Turn on electrical power to the pump box.
2.
Loosen the 2 screws that fasten top lid.
8.
3.
Unlock and open top lid.
4.
Remove the 4 2-56 LCD mounting nuts.
After replacing the PROM with a newer version, it may
be necessary to clear the setup memory and/or the logged
data memory. A warning screen will inform you if this is
2.
Loosen the 2 screws that fasten top lid.
3.
Unlock and open top lid.
4.
Remove connectors from PCB locations J4, J5, J6, J8, J9, J10,
J16. Remove connectors from PCB locations J1, J2, J3, and
J11, if applicable.
5.
Remove 14 conductor LCD ribbon cable from PCB connector
J19.
6.
Remove 7-conductor keypad ribbon cable from PCB
connector J18.
7.
Remove the 7 PCB mounting screws and 7 lock washers.
8.
Lift PCB assembly out of the enclosure.
9.
Reinstall new PCB assembly in the reverse order.
10. Turn on electrical power to the pump box.
Do not replace the battery located on the
PCB. To do so will result in the loss of all
setup and logged data.
LCD Display
Tools Required
•
Phillips head screwdriver
•
52
3/16 in nut driver
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
the case. If this screen appears, follow the clear memory
procedure under Service.
Keypad
The keypad is a non-repairable assembly. If the keypad is
defective, the front label assembly must be replaced. The label is in
two parts. The spacer contains the keypad. The overlay covers the
spacer, and contains the screen window.
Tools Required
•
7/16 inch open-end wrench
•
DF1M03
7/8 inch open-end wrench
Procedure
1. Turn off electrical power to the pump box.
Released
2.
Loosen the 2 screws that fasten top lid.
3.
Unlock and open top lid.
4.
Remove the catch from the lock, then remove the lock.
5.
Unplug the wires from the circuit breaker and remove it.
6.
Disconnect the keypad ribbon cable from the PCB.
7.
Peel the old label/keypad assembly from the unit. Heat from a
hair dryer might make this easier.
8.
Clean off any residual adhesive from the enclosure.
9.
Peel protective backing from the new spacer/keypad.
10. Feed the keypad ribbon cable through the cutout in the panel.
Be certain that the cable is aligned in the center of the lower
notch.
11. Check the alignment of the circuit breaker, lock and mounting
screen holes as you press the spacer in place.
12. Reconnect the ribbon cable to the PCB at connector J19.
3.
Cut tie wraps, remove the supply and feed lines from the
old pump and connect them to the new pump.
4.
Align and engage the pump drive spline with the motor
gear by rotating the roller assembly until the cartridge is
seated in the face plate recess.
5.
Lock the pump cartridge in the motor housing by
twisting the 4 snap pin tabs to vertical (locked), as
illustrated.
6.
Hold the cartridge vertically in the face plate recess and
press the pin tabs back until you hear a distinct click.
7.
Turn on electrical power to the pump box.
8.
Reset the pump tube life via the setup screen.
Chemical Pump Squeeze Tubing
The dispenser displays a Worn Chemical Pump Tube error
message when the flow rate from the chemical pump is less
than 50% of its original value. You should replace the tube
when this occurs.
Tools Required
•
Wire cutters
13. Replace the lock and catch.
14. Peel protective backing from the overlay.
15. Carefully align the overlay to the spacer, using the lock and
the screen window as guides. Press the overlay into place.
16. Replace and reconnect the circuit breaker.
Chemical Pump Cartridge
Tools Required
•
Wire cutters
•
Locked
Tie wraps
Procedure
Wear adequate protective clothing such as
gloves and glasses.
•
Tie wraps
Procedure
Wear adequate protective clothing such as
gloves and glasses.
1.
Turn off electrical power to the pump box.
2.
Remove the chemical pump cartridge from the motor
housing by twisting the 4 snap pins in the corners of the
cartridge.
3.
Pull the adapter fittings rearward until they clear the
cartridge.
1.
Turn off electrical power to the pump box.
4.
2.
Remove the pump cartridge from the motor housing by
twisting the 4 snap pin tabs in the corners of the cartridge to
horizontal (released), as shown in the following illustration.
Pull the roller assembly rearward to release the pump
squeeze tubing.
5.
Cut the tie wraps holding the pump squeeze tubing to the
adapter fittings and pull the tubing from the fittings.
6.
Replace the pump squeeze tubing.
7.
Push the adapters onto the ends of the tubing and secure
with tie wraps. Make certain that the buckles of the tie
wraps are both facing the same direction. This will keep
the tube from twisting in the cartridge.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
53
8.
9.
Press the 2 adapter fittings into the cartridge so the tie wrap
buckles face the center of the pump. The tube must not be
twisted inside the assembly.
Push the roller assembly onto the cartridge shaft by
compressing the springs of the upper roller arm.
10. Turn the 4 snap pin tabs on the chemical pump cartridge to
vertical.
Transport Pump
Transport pumps may be individually replaced or repaired in
place. You must replace the entire pump if the motor does not
turn.
Tools Required
•
Phillips head screwdriver
•
3/8 in nut driver
•
1/4 in nut driver
12. Turn on electrical power to the pump box.
•
Wire cutters
13. Reset the pump tube life via the setup screen.
•
Tie wraps
Pump Motor/Gear Box Assembly
•
7/8 in open-end wrench
Tools Required
•
Phillips head screwdriver
•
11/16 in open-end wrench
•
9/16 in open-end wrench
Procedure
1. Turn off electrical power to the pump box.
•
Pipe thread sealant
11. Hold the cartridge vertically in the face plate recess and press
the pin tabs back until you hear a distinct click.
2.
Turn the 4 snap pins on pump cartridge assembly 90 degrees
left or right and remove pump cartridge assembly from unit.
Suction and discharge hoses need not be removed. Support
the cartridge as required.
ATTACHING
SCREWS
DF1M04
Procedure
1. Turn off electrical power to the pump box.
2.
Remove the three screws that fasten front door. (One
screw is inside the top enclosure, beneath the lock. It
does not need to be completely removed.)
3.
Open the front door (it will hang open).
4.
Disconnect transport pump wire connectors. Note
polarity.
5.
Disconnect hose on transport pump output (to washers)
by loosening tube fitting on elbow. (If the tube fitting
cannot be removed by hand, use a 7/8 in open-end
wrench to loosen the tube fitting.)
6.
Cut tie wraps and remove tubing from tee on inlet side of
transport pump.
3.
Remove the three screws that fasten front door. (One screw is
inside the top enclosure, beneath the lock. It does not need to
be completely removed.)
7.
Remove the three 6-32 nuts from transport pump
mounting bracket.
4.
Open the front door (it will hang open).
8.
5.
Remove the 2 motor wire connectors from motor contacts for
the pump motor/gear box to be replaced. Note polarity.
Remove transport pump and transport pump mounting
bracket from unit.
9.
6.
Swing front door up and hold the door and pump motor while
unscrewing the 2 motor mounting plate screws from the front
of the unit. See illustration above.
Place transport pump and transport pump mounting
bracket on bench and remove the four 10-32 mounting
nuts.
7.
Note the orientation of the red dot on the pump motor.
Remove pump motor/gearbox assembly and motor mounting
plate from unit.
8.
Reinstall in the reverse order.
12. Install tube fittings in new transport pump.
14. Turn on electrical power to the pump box.
15. Reset the pump life via the setup screen.
Transport Pump Head
Turn on electrical power to the pump box.
