Series 3 - Starline by Washtech

PW1
Series 3
HIGH PERFORMANCE POTWASHER
ServiceManual
Foreword
User documentation
Please read this manual and keep it in a safe place for future reference.
WARNING
Before installation and commissioning, you must read the safety instructions and
warnings carefully and all the warning labels attached to the equipment.
!
!
IMPORTANT
Failure to comply (even partially) with the instructions given in this manual will
invalidate the product warranty and relieves the manufacturer of any responsibility.
IMPORTANT
The alteration of machine operation, design or the replacement of parts not
approved by the manufacturer may void warranties and approvals.
Warranty Registration
Complete the information below for quick reference.
Model Number_______________Serial Number________________
Purchased from______________ Date of Purchase______________
If you require further information regarding authorised service providers or
recommended detergent suppliers in your region, or have any other queries, please
do not hesitate to contact us.
!
IMPORTANT
TO VALIDATE YOUR WARRANTY, PLEASE COMPLETE AND
RETURN THE WARRANTY REGISTRATION CARD WITHIN 30
DAYS FROM THE DAY OF PURCHASE.
Information supplied in this manual is copyright. No part of this work may be reproduced
or copied in any form or by any means, electronic or mechanical without the express
permission of the author / publisher. Document subject to change without prior notice.
Service Manual PW1-3(S)
2
Revision 1G
Contents
Safety Instructions...................................................................................................................................................................... 4
Installation..................................................................................................................................................................................... 5
Installation Diagram ............................................................................................................6
Installation Checklist ...........................................................................................................7
Maintenance Checklist ........................................................................................................8
Operating Instructions............................................................................................................................................................. 9
Dishwashing Procedures......................................................................................................................................................10
Troubleshooting Chart...........................................................................................................................................................12
Components................................................................................................................................................................................14
Location and Access..........................................................................................................14
Timer....................................................................................................................................15
Rinse Thermostat...............................................................................................................16
Wash Thermostat...............................................................................................................17
Pressure Switch...................................................................................................................18
Wash Pump.........................................................................................................................19
Rinse Pump.........................................................................................................................20
Detergent Pump.................................................................................................................21
Assembly Diagrams ................................................................................................................................................................22
Wiring Tray Assembly.......................................................................................................22
Control Panel Assembly....................................................................................................23
Wash Assembly ..................................................................................................................24
Rinse Assembly ..................................................................................................................25
Rinse Tank Assembly ........................................................................................................26
Solenoid Valve Assembly..................................................................................................27
Schematic Diagram............................................................................................................28
Wiring Diagram..................................................................................................................30
Spare Parts...................................................................................................................................................................................32
Accessories ..................................................................................................................................................................................34
Appendices..................................................................................................................................................................................35
Rinse Aid Injector Retrofit .....................................................................................................................35
Drain Pump Retrofit................................................................................................................................36
Revisions.......................................................................................................................................................................................37
Service Manual PW1-3(S)
3
Revision 1G
Safety Instructions
WARNING
Equipment contains dangerous voltages and can be hazardous if installed or
operated incorrectly. Non-compliance with Warnings or failure to follow the
instructions contained in this manual can result in loss of life, severe personal
injury or serious damage to property.
Installation




Use qualified, skilled personnel
Follow installation instructions
Connect to correct voltage and supply current
Provide fully accessible Electrical Isolation Switch & water supply valves
Training and Supervision
 Read and Understand the Operating instructions and train all staff
 This appliance must not be operated by children or infirm persons
 Machine panels must only be removed by suitably qualified and trained
personnel – internal hazards include live electrics and very hot surfaces
 This appliance is not intended for use as a stepladder
Hot Surfaces
 Some surfaces may be hot or very hot
Chemicals
 Commercial dishwashing detergents are hazardous – handle with care
 Read and follow the safety information found on the labels of detergent
containers and Material Safety Data Sheets
 Use protective eyewear and clothing if decanting containers
Hot Water
 Do not put hands in wash water which may be over 60°C and contain
hazardous caustic detergent
 Rinse water can be over 90°C
 Door safety switches are designed for emergency use only
Cleaning
 Do not hose down the machine or splash water over the exterior
 Watch for broken glass etc when cleaning the inside of the machine
Service/Repair
 Under no circumstances the user should attempt to carry out repairs
 All service/repair work must be carried out by qualified personnel only
Service Manual PW1-3(S)
4
Revision 1G
Installation
WARNING
Installer must be suitably qualified and ensure compliance with all codes and
standards including AS/NZS3500.1.
!
Failure to comply even partially with installation instructions may void the
warranty.
Positioning
Unpack machine, check for damage and complete delivery. Install machine on
sound waterproof self-draining floor and use adjustable feet to level machine.
Allow room for detergent to one side of machine or in adjacent cupboard. 20litre
container requires about 450H x 250W x 350D, but smaller containers are available
from many suppliers.
Water Supply
Hot water temperature
Connection
Flow rate minimum
Consumption per cycle
Backflow prevention
Pressure
65°C ± 5°C
15 mm (1/2" BSP Male)
20 litres per minute
3.5 litres approximately
Atmospheric Vacuum Breaker
200-350 KPa = 30-50 Psi.
Above this range fit pressure limiter. Don’t use small diameter plastic supply lines.
FLUSH supply line before connection. Poor quality supply or excessive water
hardness may affect performance or damage machine –filtration and/or softening
is recommended.
