Power Soak PS-275 Service Manual
Contents
1. CHANGE SANITIZE SOLUTION After two hours the sanitizer tank must be drained and refilled Sanitizer Tank Slow to Fast Flashing wash solution life is expiring 15 minute warning prior to solid illumination Flashing with Green Beacon light occurs when tank is filling with water indicating near full rapid flashing indicates that the tank is full NOTE the fill indication feature is an option that must be selected in the UPM settings see programming manual 37193 Power Soak 5 8 Green Unload Load Light Flashing wash period is complete time to unload the items from the wash tank press the Load Unload button to pause the unload timer solid unload timer is paused press the Load Unload when the unloading is complete to restart the timer Unload Load NOTE Proper operation of the Load Unload button according to the flashing of the green light along with keeping the wash tank continuously operating will extend the wash solution life Improper use of the Load Unload buiton will shorten the wash solution life 5 9 Deep Cleaning Mode Lights 5 9a High Wash Fluid Temperature ON The temperature of the cleaning solution in the wash tank has reached 120 FLASHING The fluid temperature in the wash tank is above 123 F and will be uncomfortable to touch High Wash Fluid Tempreture 5 96 Deep Cleaning Mode Active Deep Cleaning Mode Active OFF The Deep2. Power Soak Appendix AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel DO NOT attempt to do these procedures without proper training To obtain information for a recommended service agent please call the Power Soak Service Department at 800 444 9624 Power Soak Other PS 275 Manuals and Related Component Manuals Description Part Number 9527 5 Operators Manual pans 36212 PS 225 amp PS 275 Installation 34453 AWI Advanced Wash Insert Owner s Manual Supplement 33754 Wall Chart AWI Installation Instructions 34293 5 275 UPM Programming Manual 37193 Soap Dispenser Installation Manual 27173 Wiring Diagrams The following wiring diagrams are the two most common wiring methods for the PS 275 The wiring diagram for a machine that is constructed with a wiring configuration other that those shown can be obtained by contacting the Power Soak service department at 800 444 9624 Power Soak EA gx 1 GSEEN J LORANG lt e 5 5 5 amp 5 el 2 g 129 MG 2 5
3. 46 10 4 Decal Locations and Part 47 10 4a Unit with Left to Right Work 47 10 46 Unit with Right to Left Work 47 ADDOBOD ossntettiibanupuiVR HD TU Up 49 Other PS 275 Manuals and Related Component Manuals 50 MV VEG d BI 2 AL Si RET 50 Electric Wiring Diagram Single Phase 51 Electric Wiring Diagram 3 5 52 WEVA UA 53 Power Soak COPYRIGHT 2012 METCRAFT INC dba POWER SOAK Reproduction of this manual is prohibited without written consent from METCRAFT INC dba POWER SOAK Power Soak Power SECTIONS 1 2 amp 3 Vh ed Introduction Section 1 1 0 Product Introduction The Power Soak pot pan and utensil washing system will provide years of dependable efficient and trouble free service Every system is manufactured to last with only high quality heavy duty 14 gauge stainless steel used in its construction All electrical components used in a Power Soak system are of the highest quality The faucets and drains are designed for quick filling and emptying of the system s tanks Most Power Soak systems are provided with a limited 3 year parts and labor warranty To inquire about the warranty status of a PS 275 Power Soak ple
4. P Ci In empty tank spray all parts with Rinse all parts with clean Soak all parts in sanitizing Place in tank and allow to air dry degreaser scrub with green no scratch pad warm water solution for at least 1 minute DO NOT wipe off sanitizer Always inspect the Advanced Wash Insert for any broken pieces and notify the manager in charge immediately if observed AWI Insert Diagram Questions Help Call Power Soak 816 222 2400 Power Soak Power Soak is a registered trademark of Cantrell Industries Inc The Power Soak Design and concept is fully patented Power Soak Systems Inc 903 East 104 Street Suite 130 Kansas City MO 64131 Phone 816 222 2400 Fax 816 222 2419 800 444 9624 www powersoak com Part 37179 Rev A Rev Date 12 19 13 Power Soak