Although repair kits are available for the pump valve
assembly, it is recommended that you replace the entire pump
head. This will expedite repair of the system and allow it to be
returned to service more quickly. Replacement of the pump
head can be completed in the following manner if necessary.
10. Reset the pump motor life via the setup screen.
54
11. Apply pipe sealant to tube fitting threads.
13. Reinstall in the reverse order from step 10. The 10-32
nuts that hold the pump to the bracket should only be
tightened until the stud is level with the top of the nut.
If the spline for the spinner in pump
cartridge assembly is not aligned properly
with the spline for pump gearbox assembly
the snap pins will not seat properly upon
reinstallation.
9.
10. Remove tube fittings (tee and elbow) from transport
pump.
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Tools Required
•
Phillips head screwdriver
7.
Loosen tube-fitting nut for water inlet to the break tank
and remove tube from fitting mounted on hanger bracket.
(If the tube fitting cannot be removed by hand, use a 7/8
in open-end wrench to loosen the tube fitting.)
•
Wire cutters
•
Tie wraps
8.
Remove the two 6-32 break tank mounting bracket nuts.
•
7/8 in open-end wrench
9.
•
11/16 in open-end wrench
Pull break tank assembly forward. It is not necessary to
disconnect the two tubes attached to the assembly.
•
9/16 in open-end wrench
•
Pipe thread sealant
10. Remove the two 6-32 float switch hanger bracket nuts.
(Nuts face up from top of assembly.)
11. Loosen and remove black plastic nut that fastens float
switch. Float switch can then be removed.
Procedure
1. Disconnect power to the pump box.
12. Obtain new float switch and trim wires to the following
lengths:
2.
Disconnect the manifold and transport fittings.
3.
Remove the screws securing transport pump head.
4.
Remove pump head by sliding down from motor.
5.
Transfer fittings to the new pump head. Use thread sealant.
6.
Slide pump head up onto pump motor.
13. Strip wire end 1/8 inch.
7.
Reconnect manifold and transport tubes.
14. Crimp 1/4 inch male quick disconnects to each wire.
8.
Run the transport pump and check all fittings for leaks.
9.
Reset the pump life via the setup screen.
15. Verify that the switch output is closed when the blue
float is in the low position. If not, remove the retaining
clip from the switch shaft and reverse the blue float end
for end. This will reverse the polarity of the switch
output.
Float Switch Assembly
Tools Required
•
Phillips head screwdriver
•
1/4 in nut driver
•
7/8 in open-end wrench
•
9/16 in open-end wrench
•
Wire cutters
•
Wire strippers
•
Wire crimper
•
1/4 inch male quick disconnect crimp lugs
•
High-level float switch - 5 inches from top of float
switch
•
Low-level float switch - 6 inches from top of float
switch
SWITCH OPEN
Procedure
If you replace either float switch in the
break tank, you must recalibrate the break
tank. See Calibrate Break Tank in this
section.
FLOAT
DF1M05
SWITCH CLOSED
1.
Turn off supply water to the pump box.
2.
Empty the break tank.
3.
Turn off electrical power to the pump box.
4.
Remove the three screws that fasten front door. (One screw is
inside the top enclosure, beneath the lock. It does not need to
be completely removed.)
RETAINING CLIP
FLOAT SWITCH POLARITY
16. Reinstall float switch and tighten black plastic nut.
17. Reinstall break tank in the reverse order from step 10.
5.
Open the front door (it will hang open).
18. Turn on electrical power to the pump box.
6.
Disconnect the 4 float switch wires. Note orientation from
harness:
19. Reset the float switch life via the setup screen.
•
White/Orange wire to high-level float switch.
•
White/Yellow wire to low level float switch.
•
White wires are common.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
POF Probe
Tools Required
•
Phillips head screwdriver
1208135
55
Procedure
You can remove the POF cell for cleaning or replacement using
the following procedure, whether the POF cell is installed in the
pump box or auxiliary pump housing.
11. Reinstall in the reverse order.
12. Turn on supply water to the pump box.
13. Turn on electrical power to the pump box.
14. Reset the valve life via the setup screen.
1.
Turn off electrical power to the pump box.
2.
Loosen the 2 screws that fasten top lid.
3.
Unlock and open top lid.
4.
Remove the three screws that fasten front door (One screw is
inside the top enclosure, beneath the lock. It does not need to
be completely removed).
SERVICE
5.
Open the front door (it will hang open).
6.
Loosen the blue retaining nut and withdraw the probe from
the tee fitting. Take care not to misplace the D shaped gasket.
7.
If you are replacing the probe, disconnect the POF cable
connector J16 at the PCB. Pull the cable through the clearance
hole.
8.
Clean or replace probe as necessary.
9.
Reinsert the probe into the tee fitting and hand tighten the nut.
Remember to check for the gasket.
Change or Transport Random Access
Memory (RAM)
All of the system setup information, as well as all logged data,
is stored in two RAM devices. Some RAM models have
internal batteries that allow them to be moved from one PCB
to another, thus preserving the stored data.
For standard systems, the RAM backup battery is located on
the PC board and removal of the RAM will cause loss of all
logged and setup data. Units supplied with nonvolatile RAM
will have a jumper bar across the NOV position of J14. The
jumper will be across the STD position for standard units.
Use caution when removing and replacing
the RAM to ensure that all of the device
pins are straight and properly aligned. Take
care not to damage the pins. When
attempting to change or transport RAMs,
use extreme caution since they are static
sensitive.
10. Reconnect the probe cable to the PCB.
11. Turn on electrical power to the pump box.
12. Run the transport system to check for leaks.
13. Secure the front panel.
There are two RAM devices on each PCB. When transferring
the devices, make certain that they are reinserted in the proper
location in the new PCB.
Solenoid Valve/Flow Regulator
Tools Required
•
Phillips head screwdriver
•
5/8 in open-end wrench
•
7/8 in open-end wrench
Clear Memory
RAM is normally cleared prior to shipment from the factory.
Although you may change the setup information, you may
also reset all setups to the factory defaults by a special
procedure described below. Historical data (chemical use,
cycle data and stored strip data) can only be cleared using the
special procedure described below.
Procedure
1. Turn off electrical power to the pump box.
2.
Turn off supply water to the pump box. Relieve pressure from
the line.
3.
Loosen the 2 screws that fasten top lid.
4.
Unlock and open top lid.
5.
Remove connector from PCB Assembly (J6).
6.
Remove the 2 wire connectors attached to solenoid valve
(purple wires).
7.
Remove the three screws that fasten front door (One screw is
inside the top enclosure, beneath the lock. It does not need to
be completely removed).
When purging both setup and logged data,
always perform the setup purge first.
8.
Open the front door (it will hang open).
9.
Reach through to the two tube fittings attached to the solenoid
valve/flow regulator assembly and remove by hand (If the
tube fittings cannot be removed by hand, use a 5/8 in or 7/8in
open-end wrench to loosen the tube fittings).
10. If present, remove the short lengths of tubing located between
the retaining tabs and body of the solenoid valve. Depress the
black retaining tabs on the top portion of the solenoid valve,
then remove valve and regulator through bottom portion of
the unit.
56
Use the following procedures with extreme
caution. The entire dispenser memory
content is vulnerable.
1208135
Clear Setup Data
1. Turn off power to the pump box.
2.
Press and hold the blue button on the PCB.
3.
While continuing to press the blue button, press and hold
the 5 and 6 keys and turn on the dispenser.
4.
Watch for the purge confirmation message on the LCD
screen. The purge process takes several seconds, and the
message passes very quickly. This returns all setup data
to its default values.