Waste
40 mm gravity drain –refer to point B on the installation diagram –run waste
directly behind the machine or through open side panels or base.
Power
Machine requires 3 Phase, Neutral and Earth, 400/415V, 15A/ph, 50Hz,
permanently wired via wall switch mounted adjacent to machine. Wash pump
rotation must be checked after installation to ensure correct direction (excessive
noise and damage with incorrect direction).
Detergent
Insert pump inlet hose into container of commercial low foam detergent. Open
machine door and switch machine on. Press and hold detergent prime switch
behind front cover until chemical flows into machine.
Commercial detergents can be hazardous –read instructions and handle with care.
Installation Checklist
Complete attached Installation Checklist to ensure machine is installed and
running correctly, and operator is familiar with operating procedures.
Service Manual PW1-3(S)
5
Revision 1G
Service Manual PW1-3(S)
6
Revision 1G
Installation Checklist
CHECK
Delivery
Supplied complete
Position
Level and stable
Water
Isolator valve fitted
DCVs fitted (Washtech only)
Temperature
Flow rate
Pressure
Cold water when required
Hardness
Power
Isolating switch
Supply as specified
Waste
Usually 40 mm
Air gap on pumped drain
Chemicals
product name
Detergent
Rinse Aid
Machine operation
Run several cycles
Confirm correct operation
Operator training
OK / NOTES
no transit damage
on sound, waterproof, self draining floor
Accessible, all fittings sound, no leaks
Correct direction
65 ± 5°C
Minimum 20 litres per minute
200-350 kpa, limiter fitted if above this range
Booster fitted if below this range
Pressure not above 350 kpa
Filter or softening if required
Fitted, functional and accessible
Voltage, current, circuit breaker
Sound, no leaks
container
no leaks
primed
conc.OK
Including correct fill levels
Confirm Operator has copy of Operator Manual and is familiar with procedures
Start-up
Pre-rinse and racking
Machine operation
Drain
Clean
Shut-down
Service Manual PW1-3(S)
Model / Serial
Owner
Location
Technician
Date
Signed
7
Revision 1G
Maintenance Checklist
CHECK
OK / NOTES
Installation – use Installation Checklist on previous page to check all services, operator training
and chemical issues
Services
water, power, drain etc.
Operator
trained / has instructions
Chemicals
squeeze tube checked – replacement
recommended every 6 months,
product type, container, leaks etc.
General conditions
Cleanliness of machine
daily maintenance
Presence of pests
Leaks
Operation
Temp °C
Amps
Elements
Wash
60
Rinse
83
Pumps
Wash
n/a
Rinse
n/a
Drain
functional
n/a
Water Flow
Wash arms and jets
jets clear, good rotation, bushes OK
Rinse arms and jets
jets clear, good rotation, bushes OK
Cycle
Fill levels
pressure switch settings
Drain operation
upstand/pump
Noise
sounds OK
Recovery between cycles
Controls
Door switch
including auto start if fitted
Switches, lights, gauges
all sound and functional including door/s
Performance
Wash and rinse
effective
Electrical
Safety test
if required
Cabinet
Door / Handle / Catch
operational
Rack slide
good rack entry / withdrawal
Comment / Action Required
Model / Serial
Owner
Location
Service Manual PW1-3(S)
Technician
Signed
Date
8
Revision 1G
Operating Instructions
Start up
Fit drain upstand, wash pump filter,
scrap trays and shut door.
Turn wall power switch on and select
any cycle (1, 2 or 3).
Power light glows red and machine fills
automatically.
Wash Ready light (water symbol) glows
amber when wash tank is ready.
Rinse Ready light (tick symbol) glows
amber when the machine is up to
required temperature and ready to run.
Operation
Select required cycle (1, 2 or 3 for
2, 4 or 6 minutes cycle accordingly).
Try cycle 3 initially and switch to faster
cycles only if necessary.
Load rack into machine and close door.
Press Start button to start the machine.
Cycle light glows green while machine
operates.
When Cycle light goes out, cycle is
complete.
Open door and remove rack.
NOTE: Machine will not operate unless
Ready lights are on.
Shut down every night
Turn machine and wall power switches off.
Remove drain upstand to drain wash tank.
Remove scrap trays and wash pump filter and rinse clean.
Replace drain upstand, filter and scrap trays.
Service Manual PW1-3(S)
9
Revision 1G
Dishwashing Procedures
for best results
Note: these are general instructions to assist in getting the best performance from Starline dishwashers – some
comments and / or illustrations may not apply to every unit.
Installation
Read the Operator Manual. Correct installation, including an adequate supply of
water at the correct temperature and pressure is essential for effective operation of
your machine. Refer installation instructions for details. Drain hose outlet height
is important on some models. Always install on a sound self-draining floor.
Water softening is recommended in hard water areas - especially for glasswashing.
Pre-rinsing
Pre-scraping of dishes is required by hygiene regulations.
The best method is to pre-rinse with a pre-rinse spray unit or alternatively by scraping or dunking in water.
Cutlery Procedures
Pre-soak cutlery in warm water, preferably containing cutlery
pre-soak compound - refer your chemical supplier.
Do not overfill cutlery containers. Cutlery should be loose with
handles down. Sort after washing rather than before. Cutlery
of only one type nests together and obscures wash water.
Racking Procedures
Do not overload racks, minimize the overlap
of crockery. Cycle times are short and water
consumption per cycle low - so there is no
advantage in overloading racks.