5. 2 11 e e aia e 2 TT o 11 9 SENSOR 1 2 1 COM ni gg CA TEMP SENSOR 1 2 at a amp M 5 TEMP SENSOR 1 2 RED 70 AWG Ci 62A2500 ZiggBee Transmiter PS 275 CONTROL BOX SINGLE PHASE 208 240VAC 60Hz F n _ _ 7 Electric Wiring Diagram Single Phase Electric Wiring Diagram 3 Phase FEE FRE FEE ID G L2 L3 MG M2gH2 F H3 e e e e 2 2 e le N M DISP PUMP 24v 2 p Cs 2 5 LED Display 3 i 62A2500 62A3000 ZiggBee Transmiter CONTROL BOX 5 272 3 PHASE 208 240VAC 60Hz Power Soale2ay V NAT E MS Place ribs along the back of Place ribs along the front Rotate the plastic guide sheet Insert a plastic guide sheet Line empty and sanitized wash tank of the tank Divider after every installation it up along back of the tank fy Line up plastic guide sheet Insert the second large Insert the small plastic Place the Wave Guide as You re done along the front of the tank plastic guide sheet guide sheet pictured on the front top of the Advanced Wash Insert Daily Closing Cleaning Instructions
6. 8 5 3 Green Status nennen nnns 10 el NE EE 10 LAOH RETE MM 10 DO Ds EITOPOOUOS unt a eee es 11 Liquid Level 11 Temperature Sensor 11 qu Seir uio T T 11 Over Temperature 11 E 11 ENO een ee ee 12 Power Soak 5 6 Blue Wash Tank 12 5 7 Red Sanitizer Tank 12 5 8 Green Unload Load Light sescenti Deis mies 13 5 9 Deep Cleaning Mode 13 5 9a High Wash Fluid 13 5 96 Deep Cleaning Mode 13 Control Panel Components Section 6 Authorized Personnel 15 6 0 Universal Programming Module 16 2 ad uk e ek iu rd 17 6 16 Membrane Encoder 18 19 PITT MIG VES 19 64 AG TCI RTT T 19 TINS ONC 21 OGON 22 22 6 8 Fuse Holder Terminal Blocks and 5 23 6 9 P sn cu acean in nisu etae en es rosae atacan deus es aea aue 24 Electrical C
7. Cleaning Mode is not operating The deep cleaning mode has been selected and the deep cleaning programming 15 controlling the operation of the PS 275 Note If the sanitizer tank is full the sanitizer timer will continue to operate When the sanitizer time period is complete the sanitizer indicator lights will operate but the lockout will automatically be turned off and allow the wash tank to continue to operate The fluid should be drained from the sanitizer tank at this time Draining the sanitizer tank will turn off the sanitizer tank lights Power Soak Intentionally blank page Power Soak Power Soak Control Panel Components Section 6 Authorized Personnel Only AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel DO NOT attempt to do these procedures without proper training To obtain information for a recommended service agent please call the Power Soak Service Department at 1 800 444 9624 Power Soak 6 0 Universal Programming Module UPM The Universal Programming Module is located on the inside of the control panel door To access the UPM remove the two screws at the top of the control panel door and swing the door down toward the floor The open door exposes high voltage terminals in the enclosure DO NOT touch the electrical terminals with hands or tools PROGRAMMING INTERFACE UPM The UPM has four indica
8. Place the components back into the rubber pad and secure them place with the retainer plate It is very important to use heat sink compound on the side of the thermo disc and thermistor that will be placed against the surface of the tank to ensure good heat transfer Slide the pad assembly back into the mounting bracket and bolt the bracket to the side of the wash tank 8 4 Chemical Dispenser Optional A chemical dispenser can be purchased from Power Soak The dispenser that is purchased from Power Soak will be mounted under the drain board on the clean side of the sink assembly and contain two or three pumps depending on the application The wiring harness has connections to supply power and operating signals to the chemical dispenser pumps Malfunctions in the chemical dispenser can lower the operating voltage of the PS 275 to levels that are unacceptable and will cause problems with the operation of the PS 275 control system See the chemical dispenser literature for more information on the operation and service of the dispenser Power Soak Power Soak Troubleshooting Section 9 AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel DO NOT attempt to do these procedures without proper training To obtain information for a recommended service agent please call the Power Soak Service Department at 800 444 9624 Power Soak 9 1 The pump will not star