Clear Logged Data
1. Turn off power to the pump box.
2.
Press and hold the blue button switch on the PCB.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
3.
While continuing to press the blue switch, press and hold the
3 and 4 keys and turn on the dispenser.
4.
Watch for the purge confirmation message on the LCD
screen. The purge process takes several seconds and the
message passes very quickly. All logged data is now purged.
Manifold Filter
Tools Required
•
A calibrated measuring container of at least 300 milliliter
capacity (for procedure 1) or 2.5 liter capacity
(for procedure 2)
•
7/8 inch open-end wrench
Procedure 1 - Volume Measurement
Tools Required
•
Phillips head screwdriver
During this procedure, the wash aisle must
be idle.
Procedure
1. Turn off electrical power to the pump box.
1.
Remove the three screws that fasten front door (One screw is
inside the top enclosure, beneath the lock. It does not need to
be completely removed).
Restart the dispenser in the test mode (see Advanced
Troubleshooting). Scroll to test screen #3. The third
line, Water Level, is the indication of the state of the
float switches.
2.
If it is not empty, drain the water from the break tank.
Test screen #3 should indicate LOW for Water Level.
5.
Open the front door (it will hang open).
3.
6.
Unscrew and remove the filter cap, by hand.
Slowly fill the break tank until the Water Level reading
just changes to OK. This indicates the switch point of the
low-level float switch.
7.
Remove the filter screen and rinse if necessary.
4.
8.
Replace the filter screen and reinstall the cap. Tighten by
hand.
9.
Turn on electrical power to the pump box.
Add and carefully measure to the nearest five milliliters
the amount of water that it takes to just change the Water
Level reading from OK to HIGH. This indicates the
switch point of the upper float switch. The measured
amount is the CAL VOLUME. Record this amount on
the break tank calibration tag.
5.
Restart dispenser in normal run mode.
6.
Go to pump setup mode and scroll to the Flow Meter
Calibration screen. Enter the new CAL VOLUME
amount.
2.
Loosen the 2 screws that fasten top lid.
3.
Unlock and open top lid.
4.
10. Run the transport system to check for leaks and to purge the
air from the filter.
11. Secure the front panel.
POF Probe
1.
Turn off electrical power to the pump box.
2.
Open the front door (it will hang open).
3.
Unscrew the retaining nut that holds the POF probe in the
POF cell.
4.
Remove the probe from the cell. Be certain not to lose or
damage the probe gasket.
5.
Clean the cell probes with a fine abrasive and rinse with clear
water.
6.
Reinstall in the reverse order. Tighten the retaining nut to
only hand tight.
Calibrate Break Tank
If you replace the break tank, alter the settings of the float
switches, or replace one or both float switches, you must
recalibrate the break tank. There are two procedures you may
choose from to calibrate the break tank. The second procedure is
the most accurate, but is harder to perform.
For the result to be useful, the
measurements must be made accurately. If
you do not have the equipment required for
accurate measurement, it is better to use
the default calibration volume of 250
milliliters.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
Procedure 2 - Direct Flow Measurement
During this procedure, the wash aisle must
be idle. Chemical requests may interfere
with the process.
1.
Disconnect any one of the transport tubes at the
discharge side of the transport pump. You may wish to
connect a short section of transport tube to the outlet of
the transport pump that will conveniently reach to the
measuring container.
2.
Go to pump setup mode and scroll to the Flow Meter
Calibration screen. Select the pump whose output has
been disconnected.
3.
Place the measuring container under the disconnected
transport pump. Run the pump briefly to clear any air
that may be in the manifold. Discard the collected water.
4.
Start and run the transport pump for exactly 1 minute,
collecting the water in the container. Measure the
volume of water (to the nearest 50 milliliters) at the end
of the 1-minute run.
5.
While capturing the water flow from the pump, write
down the flow readings on the screen each time a new
reading appears (This happens just as the water valve
opens. Listen for the click of the solenoid valve). There
will typically be four readings in 60 seconds.
6.
Calculate the average of all readings taken.
57
7.
Calculate the correction factor as follows. Divide the amount
measured in step 4 by the average calculated in step 6. The
result should be very close to 1.
8.
Multiply the correction factor by the CAL VOLUME shown
in the pump setup screen. The result is the new CAL
VOLUME. Enter this new value in the setup screen and
record it on the break tank tag.
First TR-7000-AC
Second TR-7000-AC (Optional)
Trigger
Channel
Function
Trigger
Channel
Function
1
Chemical
Pump 1
1
Sewer Drain
2
Chemical
Pump 2
2
Cold Fill
Tools Required
•
Phillips head screwdriver
3
Chemical
Pump 3
3
Hot Fill
•
4
4
Steam
Procedure
1. Remove the solenoid valve as described in Replacements.
Chemical
Pump 4
5
Chemical
Pump 5
5
Chemical Pump 7
2.
Remove the filter access plug from the valve. Remove and
clean the filter screen if necessary. Replace the filter and plug.
6
Chemical
Pump 6
6
Reuse Drain or
Chemical Pump 8
3.
Reinstall the water solenoid valve by reversing the removal
procedure.
7
Machine On
7
Reuse Fill
Solenoid Valve
5/8 inch open-end wrench
APPENDIX A. FEED MODES &
TR-7000-AC TRIGGERS
This appendix:
•
Defines each non-PDCI chemical feed mode, which you
specify during washer setup.
•
Shows the trigger assignments that are used by the TR-7000AC Trigger Module for each feed mode.
•
Lists the trigger timing limitations imposed by each feed
mode.
Table 9. Relay Mode TR-7000-AC Trigger Assignments
ENHANCED RELAY MODE
Enhanced Relay Mode is similar to Relay Mode and is for
situations where there are a limited number of chemical
triggers available from a microprocessor-controlled washer
(you have more chemicals than available signals). Like Relay
Mode, signal on time determines the amount of chemical.
Unlike Relay Mode, combinations of triggers can select
which chemical is pumped.
The TR-7000-AC trigger channels equate to the washer
functions listed in Table 10.
The PDCI chemical feed modes are
covered in Appendix B.
First TR-7000-AC
RELAY MODE
Relay mode is for microprocessor-controlled washers. The washer
controller delivers a signal of specified time to the dispenser,
which converts the duration of the signal into a chemical feed
amount. Requires one trigger for each chemical. Relay mode
trigger connections are not programmable. Trigger channel #1
triggers chemical pump #1, trigger channel #2 triggers chemical
pump #2, and so on.
Trigger channels 1-6 are for pumps 1-6 as needed. Trigger channel
7 is reserved for the machine on signal. If the account requires
more than 6 chemicals, you must add the second TR-7000-AC or
use Enhanced Relay Mode.
The TR-7000-AC channels equate to the trigger functions listed in
Table 9.
Second TR-7000-AC
(Optional)
Channel
Trigger
Assignment
Channel
Trigger
Assignment
1
See Chemical Pump
Triggers Table
1
Sewer Drain*
2
See Chemical Pump
Triggers Table
2
Cold Fill
3
See Chemical Pump
Triggers Table
3
Hot Fill
4
See Chemical Pump
Triggers Table
4
Steam
5
Unused
5
Unused
6
Sewer Drain**
6
Reuse Drain
7
Machine On
7
Reuse Fill
*This input is used if a second TR-7000-AC is connected
**This input is used only if a single TR-7000-AC is connected.
Table 10. Enhanced Relay Mode TR-7000-AC Trigger
Assignments
In Enhanced Relay Mode, the TR-7000-AC triggers equate to
the washer function listed in Table 11.