Cycle Times
For multi-cycle machine use the longest
cycle whenever possible. Note that water
consumption does not increase with
longer cycles. Only choose shorter, faster
cycles when necessary.
Detergent
Use of correct type and quantity of low foaming commercial grade
detergent is essential to the performance of the machine. We
strongly recommend that you use a professional dishmachine
chemical supplier - and will be pleased to recommend a supplier in
your region. Discuss with them the use of cutlery pre-soak
solution, detergent and drying agent.
Service Manual PW1-3(S)
10
Revision 1G
Dishwashing Procedures
for best results
Drying
Single tank commercial dishwashers do not have a drying
cycle. However, the machines do rinse at high temperatures
which promote fast drying particularly when drying agents are
used. We recommend prompt removal of the rack from the
machine - leave the rack on the bench for 2 to 3 minutes
before emptying. This time will be reduced with correct use
of drying agent (rinse fluid) which reduces water surface
tension and allows water to drain quickly from washware.
For advice on drying agents and injectors refer to your
chemical supplier.
Daily Cleaning
It is essential that the machine is drained and cleaned at the end of each day. Drain
the machine then remove, clean and replace filters as per the operating
instructions. Regularly check the wash and rinse jets and clean them if necessary –
see below.
Regular Cleaning
Remove scrap trays1 and wash pump inlet filter2, where
fitted, and rinse or brush clean.
Remove wash and rinse arms by undoing the central
thumbscrews3. If necessary, remove the end cap screws4
from the wash arms and the end screws5 from the rinse
arms and flush the arms with water and/or use a toothpick or
paperclip to clear jets.
Note: arms and filters vary with model and may appear
different from this illustration e.g. those models with plastic
wash arms have removable jets for ease of cleaning.
Regular Servicing
Regular servicing of the dishwasher is absolutely essential to
keep the machine in top working condition and obtain the
best performance.
Please contact Washtech or your Authorised Service
Provider to organize regular servicing of the dishwasher discuss a Preventative Maintenance Agreement for optimum
performance and long machine life.
Note: these are general instructions to assist in getting the best performance from Starline dishwashers – some
comments and / or illustrations may not apply to every unit.
Service Manual PW1-3(S)
11
Revision 1G
Troubleshooting Chart
PROBLEM
POSSIBLE CAUSES
REMEDY (Check/Adjust/Replace)
Water supply valve shut
Door switch faulty
Solenoid valve faulty
Rinse lines blocked
Pressure switch faulty
Water supply valve
Door switch
Solenoid valve
Rinse pump, solenoid valve filter
Pressure switch
Won't stop filling
Solenoid valve faulty
Pressure switch set too high/faulty
Pressure bell blocked, hose broken
Solenoid valve
Pressure switch
Pressure bell, hose, hose connections
Filling during
wash cycle
Heating
Rinse not heating
Pressure switch refill level too high
Upstand does not fit properly
Pressure switch
Drain upstand
Over-temp thermostat tripped
Rinse thermostat settings or fault
Rinse element faulty
Over-temp thermostat, rinse element
Rinse thermostat
Rinse element
Overheating
Thermostat adjustment
Thermostat probe out of pocket
Thermostat
Insert & secure probe
Wash water cold
Wash thermostat set too low
Wash element faulty
Machine not rinsing
Rinsing but not hot
Rinsing cycle too short
Wash thermostat
Wash element
Solenoid valve, water supply
Thermostats & elements, water supply
Timer
Not up to temperature
Rinse thermostat faulty
Door switch faulty
Give machine reasonable time initially
Rinse thermostat
Door switch
Solenoid jammed open
Timer stuck
Pressure switch faulty
Solenoid valve
Timer
Pressure switch
Timer jammed
Timer / Timer motors
Timer faulty
Timer / Timer motors
Filling
Not filling
Cycle start
Does not start
Cycle finish
Rinse doesn’t stop
Wash continues
Cycle time
Cycle too long
Cycles selection (for multi-cycle machines)
Time not changed Selector switch faulty
Advance timer motor faulty
Timer micro switches faulty
Delays
At start or
Rinse element faulty
between
Water supply cold
cycles
Water supply pressure excessive
Rinse cycle too long
Service Manual PW1-3(S)
12
Selector switch
6 sec advance timer motor
T4 or T5 timer micro switches
Rinse element
Supply hot water
Restrict supply pressure
Timer
Revision 1G
Troubleshooting Chart
PROBLEM
POSSIBLE CAUSES
REMEDY (Check/Adjust/Replace)
Drainage
Flooding
Drain waste blocked
Drain waste
Leaks
Leak from pumps
Seal failure
Pump seal
Leak from hoses
Hose damage
Hose clamp loose
Hoses
Hose clamps
Splash from door
Wash arm end caps missing
Wash jets blocked
Wash jets missing
Arms not rotating
Arms not level
End caps
Wash arm jets
Wash arm jets
Arms and bushes
Arms
Wash jets not clean
Arm bushes worn
Wash pump not working
Wash jets
Bushes
Wash pump
Rinse jets not clean
Arm bushes worn
Water supply pressure low
Rinse pump not working (if fitted)
Rinse jets
Bushes
Water supply
Rinse pump (if fitted)
Rinse pump squeals
Low pressure / blocked water supply
Noisy wash cycle
Performance
Poor wash result
Wash pump noisy
Wash pump including inlet filter
Detergent not used
Detergent pump faulty
Squeeze tube to be replaced
Overloading racks
Not pre-rinsing
Wash arms not rotating
Wash jets blocked
Low wash pressure through arms
Wash temperature low
Excessive soiling
Unrealistic expectation
Poor rinse results
Rinse jets blocked
Rinse arms not turning
Poor racking procedures
Excessive wash tank soil build up
Use quality low foam product
Detergent pump
Detergent pump squeeze tube
Do not overload racks
Use Fisher pre-rinse
Remove and clean arms/check bushes
Remove arms and clean jets
Wash pump impellor
Check wash /rinse heating
Pre-rinse/use long cycle
E.g. baked on soiling requires presoaking
Remove arms and clean jets
Remove arms, clean jets, check bushes
Do not overload racks
Pre-rinse, change wash water regularly
Not drying
Poor wash/rinse performance
Low temperatures
Drying agent not used
Refer above
Check heating systems
Use quality drying agent/rinse fluid
Wash Arms
Not rotating
Rinse Arms
Not rotating
Noise
Noisy rinse cycle
Service Manual PW1-3(S)
13
Revision 1G
Components
WARNING
All service/repair work must be carried out by qualified personnel only.