9. Power Soak 10 4 Decal Locations and Part Numbers some of the decals for a left hand unit will be different from a right hand unit The information will be the same only illustrated according to the direction of the work flow The decals will also vary due to customer preferences the part numbers for these decals may be obtained from the Power Soak service department 1 800 444 9624 10 4a Unit with Left to Right Work Flow AWI Installation Sanitizer Decal P N 34806 P N Varies with customer Attach to backsplash only Attach to backsplash for machines with AWI Work Flow Decal P N Varies with customer Attach to backsplash Maximum Temperature Decal P N 31989 Attach to backsplash Power Soak Logo P N 32424 Warranty Expiration Decal P N 27141 Attach to side of the wash tank Control Panel Overlay P N 36275 Identification Plate Attach to corner of wash tank Power Soak 10 46 Unit with Right to Left Work Flow AWI Installation Sanitizer Decal P N 34806 P N Varies with customer Attach to backsplash only Attach to backsplash for machines with AWI Work Flow Decal P N Varies with customer Attach to backsplash Maximum Temperature Decal P N 31989 Attach to backsplash dn Warranty Expiration Decal P N 27141 Attach to side of the wash tank Control Panel Overlay P N 36276 Identification Plate Attach to corner of wash tank Power Soak
10. and ratchet to unscrew the bolt 4 from the center of the pump Impeller 6 Slide the impeller and components off the motor shaft Mark the orientation of the adapter plate to the motor and unbolt the Motor 16 from the Adapter plate using a 5 16 Allen wrench to remove four Bolts 12 Push the seal base for the mechanical seal out of the Adapter Plate from the motor side seal base exits on the pump rotor side of the plate Push the Shaft Sleeve 9 out of the Mechanical Seal and remove the Sleeve O Ring 8 from the end of the shaft sleeve it may be stuck to the face of the impeller shaft instead of in the shaft sleeve seal groove 8 16 Inspection Inspect the components for damage or signs of wear Examine the Adapter O Ring 11 and the Sleeve O Ring 8 to see that they do not have nicks cuts or flat spots Both faces of the Mechanical Seal must be smooth and free of nicks or scratches The motor shaft must spin by hand with a smooth rotation and no rubbing noise Replace components if they are defective The pump impeller must not have cracks or deep grooves in the fins or support structure Impeller blades and support structure are free of grooves and cracks Holes are drilled by the manufacturer for balancing the impeller NEW IMPELLER Impeller blades have been damaged by foreign object entering the suction manifold and lodging in the pump housing Note When purchasing a new impeller the number of vanes and the dir
11. coils within one element and each heating coil has two wires to connect the coil to the electrical circuit The wires for a single coil are directly across from each other on the longest dimension of the mounting plate O Longest Dimension fa ROUND ROD STYLE HEATING ELEMENT These two wires are part of the FLAT BAR STYLE HEATING ELEMENT same heating coil on both the Note flat bar style has three elements inside round rod style and the flat bar the flat bar style The heating element in a Power Soak sink is rated at 7000 watts Electrically the Heater is considered as three separate elements each rated at 2333 watts To check operation of the heat element first turn the power off at the circuit breaker located in the enclosure on the wall Disconnect the H2 wire from terminal H2 and the H1 wire from the triac H1 terminal and H3 wire from H3 triac if 3 phase in the Control Panel Use an Ohm Meter to check between each heater lead and the control panel ground to be sure there is not a connection Check the resistance between each of the combinations of heater wires listed on the chart The heater should be within approximately 10 of the resistance value shown on the chart The voltage and phase information is imprinted on a surface of the heating element mounting flange See section 8 2 of this manual for instructions on removal of the heating element Voltage HeH3 4600 3 6583 __ HtH3 40 1 _ 3 6583
12. connected to high voltage electricity The power to the machine must be turned off at the circuit breaker in the wall mounted enclosure when working on the electrical connection for the pump motor Failure to turn off the power will result in serious injury and possibly death 7 2 Motor Thermo disc The Motor Thermo disc is a protection device to keep the motor from being damaged by excessive heat If the temperature at the Thermo disc reaches 180 F the disc opens turning off power to the UPM To check the operation first shut off the circuit breaker in the wall mounted enclosure that supplies electrical power to the control panel Open the control panel enclosure and locate the two wires extending out of the conduit fitting that is connected to the motor Unplug the connectors that are attached to the yellow wires from the wiring harness on the schematic these are shown as P9 and J10 connected to J9 and P10 for the Motor Thermo disc Use an Ohm meter to check the resistance across the two wires that are attached to the motor thermo disc wires Power Soak extending out of conduit fitting The device should read less than one ohm when closed Check each wire for a short between the wire and the system ground connection A short to ground from either side of the Thermo disc indicates that the Thermo disc is defective These conditions will the UPM from operating correctly On some motors the Thermo disc is built in