58
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Chemical
Pump
Number
Trig
Channel
1
Trig
Channel
2
Trig
Channel
3
Trig
Channel
4
1
ON
OFF
OFF
OFF
2
OFF
ON
OFF
OFF
Trigger
Channel
Function
Trigger
Channel
Function
3
OFF
OFF
ON
OFF
1
Sewer Drain
OFF
OFF
OFF
ON
Up to 3
chemical
pumps
1
4
5
ON
ON
OFF
OFF
2
Cold Fill
ON
OFF
ON
OFF
Up to 3
chemical
pumps
2
6
7
ON
OFF
OFF
ON
3
Hot Fill
OFF
ON
ON
OFF
Up to 3
chemical
pumps
3
8
4
Up to 3
chemical
pumps
4
Steam
5
Up to 3
chemical
pumps
5
Formula
Select Bit 2
6
Formula
Select Bit 1
6
Reuse Drain
or Formula
Select Bit 3
7
Machine On
7
Reuse Fill or
Formula
Select Bit 4.
Table 11. Enhanced Relay Mode, TR-7000-AC Trigger
Assignments
FORMULA MODE
Formula Mode is for washers with chart or card controllers.
Chemical dosing is chosen automatically (from the washer) or
manually (via RS-3000 Formula Select Module). A supply trigger
can occur more than once per load.
Formula mode is typically used in conjunction with mechanical
cycle timers. Chemical amounts are established in setup screens.
Trigger channels 1-5 are used as supply triggers. Channel 6 may be
used as a formula select signal, providing an alternate formula
selection. Up to three fixed amounts may be delivered for each
trigger signal received.
You can increase the number of alternate formulas to 16 by
installing an RS-3000 Formula Select Module or using the formula
select trigger signals F1-F4, respectively. F2 through F4 are
available only with a second TR-7000-AC.
One or more of the F1-F4 formula select signals may be
automatically triggered by alternate formula tracks cut in the wash
formula card (functions as an expanded B and C time trigger).
TR-7000-AC Trigger Assignments to Formula Mode
First TR-7000-AC
Second TR-7000-AC
(optional)
In Latched Formula Mode, you can assign the latch reset
signal to Triggers 1-5 or Machine On.
Table 12. Formula Mode TR-7000-AC Trigger Assignments
In formula mode, there is a 45-second qualifier between
successive allowable washer triggers on the same channel. A
valid signal must be a minimum 2 second duration. A new
signal will not be accepted if it occurs less than 45 seconds
after the previous signal has ended. Refer to Trigger Timing
Limits for more detailed information.
LATCHED FORMULA MODE
Latched Formula Mode is the same as formula mode but each
trigger can only occur once per load. Subsequent trigger
signals are ignored until the latch-reset signal is applied, or
Machine On is detected. The latch-reset signal may also call
chemicals. This mode may be useful in situations where the
supply signal is periodically interrupted because of water
level change, etc.
MIELE FORMULA MODE
Miele formula mode is the same as latched formula mode
except that trigger #2 also latches out trigger #1, even if
trigger #1 has not occurred.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
59
AUTOMATIC MODE
(STROBED/STROBELESS)
This mode provides the capability of triggering one of 32 different
functions. A function can be considered an injection group (for
example, alkali and detergent form a main wash function). A
function can consist of a group of up to 3 different chemicals.
Automatic Mode, Strobeless is for fixed cycle microprocessor
washers. Chemical triggers are encoded. This type of washer is
rare.
Automatic Mode, Strobed is for washers with chart or card
controllers. Chemical triggers are encoded. In Strobed mode,
channel 1 is used as a strobe or read signal, while channels 2-6 are
used as binary encoded chemical inputs.
The chemical trigger inputs (2-6) will not be read until the strobe
(channel 1) is activated for at least 10 seconds. This eliminates the
need for all of the chemical triggers from the controller to activate
simultaneously (the card need not be cut precisely).
If the washer controller has only four triggers available, then it will
only be possible to call eight functions (channels 2, 3, and 4 for
pump control and channel 1 for strobe).
First TR-7000-AC
Second TR-7000-AC
(optional)
Trigger
Channel
Function
Trigger
Channel
Function
1
Strobe (if
used)
1
Sewer Drain
2
See Table 11
2
Cold Fill
3
See Table 11
3
Hot Fill
4
See Table 11
4
Steam
5
See Table 11
5
Unused
6
See Table 11
6
Reuse Drain
7
Machine On
7
Reuse Fill
Table 13. Automatic Mode TR-7000-AC Trigger Assignments
A function is called based on the unique trigger pattern of the 5
trigger inputs (Channels 2-6). Table 14 shows the possible trigger
patterns.
60
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Function
Trig Channel 2
Trig Channel 3
Trig Channel 4
Trig Channel 5
Trig Channel 6
1
OFF
OFF
OFF
OFF
OFF
2
ON
OFF
OFF
OFF
OFF
3
OFF
ON
OFF
OFF
OFF
4
ON
ON
OFF
OFF
OFF
5
OFF
OFF
ON
OFF
OFF
6
ON
OFF
ON
OFF
OFF
7
OFF
ON
ON
OFF
OFF
8
ON
ON
ON
OFF
OFF
9
OFF
OFF
OFF
ON
OFF
10
ON
OFF
OFF
ON
OFF
11
OFF
ON
OFF
ON
OFF
12
ON
ON
OFF
ON
OFF
13
OFF
OFF
ON
ON
OFF
14
ON
OFF
ON
ON
OFF
15
OFF
ON
ON
ON
OFF
16
ON
ON
ON
ON
OFF
17
OFF
OFF
OFF
OFF
ON
18
ON
OFF
OFF
OFF
ON
19
OFF
ON
OFF
OFF
ON
20
ON
ON
OFF
OFF
ON
21
OFF
OFF
ON
OFF
ON
22
ON
OFF
ON
OFF
ON
23
OFF
ON
ON
OFF
ON
24
ON
ON
ON
OFF
ON
25
OFF
OFF
OFF
ON
ON
26
ON
OFF
OFF
ON
ON
27
OFF
ON
OFF
ON
ON
28
ON
ON
OFF
ON
ON
29
OFF
OFF
ON
ON
ON
30
ON
OFF
ON
ON
ON
31
OFF
ON
ON
ON
ON
32
ON
ON
ON
ON
ON
Table 14. Automatic Mode Trigger Patterns
In all of the above modes, the machine on signal may be
connected to trigger channel 7.
MACHINE ON SIGNAL
Use of the Machine On signal is optional, and the system will
pump chemicals without it. However, much of the data presented
in the management information reports relies on the machine on
information. Wash aisle efficiency data such as total machine on
time, turnaround time, and excess time cannot be determined
without a machine on signal.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
Connect the Machine On signal to the door latch or other
appropriate signal. To ensure proper cycle identification, the
Machine On signal must be wired to remain uninterrupted for
the entire machine cycle.
If a Machine On signal is not connected, the Machine On
signal must be set up for reverse logic. This will cause the
61
machine on input to appear to be on all the time. See Washer
Setup Mode.
TR-7000-AC
CH1
CH2
+
-
INPUT
CH3
TRIGGER TIMING LIMITS
WHT
24
VAC
BETALINK
CH4
GRN
+
RED
-
BLK
GND
BRN
CH5
CH6
Table 15 lists the timing limitations which must be considered
when programming the wash wheel. For more information, see
Appendix B, C, F, G and Table 21.