Location and Access
1. Test Switch
2. Detergent Prime Switch
3. Wash Pump
4. Rinse Pump
5. Over Temperature Thermostats
6. Rinse Heating Element
7. Fill/Rinse Solenoid Assembly
8. Detergent Pump
9. Timer
10. Power/Chemical Terminal
11. Relays
12. Rinse Thermostat
Service Manual PW1-3(S)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
14
Magnetic Door Switch
Contactors
Pressure Switch
Wash Thermostat
Wash Heating Element
Power/Cycle Selector Switch
Cycle Light Green
Ready Lights Amber
Power Light Red
Temperature Gauges
Start Button
Revision 1G
Timer
Part Number
32787
Function
Provides an automatic timing sequence of the wash, rinse, detergent and rinse aid injection
stages in a dishwashing cycle.
Description
The electromechanical timer has a main drive motor and gearbox which produce a full
rotation of the seven cams in 360 seconds. The advance motor and gearbox speed the
rotation of the timer to produce shorter cycles of 120 and 240 seconds. The timer cams
operate individual changeover switches in sequence during the rotation. The cams are
numbered from the main motor end. T1 controls the main motor, T2 – wash, T3 – rinse,
T4 – rapid advance motor for 120s cycle, T5 – rapid advance motor for 240s cycle, T6 –
detergent injector if fitted, T7 – may be used for electric rinse fluid injector if required.
Diagram
Replacement
To replace the timer take note of the position of each connection, preferably on paper.
Disconnect all wires and remove the timer from the tray. Compare the cam setting of the
old and new timer to ensure that special settings are duplicated. Fit new timer taking care to
locate cam T1 in the same relative position. Reconnect the wires ensuring that no
termination is under strain. Test the machine to confirm correct operation.
Adjustment
The timer cams T2, T3, T6 and T7 are adjustable. The time settings on these cams can be
increased by making the gap in a cam wider, or reduced by reducing the gap. Use a timer
adjusting tool, supplied with the machine to modify a gap in the timer cams.
!
IMPORTANT
The factory setting of the cam T3 allows for a 15 sec hot rinse. Reduction of this
time is prohibited by Health regulations. Extending this setting will increase hot
water consumption of the machine and may result in delays between the cycles as
this additional water is heated.
Service Manual PW1-3(S)
15
Revision 1G
Rinse Thermostat
Part Number
3020
Function
Controls the rinse heating elements and prevents operation of machine if the rinse
temperature is below that required.
Description
The rinse thermostat is a specially calibrated 3 pole capillary type temperature operated
device. The thermostat does not have a control knob and it is factory set to the
temperatures required by Hygiene Regulations. The first pole’s LTCO changeover contact
is set to operate at 83 ±3°C, the other two poles HTCO contacts are set to 90±3°C.
Switching capacity: 16(4) A 380 V.
!
IMPORTANT
Do not break the seal or attempt to adjust the central multi pole adjusting screw
that is sealed with red compound.
Diagrams
DO NOT
TOUCH
LTCO – Low Temp Cut Out
HTCO – High Temp Cut Out
Replacement
Take note of the connections to the wiring loom before disconnecting. Remove the
capillary bulb from the rinse tank pocket. Select a new thermostat and carefully unwind
enough capillary to reach from the pocket to the thermostat mounting position. Carefully
position the tube with no kink or stress on the tube, also have due regard for the protection
of the tube against contact with live electrical terminals – secure or insulate as appropriate.
Adjustment
The thermostat is factory set to the specified above settings and it should not
normally be adjusted. If you are sure adjustment is required, remove the grey tape
covering three adjusting screws for LTCO and HTCO settings (one or both HTCO poles
are used depends on model – check which HTCO terminals are wired before making
adjustments). Insert the thermo junction into the rinse tank pocket for the machine’s
temperature gauge. Energize the elements and check all temperatures on temperature rise.
Clockwise rotation of the screws increases the setting, anticlockwise – decreases it. Every
half turn of the adjusting screw changes the settings by approximately 6 degrees.
!
IMPORTANT
To make adjustments to the thermostat you will need a good quality thermometer
fitted with a “type K” thermo junction. The use of a stainless steel probe is not
permitted as slow response time in the device will cause inaccurate settings.
Service Manual PW1-3(S)
16
Revision 1G
Wash Thermostat
Part Number
30201
Function
Controls the wash element
Description
The wash thermostat is a single pole capillary type device. It has a single changeover contact
and a rotating shaft for a manual temperature adjustment.