13. lights on the bottom of the control panel Triac Relay is a solid state switch for connecting the high voltage to the pump motor and to the heater not all machines have heaters The Triac is a three terminal semiconductor for controlling current in either direction The Triac is used similar to a contactor When a gate voltage is applied from the UPM similar to coil voltage on a mechanical contactor relay the Triac conducts closes through the power terminals On single phase Control Panel there are two Triacs one for the Heater the other for the Motor Terminals 2 and 3 on each Triac are supplied with incoming voltage On the top of these Triacs they are labeled M1 motor leg 1 and H1 heater leg 1 On a three phase Control Panel there are four Triacs two for the Heater and two for the Motor Two of these are labeled identically to the previous single phase panel description The other two are labeled M3 motor leg 3 and H3 heater leg 3 Terminals 2 and 3 on each Triac are supplied with incoming voltage To test the Triac first verify the input voltage to the Triac An LED on the Triac board illuminates when gate voltage is applied by the UPM If this light is on the Triac should be closed and terminal 1 of the Triac should be supplying power to the respective device If the LED is off there should be no current on the output side of the Triac voltage check on the output is not a valid test on a Triac The Triac relays are conn
14. motor fan cover and spin the motor by hand to determine that the pump impeller is not rubing on anything Install the motor fan cover to prevent contact with the fan during operation 8 2 Heating Element 8 2a Disassembly Drain the wash tank and turn off the electrical power at the circuit breaker in the wall mounted electrical enclosure Remove the cover from the outside bottom surface of the wash tank and note how the existing Heater is wired it is helpful to take a picture or make a sketch of the wire connections Unbolt the cover plate inside the wash tank on the slanted surface of the back wall Remove the nuts from the heater element mounting plate on the bottom side of the wash tank and unplug the electrical wires from the terminal block Lift the element out through the opening in the back wall of the wash tank and remove the gasket from the mounting plate of the element Remove the cover on the bottom side of the tank to access the heating element mounting bolts and wiring Hemove the cover inside the tank to access the heating element 8 26 Inspection Examine the gasket for cracks or tears Examine the wires extending out of the base of the element The insulation on the wires must not be burned cracked or missing The connectors on the end of the wire must be free of corrosion crimped tight on the wire and no broken wires Clean debris off the heating element coils and inspect the coils for cracks or burned a
15. of the components connected to the wiring harness The pin numbers are identified on the schematic for determining the component connections The 24 pin connector for the UPM is identified on the schematic as J1 It carries the majority of the communication signals to and from the UPM The connector is designed so that it can only be connected in the correct orientation Identification of the pin numbering is shown below Pin 24 is located in the upper right corner when Pin 12 is located in the lower right corner when facing facing the the connector The connector The lower row is upper row is numbered 1 thru 12 numbered 13 thru 24 Pin 13 is located in the upper left corner when facing the connector Pin 1 is located in the lower row on the left corner when facing the connector Orient the connector with the clip on top as shown 6 1a Programming Interface The programming interface allows direct access to the settings in the UPM operating program The functions in the program can be turned adjusted to tailor the machines operation to a specific application The timers can be adjusted to coordinate with functions such as the fill rate of the wash and sanitizer tanks Explanation for how to set these control functions and timers is located in the programming manual number 37193 The programming interface is installed in the mounting bracket by separating the outer case from the inner frame Press the thumb tabs t