+5VDC
WHT
ALPHABUS
Tx
RED
Rx
BLK
GND
GRN
CH7
Tx
Rx
ADDRESS
SELECT
USE BLACK LEADS
WITH ADJACENT
COLOR LEADS AS A
PAIR TO CONNECT
TO TRIGGERS
Note that all patterns must first be returned to the off state for 1
second before the next trigger pattern is called by the washer.
Signal and Trigger Timing Limits
BLK
Signal
Mode
Time
Machine On
Signal
All Modes
2-second minimum
state change for on/off
recognition
Drain Signal(s)
All Modes
5-second minimum
on/off time
Utility Signals
All Modes
2-second minimum
on/off time
Chemical
Triggers
Relay Mode &
Enhanced Relay
Mode
1/2-second minimum
on/off time.
BRN
BLK
RED
BLK
ORN
BLK
YEL
BLK
GRN
BLK
BLU
L-4000 Supply Trigger Signal Inputs
Alkali
Detergent
Bleach
Sour
Soft
1
2
3
4
5
BLK
VIO
Alternate
Formula
Trigger
L-4000E
TERMINAL BLOCK
SHOWN FOR
REFERENCE
ONLY
DF1MA01
PAIRS FROM MACHINE TRIGGERS AS IDENTIFIED
IN THE IWD MANUAL
1-second resolution.
Signals from 1/2 to 3/8
seconds are logged
and interpreted as
1-second; signals from
1-1/2 to 2-3/8 seconds
are treated as 2
seconds, and so on.
Chemical
Triggers
Formula Mode &
Automatic Mode
2 seconds minimum
on time.
45 seconds minimum
off time.
Formula
Select
Triggers
Formula Mode
Strobe
Automatic Mode
2-second minimum
on/off time.
5 seconds minimum
on time.
45 seconds minimum
off time.
Washer
Triggers
Formula Mode &
Automatic Mode
2-second minimum is
required between
when F1-F4 formula
select triggers are
turned off and the next
chemical request.
2-second minimum is
required when formula
select signals are
asserted and the next
chemical request.
Table 15. Trigger Timing Limits
62
1208135
APPENDIX B. PRE-DOSE
CLASSIFICATION
IDENTIFICATION
This appendix covers the PDCI chemical feed modes, and
some of the special considerations that are required when
using these modes. This appendix:
•
Describes the accumulating trigger method utilized by
the PDCI feed modes.
•
Defines the control codes used by the PDCI feed modes
to track and identify wash cycles.
•
Defines each PDCI chemical feed mode, which you
specify during washer setup.
•
Shows the trigger assignments used by the TR-7000-AC
Trigger Module for each feed mode.
•
Lists the trigger timing limitations imposed by each feed
mode.
INTRODUCTION TO PDCI
Pre-Dose Classification Identification is a method of encoding
triggers that allows a programmable washer to signal the start,
type, and end of wash cycles, as well as to request chemicals.
Using PDCI eliminates the need for an RS-3000 Formula
Select Module in order to identify wash loads, and also
eliminates the need to locate a reliable machine on signal in
order to track wash cycles.
ACCUMULATING TRIGGERS
PDCI triggering modes use a method of collecting triggers
known as accumulating triggers. This method allows trigger
codes that are made up of multiple triggers to be accumulated
one trigger at a time. The advantage of this method is that
even those washer controllers that can activate only one or
two trigger outputs at a time can generate any possible trigger
code.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Only the PDCI control triggers (inputs 1 to 6 on the first TR-7000AC Trigger Module connected to each washer) accumulate. When
one of these triggers first appears, accumulation begins (the Accum
Trig. column on the Washer Strip reports turns on). During the
accumulation period the original trigger may disappear, and other
triggers may also come and go. As long as the gap between
triggers is less than 5 seconds, accumulation continues.
Accumulation ends when all of the triggers are off for more than 5
seconds (plus the trigger qualification delay). When accumulation
ends, the sum of all of the triggers that appeared during the
accumulation period is presented to the trigger decoding logic as if
the triggers had all occurred at the same time. This is recorded on
the Washer Strip reports as the first line after the Accum Trig.
column turns off.
It is not necessary for triggers to be accumulated one at a time. All
of the desired triggers may be applied simultaneously if the washer
controller supports this. Even if applied simultaneously, the
triggers are not recognized until 5 seconds after they all turn off.
Other triggers, such as utility fill and drain, have no effect on the
trigger accumulation process. Trigger 7 on the first TR-7000-AC
(the machine on trigger for non-PDCI trigger modes) is unused in
PDCI modes, and need not be connected.
First TR-7000-AC
Second TR-7000-AC (optional)
Trigger
Channel
Function
Trigger
Channel
Function
1
PDCI Control
Trigger
1
Sewer Drain
2
PDCI Control
Trigger
2
Cold Fill
3
PDCI Control
Trigger
3
Hot Fill
4
PDCI Control
Trigger
4
Steam
5
PDCI Control
Trigger
5
Unused
6
PDCI Control
Trigger
6
Reuse Drain
7
Unused
7
Reuse Fill
Table 16. PDCI Mode TR-7000-AC Trigger Assignments
PDCI CONTROL CODES
Trigger 6 is the PDCI control strobe. When this trigger is
present as part of an accumulated trigger code, the code is
interpreted as a control code, indicating the start or end of a
wash cycle. If one or more of triggers 1 to 5 is present along
with trigger 6, then triggers 1 to 5 identify the cycle being
started, as detailed in Table 17. If triggers 1 to 5 are all off,
then the cycle is being ended.
If trigger 6 is not present as part of an accumulated trigger
code, then the code is interpreted as a chemical feed request,
and is decoded according to the PDCI triggering mode in usesee
Table 17 for details.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
63
Meaning of
Control Code
Trig Channel 1
Trig Channel 2
Trig Channel 3
Trig Channel 4
Trig Channel 5
Trig Channel 6
End of (Any)
Cycle
OFF
OFF
OFF
OFF
OFF
ON
Start of Cycle 1
ON
OFF
OFF
OFF
OFF
ON
Start of Cycle 2
OFF
ON
OFF
OFF
OFF
ON
Start of Cycle 3
ON
ON
OFF
OFF
OFF
ON
Start of Cycle 4
OFF
OFF
ON
OFF
OFF
ON
Start of Cycle 5
ON
OFF
ON
OFF
OFF
ON
Start of Cycle 6
OFF
ON
ON
OFF
OFF
ON
Start of Cycle 7
ON
ON
ON
OFF
OFF
ON
Start of Cycle 8
OFF
OFF
OFF
ON
OFF
ON
Start of Cycle 9
ON
OFF
OFF
ON
OFF
ON
Start of Cycle 10
OFF
ON
OFF
ON
OFF
ON
Start of Cycle 11
ON
ON
OFF
ON
OFF
ON
Start of Cycle 12
OFF
OFF
ON
ON
OFF
ON
Start of Cycle 13
ON
OFF
ON
ON
OFF
ON
Start of Cycle 14
OFF
ON
ON
ON
OFF
ON
Start of Cycle 15
ON
ON
ON
ON
OFF
ON
Start of Cycle 16
OFF
OFF
OFF
OFF
ON
ON
Start of Cycle 17
ON
OFF
OFF
OFF
ON
ON
Start of Cycle 18
OFF
ON
OFF
OFF
ON
ON
Start of Cycle 19
ON
ON
OFF
OFF
ON
ON
Start of Cycle 20
OFF
OFF
ON
OFF
ON
ON
Start of Cycle 21
ON
OFF
ON
OFF
ON
ON
Start of Cycle 22
OFF
ON
ON
OFF
ON
ON
Start of Cycle 23
ON
ON
ON
OFF
ON
ON
Start of Cycle 24
OFF
OFF
OFF
ON
ON
ON
Start of Cycle 25
ON
OFF
OFF
ON
ON
ON
Start of Cycle 26
OFF
ON
OFF
ON
ON
ON
Start of Cycle 27
ON
ON
OFF
ON
ON
ON
Start of Cycle 28
OFF
OFF
ON
ON
ON
ON
Start of Cycle 29
ON
OFF
ON
ON
ON
ON
Start of Cycle 30
OFF
ON
ON
ON
ON
ON
Ignored
ON
ON
ON
ON
ON
ON
Table 17. PDCI Control Codes
PDCI RELAY MODE
PDCI Relay Mode uses coded triggers to request the desired
chemical. The code is entered using the PDCI control triggers as
shown in Table 18. The amount of chemical requested is
controlled by the washer.