Factory default setting is 65°C.
Contact switching capacity: 16(4) A 380 V.
Diagram
Replacement
Drain the wash tank. Take note of the connections to the wiring loom before
disconnecting. Release thermostat’s gland nut, move the capillary bulb out of the mounting
bracket inside the tank and remove the bulb from the wash tank (remove the probe from
the pocket in the wash tank on the models supplied with a pocket for the thermostat
probe). Replace in reverse order.
Adjustment
Insert the probe of a digital thermometer into the wash tank. Check the thermostat settings
on a temperature rise. Adjustment is performed by rotating the adjustment shaft of the
thermostat. Clockwise rotation of the shaft increases the setting, anticlockwise– decreases it.
NOTE: the adjustment shaft in a flat horizontal position is a factory default setting
corresponding to 65°C (see the diagram).
Service Manual PW1-3(S)
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Revision 1G
Pressure Switch
Part Number
600 30308
Function
Controls filling of wash tank and protects wash elements.
Description
The pressure switch is attached to the pressure bell. As the water level in the wash tank
rises air is trapped in the bell and increasing pressure is transmitted to the pressure switch.
When the tank is full the pressure switch shuts off the fill solenoid valve and switches on
the wash element. It allows a water level differential so that the tank level may drop with
the operation of the wash pump, without causing refilling of the machine.
Diagram
LEVEL ADJUSTING SCREW
CW rotation increases upper level
setting
DIFFERENTIAL SCREW
CW rotation increases
differential and reduces lower
level settings
Adjustment
Before making any adjustments drain wash tank, remove pressure tube from pressure bell,
blow gently into tube to check switching of pressure switch and then fit tube back.
Turn the power switch on, machine should start to fill. The machine should cease filling
when the water attains a level about 10mm below an overflow level of the upstand. Adjust
fill level if necessary by Level adjusting screw on the pressure switch.
Remove drain upstand to begin draining the wash tank. Fit back the upstand when Wash
Ready light goes off and measure the refill water level. A refill level should be set 10-20mm
above the wash element. Adjust if necessary by Differential screw on the pressure switch.
Close door to refill the wash tank and re-check the fill level.
Replacement
To remove the switch take note of the electrical connections and remove the wires. Slide
the switch from the mounting bracket and remove the rubber tube from the switch
connector. Replace in reverse order. Whilst in the process of replacing the pressure switch,
ensure that the pressure tube is in good order and clear of obstruction.
!
IMPORTANT
Ensure the tube from the air bell always goes up to the pressure switch.
Do not use thin wall vacuum tube for replacement.
Service Manual PW1-3(S)
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Revision 1G
Wash Pump
Part Number
3906
Function
Pumps water from the wash tank to the wash arms providing a recirculating wash
cycle.
Description
Electric Pump FIR
Power:
Voltage:
Frequency:
HP 2 Kw 1.4
415 V
50 Hz
Speed:
Amperes:
Construction:
2800 rpm
3.1 A
IP44
Diagram
Replacement
Drain the wash tank and switch off the power.
Disconnect the wires from the wiring connectors inside the pump junction box.
Remove two M8 bolts that fasten the pump to the platform.
Release the hose clamps on the inlet and outlet pump hoses and remove the pump.
Replace in reverse order.
Service Manual PW1-3(S)
19
Revision 1G
Rinse Pump
Part Number
600 30400
Function
The pump is fitted after a hot water inlet solenoid valve to boost the pressure of
hot water supply. It pumps hot water through the boiler to the rinse arms,
providing a hot rinse cycle.
Description
Electric Pump R63
Power:
0.33Hp / 0.25kW
Voltage:
230 V
Frequency: 50 Hz
Amperes:
Capacitor:
Speed:
1.2 A
8 uF
2800 rpm
Diagram
ITEM
1
2
3
4
5
6
PART
600 41181
600 41182
600 41183
600 41203
DESCRIPTION
O Ring
Mechanical Seal
Impeller
Pump Housing
Screw
Washer
Replacement
Switch off the power to the machine.
Disconnect the wires from the pump connectors.
Remove M6 bolt that fastens the pump to the floor of the machine.
Release the hose clamps on the inlet and outlet pump hoses and remove the hoses.
Replace in reverse order.
Service Manual PW1-3(S)
20
Revision 1G
DetergentPump
Part Number
600 30094
Function
When fitted the pump automatically injects detergent into wash tank during filling
of the machine and at the start of each wash cycle.
Description
Peristaltic pump with flow rate of 0.33 ml per second, 230 V / 50 Hz.
Replacement
Peristaltic pumps provide reliable and
accurate detergent dosing. However over
time the squeeze tube in the pump will flatten
and become ineffective, and/or split and leak.
We therefore recommend quarterly
inspection of the squeeze tube and
replacement every six months in high use
situations, particularly when chlorinated
detergents are used.
To replace squeeze tube – wear safety
glasses and gloves, switch machine off,
remove the transparent lid, ease the squeeze
tube off rollers and replace the new one.
CAUTION –caustic based detergents are
hazardous.
To replace complete pump – disassemble the pump after unscrewing two screws
from the support bracket; assemble the new pump in reverse order. To prime
pump on electromechanical machines, press and hold detergent prime switch either on top control panel or behind front cover. On electronic machines, drain
and refill the machine - detergent will come up to full strength after several cycles.
Adjustment
Standard machine controls operate the detergent pump continuously during filling
of the wash tank. The concentration during fill is equal to the detergent dosed
(ml/min) / the water filling rate (L/min).
