Instruction Manual - Sage Sanitizing System

Bypass Unloader Valve
Dedicated Sage Technician
Sage Systems has established a dedicated Sage Service
Technician. Our Technician verifies warranty claims,
offers technical support, and connects users with Sage
Systems authorized service agencies in their area.
Authorized Service Agents
Sage Systems has gathered a full network of CFESA or
NAFEM service agencies across the country. These
professionals are experienced food equipment repair
personnel. They inspect every new remote system
installation at Start-up, and can offer regular
maintenance or service on demand. To obtain a list of
Sage Systems authorized service agents in your area,
call our dedicated Sage Technician at (888) 757-3784.
Helpful Service Tips
A complete understanding of the interrelation of all the
components of a Sage System is essential before any
adjustments or repairs are attempted. Please make sure
to read the entire manual before proceeding with service
The Troubleshooting section includes many helpful tips
and suggestions to overcome common problems with
Sage machines. Make sure to check this section for
some ideas that may not be repeated in this Service
High Pressure Pump(s)
The high-pressure pump is a positive displacement,
direct drive design. The pump is mounted to the front
of the motor with four bolts for easy maintenance.
The pump rotations per minute (rpm) must be
maintained at the fixed design rate in order to produce
the optimal flow rate without variation. Typically, all
T&S Sage machines are set to output between 2.75 and
2.95 gallons per minute, gpm (10.4 and 11.2 liters per
minute, lpm)
The pump is supplied fresh water from the float tank at
the rear of the machine. The tank cover removes for
inspection of the valve inside. The float valve is
adjustable, and should be set so that the highest water
level is 1 in (2.5 cm) below the over level of the tank.
The 1 in (2.5 cm) gap between the tank and cover serve
as a back-siphon and back-pressure prevention device.
The pump draws water from the float tank with suction.
Water is pulled through an in-line water filter, down the
pump inlet hose, and to the water inlet manifold of the
pump. The inline water filter should be opened and the
screen cleaned every month to prevent water starvation
of the pump.
The Bypass Unloader Valve is attached to the pump’s
high pressure outlet side, and allows the the pumped
fluid to recirculate back to the pump inlet whenever the
Spray Gun trigger is released. This valve, rather than
the pump, can often be responsible for causing a drop in
pressure, drop in water flow, or a binding of the pump.
Be aware that down stream restrictions in the outlet line
may increase pressures above the unloading valve
setting. The unloader valve may need readjustment if
new hoses, lines, or spray nozzles are added after the
machines first installation.
When an unloader valve is not seating properly, some
of the pump output will recirculate, even when
spraying, causing a reduced volume and reduced
pressure at the nozzle.
An unloader valve that sticks open causes a complete
loss of pressure although the pump and motor are
running normally.
An unloader valve that sticks in the closed position can
cause severe pump damage when the spray gun is
released and the excess pressure has no release. As a
safety feature, all Sage machines include a Pressure
Relief valve opposite the Bypass Unloader valve, which
will discharge when the pressure exceeds the machine
maximum by 25%.
Setting the Unloader Valve
To reset the Bypass Unloader valve, you will need a 02000 psi pressure gauge with a ¼” (.64 cm) QD socket
inlet and a QD plug outlet, and a crescent wrench.
Install the pressure gauge assembly to the plug on the
front of the machine. Install the high-pressure spray
hose and spray gun to the outlet of the gauge assembly.
Start the machine and spray through the spray gun with
the nozzle pulled in to the high-pressure position.
Loosen the hex knob on the unloader valve down until
the pressure is at least 100 psi (6.9 bar) below the
maximum rated pressure for the machine, either 600,
800, or 1000 psi (41, 55, or 69 bar). Then tighten the
hex knob on the unloader until the pressure reaches its
maximum just below the maximum rated pressure. You
should not be able to drive the pressure above the rated
maximum, but should be able to get within 50 psi (3.5
bar) of the maximum rating.
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The normal bypass pressure is within 200 psi (1.4 bar)
of the unloader setting. In other words, the unloader
valve will open and allow the water to bypass into
recirculating mode when the spray gun is released, and
the pressure goes up at least 200 psi (1.4 bar) beyond
the set pressure.
Warning! The AutoChem switch
setting should never allow chemical
feed when the trigger is released and
the pressure rises as the machine
unloads into bypass mode.
Note! It is essential that the correct
nozzle for the machine be installed to
all spray guns on the system.
Loosening or turning counter clockwise the top half of
the switch reduces the set point pressure. Tightening or
turning clock-wise the top half of the switch increases
the set point pressure.
A different orifice size can greatly affect flow rate,
maximum pressure, and even amperage. Each nozzle is
specified for each machine to optimize flow rate at the
specified pressure, while minimizing amperage. Using
a different nozzle than is originally specified may cause
sever machine damage, and will void warranty.
Pressure Switches
Temperature Relief Valve
The rear pressure switch controls the AutoChem
feature. At the factory, the rear switch is wired
terminals 1-3, allowing chemical flow at pressures
below the set point, and stopping chemical flow at
pressures above the set point.
The chemical feed should work in low pressure, and
stop in high pressure if the AutoChem feature is
working properly. This switch is set between the high
and low pressures produced by pulling in or pushing out
on the spray nozzle. When the pressure drops to low,
the switch signals to open the solenoid valve to the start
the pump, to allow chemicals to flow.