64
1208135
In cases where all of the triggers appear and disappear
simultaneously, the amount of chemical requested depends on
the length of time that the triggers are present. In cases where a
feed code is being accumulated one trigger at a time, the amount
of chemical requested depends on the total amount of time that
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
any trigger is on. Periods of time where all triggers are off do
not affect the requested amount.
Because of the use of accumulating triggers, the requested feed
will not begin until the end of the chemical request, five seconds
after the triggers disappear. This delay should be kept in mind
when making lengthy chemical requests.
To clarify this: Suppose trigger 1 appears for five seconds, then
disappears. Three seconds later, trigger 3 appears for six
seconds, then disappears. Then five seconds elapses with no
triggers present. In this case a request for 11 seconds (five
seconds of trigger 1, plus six seconds of trigger 3) worth of
chemical 5 (trigger 1 plus trigger 3 = chemical 5) will be
generated.
PDCI Relay Mode will process chemical feed requests even
when no wash cycle is running. This is done so that if the pump
box should miss the start of the cycle for some reason, it will
still deliver the requested chemicals, and only the logging of the
cycle will be affected.
Meaning of
Feed Code
Trig Channel 1
Trig Channel 2
Trig Channel 3
Trig Channel 4
Trig Channel 5
Trig Channel 6
Request
Chemical 1
ON
OFF
OFF
OFF
OFF
OFF
Request
Chemical 2
OFF
ON
OFF
OFF
OFF
OFF
Request
Chemical 3
ON
ON
OFF
OFF
OFF
OFF
Request
Chemical 4
OFF
OFF
ON
OFF
OFF
OFF
Request
Chemical 5
ON
OFF
ON
OFF
OFF
OFF
Request
Chemical 6
OFF
ON
ON
OFF
OFF
OFF
Request
Chemical 7
ON
ON
ON
OFF
OFF
OFF
Request
Chemical 8
OFF
OFF
OFF
ON
OFF
OFF
All other codes (with trigger channel 6 OFF) are unused.
Table 18. PDCI Relay Feed Codes
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
65
PDCI FORMULA MODE
Note that the formula triggers are coded, not single triggers as
with the non- PDCI formula modes. Because of this, it is not
possible to generate multiple formula triggers simultaneously.
In PDCI Formula Mode the washer can generate up to five
formula triggers, using the PDCI control triggers as shown in
Table 19. Up to three chemical doses may be delivered for each
formula trigger. The doses may vary depending on which cycle
type (formula) the washer is running.
Because the chemical doses may vary depending on the cycle
type that is running, the dispenser will not honor formula
triggers that arrive while it thinks that no cycle is running. Such
formula triggers will cause an error to be logged, and will
activate an alarm if one is connected.
Meaning of Feed
Code
Trig Channel 1
Trig Channel 2
Trig Channel 3
Trig Channel 4
Trig Channel 5
Trig Channel 6
Formula Trigger 1
ON
OFF
OFF
OFF
OFF
OFF
Formula Trigger 2
OFF
ON
OFF
OFF
OFF
OFF
Formula Trigger 3
ON
ON
OFF
OFF
OFF
OFF
Formula Trigger 4
OFF
OFF
ON
OFF
OFF
OFF
Formula Trigger 5
ON
OFF
ON
OFF
OFF
OFF
All other codes (with trigger channel 6 OFF) are unused.
Table 19. PDCI Formula Feed Codes
66
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
PDCI AUTOMATIC MODE
PDCI Automatic Mode will process chemical feed requests even
when no wash cycle is running. This is done so that if the pump
box should miss the start of the cycle for some reason, it will
still deliver the requested chemicals, and only the logging of the
cycle will be affected.
PDCI Automatic Mode allows the triggering of up to 31
different functions, using the PDCI control triggers as shown in
Table 20. Up to three chemical doses may be delivered for each
function.
Meaning of
Feed Code
Trig Channel 1
Trig Channel 2
Trig Channel 3
Trig Channel 4
Trig Channel 5
Trig Channel 6
Call Function 1
ON
OFF
OFF
OFF
OFF
OFF
Call Function 2
OFF
ON
OFF
OFF
OFF
OFF
Call Function 3
ON
ON
OFF
OFF
OFF
OFF
Call Function 4
OFF
OFF
ON
OFF
OFF
OFF
Call Function 5
ON
OFF
ON
OFF
OFF
OFF
Call Function 6
OFF
ON
ON
OFF
OFF
OFF
Call Function 7
ON
ON
ON
OFF
OFF
OFF
Call Function 8
OFF
OFF
OFF
ON
OFF
OFF
Call Function 9
ON
OFF
OFF
ON
OFF
OFF
Call Function 10
OFF
ON
OFF
ON
OFF
OFF
Call Function 11
ON
ON
OFF
ON
OFF
OFF
Call Function 12
OFF
OFF
ON
ON
OFF
OFF
Call Function 13
ON
OFF
ON
ON
OFF
OFF
Call Function 14
OFF
ON
ON
ON
OFF
OFF
Call Function 15
ON
ON
ON
ON
OFF
OFF
Call Function 16
OFF
OFF
OFF
OFF
ON
OFF
Call Function 17
ON
OFF
OFF
OFF
ON
OFF
Call Function 18
OFF
ON
OFF
OFF
ON
OFF
Call Function 19
ON
ON
OFF
OFF
ON
OFF
Call Function 20
OFF
OFF
ON
OFF
ON
OFF
Call Function 21
ON
OFF
ON
OFF
ON
OFF
Call Function 22
OFF
ON
ON
OFF
ON
OFF
Call Function 23
ON
ON
ON
OFF
ON
OFF
Call Function 24
OFF
OFF
OFF
ON
ON
OFF
Call Function 25
ON
OFF
OFF
ON
ON
OFF
Call Function 26
OFF
ON
OFF
ON
ON
OFF
Call Function 27
ON
ON
OFF
ON
ON
OFF
Call Function 28
OFF
OFF
ON
ON
ON
OFF
Call Function 29
ON
OFF
ON
ON
ON
OFF
Call Function 30
OFF
ON
ON
ON
ON
OFF
Call Function 31
ON
ON
ON
ON
ON
OFF
Table 20. PDCI Automatic Feed Codes
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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67
TRIGGER TIMING LIMITS
Table 21 lists the timing limitations which must be considered
when programming the wash wheel. PDCI Relay Mode is
designed for use with microprocessor controlled washers, and so
has no filtering of the trigger inputs. PDCI Formula mode is
designed for use with chart or card driven controllers, and so has
substantial trigger filtering. PDCI Automatic mode has
switchable trigger filtering, for use with either type of controller.