The detergent pump is also set to operate during the wash cycle. Factory timer
settings in seconds of pump operation per wash are as follows:
Model(s)
GM, XG
GL, GLV, UD, UE, M1, M2
AL, AL8, PW1, TW
PW2, PW3
Dosing Time
10 sec
15 sec
20 sec
30 sec
If the recommended concentration of your detergent differs from 2ml/L then the
dosing time should be adjusted – refer to instructions on the Timer page for
electromechanical machines or Electronic Controller pages for electronic
machines.
Dosing Time Equation: T = 3V x C, where T = Dosing time (sec),
V = Water used per cycle (L), C = Detergent concentration (ml/L).
On glasswashers where cold final rinse is used longer injection times are required
to compensate for the dilution of wash water by the cold rinse.
Service Manual PW1-3(S)
21
Revision 1G
Assembly Diagrams
PW1(3) WIRING TRAY ASSY
824 10221 25/10/2011 REV 3-C
PERSPECTIVE VIEW
19
24
10
23
22
21
4
9
5
13
10
17
23
8
1
15
14
15
7
2
16
20
3
20
SIDE VIEW
11
MAIN VIEW
4
6
17
17
12
1
6
12
11
Parts List
ITEM
PART NUMBER
DESCRIPTION
Parts List
QTY
ITEM
PART NUMBER
DESCRIPTION
QTY
1
3035
SWITCH SINGLE POLE BIASED BLACK
2
13
3231-150
DIN RAIL ANLY
1
2
8816
MS RH BRASS 3/16 X 3/4
1
14
8801
MS PAN POZI ZP M4x12
4
3
8151
NUT HX BRASS 3/16" PRESSED
1
15
label det 3
POWER CONNECTIONS LABEL
1
4
3020
3 POLE THERMOSTAT
1
16
32787
TIMER 32822 FITTED WITH 6 MIN GEAR SET
1
5
8800
MS PAN POZI ZP M4x6
2
17
REF
LABEL THERMOSTAT ADJUSTMENT
1
6
REF
LABEL TEST SWITCH
1
18
3231-120
DIN RAIL ANLY
1
7
8802
MS PAN POZI ZP M4x25
2
19
824 10223
AL8(3)/PW1 WIRING TRAY SUB ASSEMBLY
1
8
3229
TERMINAL STRIP 12 WAY
1
20
600 30089-1
BUSH SNAP - IN 25mm
2
9
600 30081
BASE 2 POLE RELAY
2
21
600 30250
PRESSURE SWITCH 140/70mm
1
10
600 30080
RELAY 2 POLE (240VAC)
2
22
600 30131
P CLIP 20.8mm
1
11
600 30094-2
PERI PUMP 1.5L/H SEKO-KIT
1
23
REF
CHEMICAL CONNECTIONS LABEL
1
12
REF
LABEL DETERGENT PRIME SWITCH
1
24
600 30337
CONTACTOR 20A 3NO/NC 230-240V
2
Service Manual PW1-3(S)
22
Revision 1G
AL8(M)/PW CONTROL PANEL ASSEMBLY
400 10139
5/07/2009 REV 3-D
EXPOLODED PERSPECTIVE
6
7
3
5
4
4
8
2
1
1
10
9
Parts List
ITEM
Service Manual PW1-3(S)
PART NUMBER
DESCRIPTION
QTY
1
600 90080
TEMP GAUGE RECTANGULAR 58x25
2
2
600 30161
LENS & NEON ASSY (RED) 12mm
1
3
600 30163
LENS & NEON ASSY (GREEN) 12mm
1
4
600 30162
LENS & NEON ASSY (AMBER) 12mm
2
5
400 70079
M2 - AL CONTROL LABEL
1
6
600 30269
SWITCH 4 WAY QUICK CONNECT
1
7
30415
KNOB 4 POSITION
1
8
400 10140
M2 THROUGH TO PW3 CONTROL PANEL SUB-ASSY
1
9
600 30244
BUTTON ROLD "START" PRINTED
1
10
600 30101
SWITCH START ROLD-SP MOMENTARY
1
23
Revision 1G
Service Manual PW1-3(S)
24
Revision 1G
PW1-3(S) RINSE SYSTEM
PW1 30003 12/12/16 3 F
A
E
B
C
D
Service Manual PW1-3(S)
F
25
Revision 1G
ASSY RINSE TANK 1/2" AL/PW1
400 10122
7/07/2008 REV 1-B
ISO VIEW
5
4
2
1
3
3
2
NOTE:
USE GRAPHITE JOINING COMPOUND ON BOTH SIDES
OF GASKET BEFORE INSERTING ONTO ELEMENT.