16. water in the wash tank which will cause serious damage to the unit 4 2 Monthly 4 2a Clean the motor fan shroud The motor fan shroud is the vented cover located at the end of the motor closest to the control panel Shut off the electrical supply at the electrical circuit breaker located in the wall mounted enclosure Clean the pump motor fan shroud with a stiff bristle brush and a vacuum If a brush and vacuum are unavailable clean the shroud with a damp soapy cloth This will prevent grease and dust from accumulating in the openings of the cover and obstructing the airflow that cools the motor 4 2b Clean the Heating Element Shut off the electrical supply at the system s electrical circuit breaker located in the wall mounted enclosure Remove the cover plate located in the slanted surface of the back wall of the wash tank Remove debris that has collected in and around the heating element Install the cover plate when cleaning is completed The cover plate must be installed after cleaning to prevent foreign objects from entering the pump suction and causing damage to the pump Failure to shut off the electrical supply will result in personal injury including serious injury or death and extensive equipment damage 4 3 Quarterly or as needed 4 3a De lime the wash sink Select a de liming agent that is safe for plastics and stainless steel sinks Follow the instructions on the package for mixing and fill the tank with water
17. wrench Drain slot alignment Flange orientation on units that are made Flange orientation on units that are for Left to Right work flow made for Right to Left work flow Sanitize tank on right side of wash tank Sanitize tank on left side of wash tank Power Soak Wipe the faces of the mechanical seal parts so that they are free of debris and slide the shaft sleeve assembly onto the motor shaft so that the protruding ceramic face of the mechanical seal makes contact with the white face of the seal base Place the Shaft Seal 8 into the groove on the end of the Shaft Sleeve 9 Insert the Impeller Key 7 into the motor shaft with the flat side of the key oriented toward the bottom of the motor keyway The rounded side of the key will fit into the rounded groove in the impeller Orient the keyway in the Impeller 6 to allign with the motor key way and slide the impeller onto the motor shaft Secure the impeller to the shaft with the Impeller Bolt 4 tighten it to approximately 23 ft lb of torque Inspect all the mating faces in the shaft assembly to be sure that the seals have not slipped out of position Smear a thin coating of food grease on the O Ring 11 and place it in the groove on the outer diameter of the Adapter Plate 13 Slide the ears of the adapter plate over the studs on the Volute pump housing 1 and secure the plate with the Washers 14 and Nuts 15 Tighten the nuts to approximately 23 in lb of torque Remove the
18. 2 Light Illumination Code CONDITION INDICATED BY LIGHTS pump may off wash will not operate Wash tank is near full or full flash rate increases when top sensor is reached Wash period is finished Unload Load wash tank flashing is at a constant rate Wash Program is running Sanitizer tank is near full or full flash rate increases when top sensor is reached Power is on no program running Fill or change fluid in wash tank Fluid life in wash tank has expired Fluid life in sanitize tank has expired flash rate increases as time expires Low voltage from the transformer locked out Programming option Fill or change fluid in sanitize tank Sanitizer life has expired and wash tank is transformer in the control panel has failed The power turned tothe machine 15 OFF or the control Panel tights Status Green Wash Tank Blue Sanitize Tank Red ON when the power is applied to the machine and the transformer in the control panel is producing 24VAC When Power White there is power to the machine and the light is OFF it indicates a transformer failure The Error light will flash a pattern that indicates the type of operating error see the section 5 5a for the Error Codes NENNEN NENNEN GNE Aert tight System 4 4 4 ooo ooo o The orange beacon illuminates when the Deep Cleaning Mode is elevating the wash fluid temperature for the Deep Cleaning operat