The switch can be set to allow chemical feed in both
low and high pressures. For soap and sanitize to work
in low and high pressure, turn the upper half of the
switch clockwise to increase the kick-over point above
the high pressure, but less than the unloaded pressure.
The feed should work in low pressure and high
pressure, but stop when unloaded into bypass mode.
If the temperature reaches 165oF (74oC), the
Temperature relief valve will discharge 3.4 oz (100 ml)
of heated water from the recirculating loop, and replace
it with cooler water from the float tank. This will repeat
every time the recirculating water reaches 165oF (74oC).
Pressure Relief Valve
The Pressure Relief Valve is set at the factory to 25%
above the maximum rated pressure. Its purpose is to
guarantee that the high-pressure side of the pump never
sees a pressure more than 25% above the maximum
rated pressure. This condition could only occur if
certain components, like the unloader valve, failed or
were altered from their factory state.
The PRV discharges water if the discharge pressure
exceeds its set pressure. If you suspect that the PRV is
the source of a problem, check it’s setting. With a
pressure gauge mounted to the front of the machine, and
the Spray Gun spraying in high pressure, verify the
pressure is within 50 psi of the maximum rated
pressure. Make sure the PRV is not leaking in this
condition. If not, loosen until the leaking begins and
the pressure begins to fall. Then tighten 2 full turns
past the leak point to reseal the PRV and to set it at 25%
above the maximum rated pressure. If the PRV leaks
constantly, maximum efficiency will be impossible to
obtain, and the PRV should be replaced and set as
described above.
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In-line Water Filter
This filter is designed to limit the debris that can enter
the pump from the inlet water supply or the float tank.
Regular service should include simply replacing the oring and filter screen by removing the big bottom cap
with the hex nut feature, cleaning or replacing the two
components, and reseating the cap.
Chemical Feed Devices
Gravity fed systems, Solenoid Valves
The solenoid valves used with Sage systems are not
repairable. If in troubleshooting it is determined that a
solenoid valve is malfunctioning, the entire valve
should be replaced using one of the Kits provided by
Sage Systems.
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Pump fed systems, Peristaltic pumps
Replacing the Tubing
The peristaltic pump(s) pull chemical from their
containers with a tripod arrangement of rollers
compressing surgical tubing and rolling along the
tubing. This creates a suction, and forces chemical into
the water lines that feeds the pump.
There are two typical Peristaltic pump repair operations.
First, you may need to replace the inner tubing. Or, you
may need to replace the entire pump.
Replacing the Tubing
First, turn the speed control to OFF. Unscrew the nuts
attaching the polytubing to the pump, and pull the
polytubing from the white fittings.
Pull off the red retaining knob from the motor shaft, and
remove the clear cover. Lift out the tubing and fitting
assembly. Be careful not to come in contact with any
non-diluted chemicals in the tubing or pump assembly.
You may turn the pump rollers by hand to assist with
removing the tube.
Wipe clean the pump head area, and if necessary, clean
with a mild soap solution, and rinse with clean water.
Lubricate the shaft and rollers with one of the two
approved lubricants, either Union Carbide L-45
Dimethyloplysioxane or GE SF96-100 silicone fluid.
Note! The replacement tube is not
Position the rollers so that there is space between the
first roller and the right side wall.
Hold one end of the replacement tubing with fittings in
your right hand, with the BW on the fitting facing you.
The other end should turn down and to the left. If not,
you are holding the wrong end. This twist is essential
to allow for the difference of inside and outside length
when the tube is threaded into the pump.
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Hold the right fitting in the right hand, and left in the
left, in a loop with thumbs on the BW letters. The
looped tube should bend away from you.
To thread in the tube, insert the right side fitting firmly
and all the way into the right lock socket. Feed the
tubing between one roller at a time, turning the rollers
as necessary to help feed the tubing between the roller
and the wall. Keep the BW in the left hand facing up,
without twisting the tubing to do so. Use the right
thumb to assist with pressing the tubing down between
the roller and the wall.
Pump fed systems, Diaphragm pumps
Caution! Be careful to avoid pinching
fingers in he turning rollers.
After the tubing is in place at all three rollers, press the
left fitting into its place. Replace the cover and retating
knob. Cut about 0.25 in (0.2 cm) from the end of the
inlet and outlet polytubing, making sure to keep the nut
up the tubing while cutting. Press the freshly cut inlet
and outlet tubing onto the pump fittings, and tighten the
nuts over the connections. Reset the control knob to its
previous position for the same feed rate as before.
Replacing the Pump
Turn the Machine and Master Power off at the MCP.
Disconnect the inlet and outlet polytubing. Disconnect
the yellow electrical fitting from the wiring box in the
Unscrew the two screws that hold the pump to the
welded vertical bracket inside the machine. Remove
the pump.
Insert the new pump, and attach to the bracket with the
two screws. Attach the ¼ turn electrical connector of
the new pump to the same port where the previous plug
was attached.
Cut about 0.25 in (0.2 cm) from the end of the inlet and
outlet polytubing, making sure to keep the nut up the
tubing while cutting. Press the freshly cut inlet and
outlet tubing onto the pump fittings, and tighten the nuts
over the connections.
The diaphragm pump(s) pump chemical from their
containers with an oscillating diaphragm that forces
chemical into the water lines that feeds the pump.
Diaphragm pumps are not repairable and must be
replaced as a unit if found to be defective. Sage
Systems offers kits complete with all items necessary to
replace Diaphragm pumps.
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