Parts List
ITEM PART NUMBER
Service Manual PW1-3(S)
DESCRIPTION
QTY
1
400 10130
AL(3) RINSE TANK SUB ASSY
1
2
3005
5KW RINSE ELEMENT
1
3
3006
ELEMENT GASKET
1
4
600 80052
MS RH ZP M3x6
1
5
600 30088
TSTAT TY60/R-110C [WITH E BKT]
2
26
Revision 1G
ASSY RINSE SOLENOID AL3(S)/AL8(S)/PW1(S)
1672
PERSPECTIVE VIEW
2/03/2015 REV 3-H
END VIEW
PLUG
(NOTE #4)
EXPLODED VIEW
5
4
9
7
10
3
NOTE #2
NOTE #2
NOTE #2
8
1
2
NOTE #1
NOTES:
1. USE 243 OR 290 LOCTITE TO LOCK BOLT TO BASE PLATE
2. USE A131 PERMABOND ON ALL JOINTS
3. ENSURE LINE STRAINER AND SOLENOID FLOW DIRECTIONS ARE AS SHOWN
4. ANGLE LINE STRAINER PLUG 45 DEGREE FORWARD TO ALLOW REMOVAL .
Parts List
ITEM PART NUMBER
Service Manual PW1-3(S)
DESCRIPTION
QTY
1
600 80009
M10 SS HX NUT
2
2
600 80024
MS HX SS 304 M10x60mm
1
3
6047
NIPPLE HEX 15mm
1
4
6153
TAILPIECE 1/2"X1/2" BSP
1
5
6075
MUNSEN RING SADDLE CLAMP BR 20mm
1
6
600 60003
NIPPLE 15mm x 50mm BRASS BARREL
1
7
600 60104
SHB&H 1/2" LINE STRAINER
1
8
600 30403
SOLENOID VALVE w COVER
1
9
6053
CROX SOCKET
1
10
600 30309
FLOW RESTRICTOR 12L/MIN
1
27
Revision 1G
Service Manual PW1-3(S)
28
Revision 1G
Service Manual PW1-3(S)
29
Revision 1G
Service Manual PW1-3(S)
30
Revision 1G
Service Manual PW1-3(S)
31
Revision 1G
Spare Parts PW1-3(S)
DESCRIPTION
PART NO
REC. STOCK
600 30337
600 30183
30415
600 30161
600 30308
600 30080
600 30081
600 30162
600 30163
600 30244
600 30269
600 90080
3229
3035
32787
1
1
600 30088
3005
400 10122
3020
600 30159
30201
1
1
6195
3067
600 60073
400 90076
6194
61942
61941
200mm
500mm
2000mm
Controls & Indicators
Contactor
Door Reed Switch
Knob 4 Position
Power Light
Pressure Switch
Relay 2 pole 240V
Relay Base
Ready Light
Run Light
Start Button
Switch 4 Position
Temperature Gauge
Terminal Strip 12 Way
Test Switch
Timer 2/4/6 Min
1
1
1
1
1
1
1
1
1
Heating Components
Over Temperature Thermostat
Rinse Element 5 KW
Rinse Tank Assembly
Rinse Thermostat
Wash Element 2.5 KW
Wash Thermostat
1
1
1
Hoses & Fittings
Lower & Upper Wash Connection Hose
Pressure Switch Hose
Rinse Hose
Rinse Tee SS
Upper Wash Hose
Wash Pump Inlet Hose
Wash Pump Outlet Hose
Service Manual PW1-3(S)
32
650mm
100mm
150mm
Revision 1G
Spare Parts PW1-3(S)
DESCRIPTION
PART NO
REC. STOCK
600 30094
600 30148
600 30134
600 30400
1672
600 30403
600 60104
3906
1
1
2
1
400 10145
280409C
351 11025
400 10239
400 10244
C190624
261004C
400 30200
400 30087
C450218
351 12003
400 30191
400 20066
400 10077
190621C
400 30101
600 80072
351 11026
1
1
Pumps & Valves
Detergent Pump
Detergent Pump Hose
Detergent Squeeze Tube
Rinse Pump
Solenoid Valve Assembly
Solenoid Valve
Strainer Line 1/2 ”
Wash Pump
1
1
Wash Tank Components
Drain Upstand
Locknut Wash Arm
Rack Slide Assembly
Rinse Arm Assembly (from s/n 145404)
Rinse Arm Assy & Spindle (before s/n 145404)
Rinse Arm Bush
Rinse Arm Cap Screw
Rinse Arm End Plug
Rinse Arm Jet
Rinse Arm Spring Retainer Screw
Scrap Tray
Slip Ring AL(3) Black Acetal
Temperature Gauge Probe Clamp
Wash Arm Assembly
Wash Arm Bush
Wash Arm End Plug
Wash Arm End Screw
Wash Pump Inlet Filter
4
2
2
2
2
2
4
2
2
Note:
For more parts look in the section “Assembly Diagrams”.
Service Manual PW1-3(S)
33
Revision 1G
PW1(3) ACCESSORIES
C660508
CUTLERY BASKET CP8
824 30001
PW1 RACK
600 70029
CUPRACK CB 500mm X 75mm high
0452
CUP COVER W/P 435mm FOR 500mm RACK
TIMER ADJUSTMENT TOOL
600 70028
DISHRACK
Service Manual PW1-3(S)
34
Revision 1G
Appendices
R/AID INJECTOR KIT TYPE G - P/N 0440014
400 90157
9/03/2010 REV 1-A
1
2
8
7
ADJUSTING
SCREW
PARTS LIST - RINSE AID INJECTOR KIT TYPE G - 0440014
ITEM
4
4
PART NUMBER
DESCRIPTION
QTY
1
400 20123
BRACKET RINSE AID MOUNTING
1
2
600 30324
RINSE AID INJECTOR
1
3
@600 30324
DETERGENT/RINSE AID TEE
1
4
@600 30324
RINSE AID TUBE
1
5
@600 30324
METALIC FILTER BALLAST
1
6
@600 30324
RINSE AID FILTER
1
7
8110
M5 SS HEX NUT
1
8
8567
WASHER SPRING SS 304 M5
1
9
ASS6
HOSE CLAMP
2
10
400 90157
RETROFIT DIAGRAM
1
3
9
9
5
6
INSERT INTO RINSE TANK OUTLET HOSE
INSTALLATION
1. MOUNT BRACKET 1 & INJECTOR 2 UNDERNEATH THE WASH TANK OF MACHINE ON THE
STUD PROVIDED.