19. ERROR are blinking with a pattern of long and short flashes Possible Cause A problem has been detected by the program and the UPM is signaling an error code Solution see section 5 5a to determine the error message 9 1e All of the lights on the control panel and all of the Alert Lights are flashing Possible Cause The transformer output voltage is below an acceptable level Solution 1 Check the voltage on the transformer see section 6 5 2 Check the electrical connections to the transformer for correct connection to the power source and correct connection for 24V output 9 2 Motor starts but makes noise Possible Cause 1 Debris lodged in the pump housing 2 The motor fan cover has been dented or has collected debris 3 The motor is rotating the in the wrong direction only occurs when motor is first installed or replaced Solution 1 Turn the power off to the machine at the circuit breaker in the wall mounted electrical enclosure and remove the motor assembly see sections 7 1 amp 8 1 Be sure that the heater cover in the back wall of the wash tank is secure with no gaps around the edges that will allow foreign objects to enter the pump suction manifold see section 8 2 2 Turn off the power to the machine at the circuit breaker in the wall mounted electrical enclosure and remove the motor fan cover Straighten the cover or replace it if the cover is damaged clean the debris and install the cover back onto t
20. Encoder smallest connector plugs into the wire harness The cables from the overlay membrane should be a tight fit onto the pins The connectors should not slide on or off the pins easily The tight fit is wnat keeps the connectors plugged into the components The tight fit also makes it difficult to unplug the connectors The middle size connector plugs into the pins at the end of the outer row of pins Power Soak 6 2 Communication Port A communication port USB A style is located on the bottom of the control panel enclosure and connected to the UPM by acable The connection port is protected by a cover that screws on to the body of the connector The operating program is loaded into the UPM or copied from the UPM by using this port Inserting a blank USB Flash Drive into this port will activate the programming module to copy the operating program to the flash drive Inserting a USB Flash Drive that contains an operating program will activate the UPM to load the program into the module overwriting any program already contained in the UPM 6 3 Alert Lights The Alert lights are inserted through holes in the bottom of the control panel box and are secured with a nut screwed onto the body of the light A connector is plugged into each of the lights The connector for each light has a wire with a colored stripe that matches the color of the light to which it is connected Communication port 6 4 Triac Relay Alert
21. Power Soak Service Manual Intentionally blank page Power Soak Table of Contents Introduction Section 1 2 LUND rere WEF OO CHO PER E 2 1 1 General 2 Messages Section 2 3 2 0 Explanation of Warning 3 OO ETE UU UU TEES 3 2 LUN 3 Ro ON dez TAZA 3 2 4 Personal Injury 3 Detergents and Sanitizer Section 3 4 ol dc 4 SEAE ee TE ee a a 4 AC A 4 Preventative Maintenance Section 4 D 4 0 6 6 4 1a Clean the liquid level 6 6 4 2a Clean the motor fan shroud 6 4 2b Clean the Heating 6 4 3 Quarterly or as need6ed tu ada utut du ut urea 6 4 De lime the wash 6 Control Panel Lights Section 5 7 5 1 Control Panel nennen nnns 8 5 2 Light Illumination
22. R white light is on STATUS green light is on and WASH TANK blue light is 38 9 1d Control panel POWER white light is on STATUS green light is on and SANATIZER TANK red light is on 38 9 1d Control panel STATUS light and ERROR are blinking with a pattern of long and short 39 9 1e All of the lights on the control panel and all of the Alert Lights NASM e E A 39 9 2 Motor starts but makes 00 39 9 3 Motor starts but no water flows in the wash tank 40 9 4 The control circuit fuse blows when the power is turned on 40 9 5 The lights indicate that the tank is empty when it is actually full 40 9 6 The water gets too hot and stops the machine 41 9 7 The chemical dispenser pump runs but does not pump the chemical 41 Parts Lists Section 10 42 10 1 Motor and Pump 43 10ta PANS 43 10 16 60 Hz Motor and Impeller 44 10 16 50 Hz Motor and IMD CN esena a aE 44 10 1d Pump Parts Common to all Assemblies 44 44 10 2 Heater amp Sensor nnne 45 30 9 COBIFOL reteset een fe Yon ond