Signal
Mode
Time
Drain Signal(s)
All Modes
5-second minimum on/off
time
Utility Signals
All Modes
2-second minimum on/off
time
PDCI Control
Triggers
PDCI Relay
Mode
1/2-second minimum
on/off time. 1-second
resolution.
Signals from 1/2 to 1 3/8
seconds are logged and
interpreted as 1 second;
signals from 1-1/2 to 2-3/8
seconds are treated as 2
seconds, and so on.
PDCI Control
Triggers
PDCI Formula
Mode
5-second minimum on
time
20-second minimum off
time
PDCI Control
Triggers
PDCI
Automatic,
Chart
5-second minimum on
time
20-second minimum off
time
PDCI Control
Triggers
PDCI
Automatic,
Micro
1/2-second minimum
on/off time
PDCI End of
Accumulation
Delay
All Modes
All triggers off for 5
seconds beyond end of
qualification time
Capability
4 Triggers
5 Triggers
6 Triggers
Number of cycles
that may be
identified
7
15
30
Number of
chemicals in PDCI
Relay Mode
7
8
8
Number of supply
triggers in PDCI
Formula Mode
5
5
5
Number of functions
in PDCI Automatic
Mode
7
15
31
Table 22. PDCI Capabilities With Reduced Triggers
APPENDIX C. PROGRAMMING
THE WASH WHEEL
The following is a general guide to connecting the washer
supply triggers to the TR-7000-AC trigger module inputs. This
information is of a general nature since it is not practical to
detail every washer.
COMMON (RETURN)
CONNECTIONS
The TR-7000-AC provides for isolated common or return
circuits for each of the 7 trigger channels. In most cases, the
washer supply signals all have a single common and you can tie
these trigger commons together. The most frequent exception to
this is in washer control schemes that lock out certain, but not
all, supply triggers until the proper water level has been reached.
You may need to connect an individual common to each portion
of such a circuit.
MICROPROCESSOR-CONTROLLED
WASHERS
Relay Mode
Table 21. PDCI Trigger Timing Limits
OPERATION WITH FEWER
TRIGGERS
Six programmable triggers are required to make full use of
PDCI triggering. However, fewer triggers may be used if some
reduction in functionality is acceptable. Table 22 summarizes
the possibilities.
When using only five triggers, connect triggers 1 through 4, and
trigger 6. Leave trigger input 5 unconnected. When using only
four triggers, connect triggers 1 through 3, and trigger 6. Leave
trigger inputs 4 and 5 unconnected.
If the washer is microprocessor-controlled, you will most likely
be operating in the relay mode. The normal relay mode requires
one trigger signal per chemical. Trigger channel 1 controls pump
1, channel 2 pump 2, and so on. Connect trigger channel 1
(brown wire) to supply signal 1, channel 2 (red) to supply 2, and
so on, up to and including channel 6 to supply 6.
If your account uses more than six chemicals, you must use a
second trigger module for chemical pumps 7 and 8. Connect
trigger channel 5 of the second trigger module to supply signal 7
and channel 6 to supply signal 8.
In most cases, you may tie all the common (black) wires
together and connect them to the supply common signal. Consult
the washer schematic or IWD for exact connections.
If you have more chemicals than supply
triggers, you will need to use Enhanced Relay
Mode.
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Enhanced Relay Mode
Automatic Mode
Enhanced relay mode serves accounts where the washer
microprocessor has fewer supply triggers than you have
chemicals. The chemical amount is still controlled by the length
of time the supply signal is on, but the chemical pump selection
is controlled by the combination of supply triggers
(see Table 11).
Automatic mode can be used for both mechanical and
microprocessor controller applications. The strobed mode is for
mechanical controls, and the strobeless mode is used in
microprocessor applications. In both cases, up to 5 trigger
signals are used to create individual patterns. Each unique
pattern calls a chemical injection function. This function can
contain up to 3 different chemicals, each with its own amount
(referred to as dose in the washer setup screens).
Connect supply signal 1 to trigger channel 1 (brown), signal 2 to
channel 2, signal 3 to channel 3, and signal 4 to channel 4. These
four signals are all that are required to pump up to 8 different
chemicals. Refer to Washer Setup Mode.
PDCI Relay Mode
PDCI relay mode operates much like enhanced relay mode, but
it offers the additional advantage of PDCI operation. The
combination of supply triggers applied determines which
chemical is selected, and the duration of the signals determines
the amount requested. Accumulating triggers are used, so the
feed will not begin until all of the supply signals turn off.
Connect supply signal 1 to trigger channel 1 (brown wire),
signal 2 (red) to channel 2, and so on up to and including signal
6 to channel 6. Supply signal 5 need not be connected if 15
different cycle types are adequate; all eight chemicals are still
available in this case. Supply signals 4 and 5 need not be
connected if seven different cycle types are adequate; seven
chemicals are available in this case.
Formula Mode
This mode of triggering is intended for use when the washer is
controlled by a mechanical chart or card control. The
relationship of supply triggers to chemical pumps and injection
amounts is controlled entirely by how you connect the washer
signals to the TR-7000-AC Trigger Module.
If you are using an RS-3000 formula select module for this
washer, connect the TR-7000-AC Trigger channel 1 (brown
wire) to supply signal 1, channel 2 (red) to supply 2, and so on
up to and including channel 5 to supply 5 (if available).
If you are not using the RS-3000, and you wish to select
alternate injection amounts (formulas) automatically, you may
connect up to four other available supply triggers to the formula
select inputs. These four inputs can be used to select 16 different
chemical injection formulas for each of the five supply triggers
(see Table 12 and Washer Setup Mode).
PDCI Formula Mode
PDCI formula mode is similar to conventional formula mode,
but it offers the additional advantage of PDCI operation. The
five individual “formula triggers” of conventional formula mode
are replaced with coded combinations of supply triggers 1
through 3. Accumulating triggers are used, so the feed will not
begin until all of the supply signals turn off.
Connect supply signal 1 to trigger channel 1 (brown wire),
signal 2 (red) to channel 2, and so on up to and including signal
6 to channel 6. Supply signal 5 need not be connected if 15
different cycle types are adequate; all five formula triggers are
still available in this case. Supply signals 4 and 5 need not be
connected if seven different cycle types are adequate; all five
formula triggers are still available in this case.
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
Connect the washer supply signals 1 through 5 to trigger
channels 2 through 6, respectively. You can use fewer channels
for fewer functions.
If you are using the strobed mode, connect an unused supply
trigger to trigger channel 1. This signal will be the strobe (read)
signal. The strobe signal is used so that the other signals need
not be activated exactly simultaneously, a difficult requirement
in mechanical controls (strobeless mode does not use this signal,
but instead generates its own read signal five seconds after any
of the other trigger channels are turned on).
PDCI Automatic Mode
PDCI automatic mode is similar to strobeless automatic mode,
but it offers the additional advantage of PDCI operation. It may
be used with either mechanical chart/card or microprocessor
driven controllers. Accumulating triggers are used, so the feed
will not begin until all of the supply signals turn off.
Connect supply signal 1 to trigger channel 1 (brown wire),
signal 2 (red) to channel 2, and so on up to and including signal
6 to channel 6. Supply signal 5 need not be connected if 15
different cycle types and 15 chemical injection functions are
adequate. Supply signals 4 and 5 need not be connected if seven
different cycle types and seven chemical injection functions are
adequate.