2. CUT RINSE TANK OUTLET HOSE AT AN APPROPRIATE POINT, INSERT PLASTIC TEE 3 BET
WEEN HOSE ENDS AND SECURE WITH HOSE CLAMPS 9.
3. ASSEMBLE ALL COMPONENTS AS SHOWN ABOVE AND INSERT INJECTOR INLET TUBE
INTO CHEMICAL CONTAINER.
4. RUN THE MACHINE. CHECK THE AMOUNT OF THE FLUID RISING UP INSIDE THE INLET TUBE D
URING THE PULSE AT THE START OF THE RINSE CYCLE - A 75mm RISE WITHIN THE TUBE CORRESPOND
S TO THE VOLUME OF 1 ml OF RINSE AID FLUID PER CYCLE. ROTATE ADJUSTING SCREW CLOCKWIS
E TO REDUCE FLOW AND ANTICLOCKWISE TO INCREASE FLOW. EVERY TURN OF THE ADJUSTING S
CREW WILL INCREASE/DECREASE THE DOSE OF RINSE AID FLUID BY 0.4ml MORE/LESS.
THE VOLUME OF RINSE AID FLUID WILL DEPEND ON FACTORS SUCH AS PRODUCT TYPE, W
ATER HARDNESS, ETC, BUT TYPICALLY 0.5ml PER LITRE OF WATER IS REQUIRED - REFER INSTALLA
TION INSTRUCTION FOR THE VOLUME OF RINSE WATER CONSUMED BY THE MACHINE PER CYCLE.
Service Manual PW1-3(S)
35
Revision 1G
DRAIN PUMP KIT 0440031 - XP/AL3/AL8/PW1
400 90144 19/11/2013 REV 1-G
3
4
23
2
17
TO SELECTOR
SWITCH
14
10
16
15
22
20
17
9
21
17
8
2
17
1
DRAIN PUMP KIT 0440031
ITEM
PART NUMBER
DESCRIPTION
1
600 30102
SWITCH C/RINSE ROLD SPCO
1
2
ASS16
HOSE CLAMP
4
3
600 30173
P CLIP
1
4
600 60105
HOSE DRAIN 2.5M
1
5
600 60102
DRAIN PUMP
1
6
88461
MS HX SS 304 M6 x 12
1
7
8566-1
WASHER SPRING SS 304 M6
1
8
600 90074
UD UHB25 HOSE BEND
1
9
38823
DRAIN PUMP UNION
1
10
38824
GASKET DRAIN PUMP UNION
1
11
400 900144
RETROFIT DIAGRAM
1
12
600 30032
WIRE 0.75 YELLOW/BROWN
0.7m
13
600 30016
WIRE 0.75 BLACK
1.5m
14
600 30015
WIRE 0.75 RED
0.5m
15
600 30033
WIRE 0.75 WHITE/BLUE
0.2m
16
600 30023
WIRE 0.75 BROWN
0.2m
17
H3560
TERMINAL RED SPADE
7
18
H4207
TERMINAL RED FLAT
2
19
600 30297
BUTTON WITH DRAIN SYMBOL
1
20
600 30081
BASE 2 POLE RELAY
1
21
600 30080
RELAY 2 POLE (240VAC)
22
REF
3M VHB TAPE
23
400 10021
ASSY DRAIN PUMP FILTER
19
13
QTY
TO POWER
18 TERMINAL
2
13
12
2
17
5
6
7
1
40mm
1
1. Pre-assemble the drain pump with the flexible outlet hose #4, the inlet hose #8, the drain pump union #9.
Secure the hoses with the supplied hose clamps #2.
2. Secure drain pump to base with M6 bolt #6 and the spring washer #7, provided in the kit.
3. Fit the drain union gasket #10 into the drain pump union #9. and screw the drain pump union #9 on to the drain waste of the
machine.
4. Secure drain outlet hose above the water level using P clip #3 supplied in the kit.
5. Cut out the right side hole below the wash temperature gauge in the control panel label (if see from the front). and fit the drain
switch #1. Fit the base and the relay #20 & 21 at the back of control panel using double-sided adhesive tape provided.
6. Wire the drain pump, the drain switch and the drain relay according to electrical diagrams, provided in service manual or
schematic diagram, supplied with the machine.
Service Manual PW1-3(S)
36
Revision 1G
Revisions
Manual Revisions
REVISION
STATUS
REVISION
DATE
FROM
SERIAL NO:
1A
10/03/08
113946
1B
28/10/08
115216
Change chemical terminal wiring,
Timer configuration and settings.
1C
23/02/09
114966
Change s/s upstand to plastic.
Add drain pump retrofit kit.
1D
6/07/09
New pressure switch 140/60mm.
1E
25/11/11
Change solenoid and rinse pump
1F
4/03/15
Update Components/Assy/Spares
1G
22/12/16
Service Manual PW1-3(S)
145404
37
CHANGE
DESCRIPTION
Rinse Arm assembly with shorter
hub and shorter spindle
Revision 1G
Information supplied in this manual is copyright. No part of this work may be
reproduced or copied in any form or by any means, electronic or mechanical
without the express permission of the author / publisher.