23. Turn on the pump motor to circulate the mixture in the tank and pump manifolds Power Soak Power Soak Control Panel Lights Section 5 5 275 5 1 Control Panel Overlay The Control Panel Overlay is bonded to the surface of the enclosure door and conceals the membrane that contains the push buttons and lights The panel lights are used to indicate conditions that have been detected by the operating program The lights on the face of the control panel operate in conjunction with the Alert Light System located on the bottom surface of the control box lights that shine on the floor There are some conditions that are indicated by the control panel lights which are not part of the Alert Light System The operator should review the control panel lights when determining the operating situation of the machine See the chart in section 5 2 for interpreting the light combinations HOT WASH FLUID CAUTION DEEP CLEAN DEEP Power Soak GREEN STATUS LIGHT SECTION 5 3 4 GREEN Stop Idle Unload Load UNLOAD LOAD WHITE SECTION 5 8 OW E R 5 Wash Tank Tanque de Lavado Sanitizer Tank LI G HT Status Estatus NF SECTION 5 4 sD end RED SANITIZE 5 SECTION 5 7 A MIN ane ip ic RR P U R LE Power Systems 1 816 222 2400 www PowerSoak com 36275 ERROR LIGHT SECTION 5 5 BLUE WASH TANK SECTION 5 6 Power Soak 5
24. __ If the reading varies significantly from the chart above the heater may be defective or there may be a broken wire or loose connection Power Soak 7 4 Heating Element Thermo disc The Heater Thermo disc is a devise used to detect a high temperature created by the heating element If the temperature at the Thermo disc reaches 135 F the disc opens turning off power to the UPM The Thermo disc is located close to the Heater inside the sensor Pad see section 8 3 for Sensor Pad or on the mounting flange of the heating element To check the operation of the thermo disc turn off the circuit breaker in the wall mounted enclosure that supplies electrical power to the control panel Unplug the spade connectors for the motor thermo disc see section 7 2 and locate the yellow wire with the male spade connector Locate the connection to the transformer wires that has a grey wire from the wiring harness and remove the grey wire from the connection Use an Ohm meter to measure the resistance across the male spade connector and the grey wire If this measurement shows more than one ohm of resistance it will the UPM operating correctly Individually check the male spade connection and grey wire for continuity to the machine ground Continuity to the ground would indicate a defective thermo disc that will need to be replaced Reconnect the wires after the evaluation is completed NOTE The motor thermo disc is wired in se
25. al If the reading is greater than one ohm clean the face of the sensor inspect the wiring connections or replace the sensor A reading greater than one ohm may be caused by a dirty sensor a broken wire or a loose connection The loose connection may be at the sensor connection to the wiring harness or the wiring harness connector may not be tight at the back of the Control Panel Hole Cover Or Wash Tank High Optional Level Sensor Chemical Dispenser Power Soak Power Soak Assembly Procedures Section 8 Authorized Personnel Only AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personnel DO NOT attempt to do these procedures without proper training To obtain information for a recommended service agent please call the Power Soak Service Department at 1 800 444 9624 Power Soak 8 1 Motor and Pump 8 1a Disassembly Turn off the electrical power to the machine at the circuit breaker in the wall mounted enclosure and drain the wash tank To service the pump or motor the wash tank must be empty Refer to the illustration in Section 10 1for the following description Remove the Nuts 15 holding the Adapter Plate 13 with a 9 16 wrench and then slide the adapter plate and motor assembly off the studs NOTE This assembly will weigh approximately 45 pounds and must be supported so that it does not drop on the floor when it is removed Use a 9 16 socket
26. ase call the following number and have the serial number of the machine available at the time of the call Power Soak Systems 800 444 9624 The people at Power Soak Systems take pride in manufacturing the Power Soak equipment and are committed to standing behind Power Soak customers and products 100 1 1 General Description The Power Soak PS 275 can be built with many variations to meet the needs of Power Soak customers The illustrations shown in this document cannot match all the possible machine configurations however the information will apply even if a machine does not match the illustration The general configuration of a machine will start the work flow in the scraping area and or wash tank and finish in a sanitize tank and or on a drain board The units that start with the scraping area and or wash tank on the left are referred to as a left to right or left hand unit A right to left or right hand unit will start with the scrap area and or wash tank on the right hand side Power Soak Messages Section 2 2 0 Explanation of Warning Messages Be sure to read understand and follow all DANGER WARNING and CAUTION messages located in this document and on the equipment These messages are used to identify areas of the machine that are harmful 2 1 Danger Personal Injury and Property Damage hazard Will result in serious injury or death Will cause extensive equipment damage 2 2 Warning Property Da