Machine On Connection
Trigger channel 7 of the primary trigger module is dedicated to
the machine on function for all non-PDCI triggering modes. In
PDCI modes, this input is unused, and may be left unconnected.
Connect the violet wire to a signal that most closely represents
when the washer is actually running a load. In many cases, this
signal may utilize, or be referenced to, a different common than
the supply triggers described under PDCI Automatic Mode.
For this reason, you may need to connect the specific common
wire associated with the machine on channel 7. This common is
the black wire connected to the pin just below the violet wire.
PDCI MODES
In the three PDCI feed modes the trigger inputs perform the
additional function of tracking and identifying wash cycles,
besides their usual job of requesting chemicals. This additional
function requires some extra thought when programming the
washer.
For accurate cycle timing, the cycle start/identification and cycle
end codes should be programmed to occur as close to the actual
start and end of the wash cycle as possible. Some washers may
have interlocks that prevent chemical triggers when there is no
water in the washer, which prevents accurate cycle timing. The
dispenser can compensate for this by means of the “add time”
setting (refer to Washer Setup Mode).
69
Chart driven washers often use the same chart for several
different wash formulas, using a formula selector module to
determine which formula is being run. This can be
accommodated when using PDCI triggering by “stacking”
several different cycle start codes together at the beginning of
the chart, with a minute or two between them. The dispenser
will log the first such cycle start code it detects, and will ignore
those following it.
Ideally (if there’s room for it), a PDCI cycle end code would be
programmed prior to each cycle start code (except when start
codes are “stacked”, as explained in the previous paragraph).
This end code forces an end to any cycle that might be left
running if the controller (particularly a mechanical controller) is
“jumped ahead” to start a new cycle before the previous cycle
has completely ended.
RELAY MODE/ENHANCED RELAY
MODE WASHER CONNECTIONS
If you are using relay mode, the only consideration is that the
signals be a minimum of 1 second in duration. Any and all
signals may be activated as required by your wash process. If
you are using a drain signal, the supply requests must not occur
when the drain is open.
CARD AND CHART CONTROLLED
WASHERS
Formula Mode
The minimum on time for a formula mode trigger is 2 seconds.
Also remember that a second trigger (on the same channel) will
be ignored if it happens within 45 seconds of the end of the
previous signal. As with all other triggering modes, do not begin
the supply request until after the drain is closed (this
requirement does not apply to formula select bits). Formula
select bits (alternate formula tracks) should be cut to begin prior
to, and continue into, the supply request cut.
Automatic Strobed Mode
Automatic mode trigger signals have the same 2 seconds on, 45
seconds off requirement as the formula mode triggers. Cut the
function request pattern first, followed by the strobe cut. Allow
enough time (5 to 15 seconds) between the beginning of the
function cuts and the strobe cut to compensate for any timing
irregularities caused by switch or finger misalignment.
If you are using enhanced relay mode, the supplies must be
called by individual steps of the wash process. To use this mode,
you must be able to program the washer to activate two supply
triggers at the same time. After each supply request, all of the
triggers must be off for a minimum of 2 seconds before the next
chemical request.
Enhanced Relay Mode Example
1. Fill
2.
Supply 1 - The supply trigger is on for chemical 1 (for
example, DET).
3.
Short step (or other no-op)
4.
Supply 2 - The supply trigger is on for chemical 2 (for
example, ALK).
5.
Wash
6.
Rinse
7.
Other baths
8.
Supply 1 & 2 - This decodes as supply trigger on for
chemical 5 (for example, SOUR).
9.
Short step (or other no-op)
10. Supply 1 & 3 - This decodes as supply trigger on for
chemical 6 (for example, SOFT).
11. Other steps
Once a trigger pattern has been established
(the one or two signals have been on for 1
second or more) any change in the pattern
will be interpreted as the end of the request.
This is to prevent the code from changing and
a wrong chemical from being called should a
single output signal fail during a feed request.
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
APPENDIX D. ASSEMBLY
DRAWINGS
PARTS LIST & ASSEMBLY
DRAWINGS
Seq #
ITEM #
DESCRIPTION
1
096908
PCB, ILS OPL, MK3
2
093734
LCD Display, (with cable)
3
093126
TR7000AC Trigger Module only
(not shown)
10
099309
Solenoid valve
11
042595
Float Switch
12
096093
Strainer, (Filter assembly)
13
096177
Strainer element, 20 mesh
14
027580
Foot Valve,& Strainer
15
043533
Key
16
093492
Pump Insert, Barbed Fitting
17
091972
Circuit Breaker, 5 amp
18
091974
Fitting, Elbow, 3/8 MPT x 3/8 Tube
19
091505
Fitting, T, 3/8 MPT x 3/8 Barb
20
096800
Diaphragm Pump, 3°, Viton valve
4
093489
Chemical Pump Cartridge, Silicone
Tube, (includes 056921)
21
097073
Aerator
5
056921
Pump Tube, (Silicone)
22
091016
Flow Regulator, 3 gpm
6
096802
Pump Head Kit, 3° Viton valve,
(includes 096803)
23
091502
Fitting, elbow, 1/2 MPT x 3/8 Barb
24
091501
Fitting, Straight, 1/2 MPT x 3/8 Barb
7
096803
Valve Kit, Viton
25
091506
Fitting, “T”, 3/8 Barb
8
099905
Proof of Flow Cell
26
093717
Bulk Silicone tubing, 3/8” ID
9
067530
Seals for POF/POD cell (Pkg 10)
91
093723
Flow Restrictor
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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71
10
22
14
21
20
11
18
19
6
7
DF1MA03
72
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
DF1MA04
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
73
Before connecting the RS-3000 to the
AlphaBus, you must open the RS-3000 and
move the internal connector from the BetaLink
(rightmost) position to the AlphaBus (leftmost)
position. Failure to do so may damage the RS3000.
APPENDIX E. ILS MAX
EMULATION
With the addition of a Washer Interface Module (See Table 23)
and a POD cell, the system may be configured to provide the
same proof of delivery, local alarm and washer hold features
offered by ILS Max.
To enable ILS Max emulation, set the washer system type to
Washer Interface (See Washer Setup Mode). All washer and
pump setup screens will operate the same as with other washer
system types, except that some options that are disabled with
other systems (such as washer hold) are now enabled.
The trigger and utility monitor connections in ILS Max
emulation mode are the same as in other ILS OPL operating
modes. All of the normal trigger modes, including PDCI
triggering, are available. See Appendix A and Appendix B for
details on trigger module wiring and trigger modes.
When used with a Washer Interface Module, the TR-7000
Trigger Modules and RS-3000 Formula Select Module are
connected to the Washer Interface Module using the AlphaBus,
and the Washer Interface is connected to the pump box using the
BetaLink. See Figure 30 for an illustration of the wiring
connections.
Component
Provides
Catalog No
Notes
Washer Interface Module Kit
See washer module options in Table 4.
056684
One required per washer
TR-7000-AC Trigger Module Kit
See washer module options in Table 4.
093600*
One module minimum per
washer
RS-3000 Formula Select Module Kit
See washer module options in Table 4.
094488
One per washer. Optional
*For washers using DC supply-trigger voltage, use TR-7000 code #059011 (pair with cable).
Table 23. ILS Max Emulation
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ILS OPL (Dwg# 16571-00, Rev B) January, 2007
Figure 30. ILS Max Emulation Wiring
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
1208135
75
NOTES
Beta Technology is ISO 9001 Certified
76
1208135
ILS OPL (Dwg# 16571-00, Rev B) January, 2007
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