27. cted by the UPM section 5 5a identifies the meaning of the flashing sequence Power Soak 5 5a Error Codes Certain conditions create errors in the program operation The purple ERROR light on the front of the control panel along with the ERROR CODE light on the UPM will blink in patterns to indicate the source of the error The definitions for the patterns are as follows symbol represents a long flash symbol represents short flash 3 long amp 1 short _____ Liquid Level Error long 8 2 short ___ Temperature Sensor Error long amp 3 short ___ Oyer Current Error 3 long amp 4 short ___ Over Temperature Error 3 long amp 5 short ____ Current Sensor Error 3 long amp 6 short ___ Membrane Error Liquid Level Error This error appears when the upper liquid level sensor sends a signal to the UPM W H light is illuminated and the low liquid level sensor is not sending a signal to the UPM W L is not illuminated The low level sensor may not be functioning due to a coating of debris or a broken disconnected wire that is preventing the signal to the A continuous signal from the upper level sensor can be caused by debris coating the face of the sensor or faulty wiring that has the sensor connection grounded to the wash tank when there is no fluid in the tank The liquid level lights on the UPM can be used to help determine the problem see Section 6 0 UPM amp Sect
28. d electrical enclosure and replace the contactor 9 5 he lights indicate that the tank is empty when it is actually full Possible Cause 1 he sensor is coated with debris 2 he wire connected to the sensor is loose or broken 3 he control panel connector is loose Solution 1 Clean the face of the sensor with a washcloth and soapy water 2 Check the nut that secures the wire to the sensor on the outside of the tank 3 Examine the control panel connector to see that it is properly connected Power Soak 9 6 The water gets too hot and stops the machine Possible Cause 1 Incorrect soap is creating too much foam Foam causes excess heat by reducing the efficiency of the pump and it insulates the top of the tank which holds in heat 2 The Triac has failed and is passing current to the heater when it is turned off Solution 1 Change the wash solution and use a low foaming soap designed for continuous ware washing or reduce the quantity of low foaming soap that is added to the water 2 With the machine operating check the amperage on the heating element wires when the indicator light goes off If the current does not go off when the indicator light is off the Triac is defective 9 7 The chemical dispenser pump runs but does not pump the chemical Possible Cause 1 The hose has been punctured or ruptured 2 The fitting has not been screwed onto the chemical container properly Solution 1 Replace the def
29. ected to high voltage electricity The power to the machine must be turned off at the circuit breaker in the wall mounted enclosure when working on the Triacs Failure to turn off the power will result in serious injury and possibly death Power Soak Triacs for 3 phase Triacs for 3 phase Heater Control PA Motor Control High Voltage Power Connections Low Voltage Gate Connection The connectors are matched to the gate connection according to the location in the wiring harness and the location of the gate connection Control Box with Triacs for 3 Phase Motor and Heater Alert Lights are not shown for clarity Gate Connections pe Alert Light Connections The unused signal connectors are tied to the wiring harness Control Box with Single Triac for Single Phase Motor and Heater Power Soak The wiring harness connectors for the Triac gates must be connected to the proper location The connector location is matched to the gate connection by the location in the wiring harness The first wire connector exiting the wiring harness will attach to the first gate connection on the heater control On a single phase machine or when heating element is not used the additional Triacs will not be installed and the connectors will be tied to the wiring harness The connectors have a common connection that is in series with each of the connectors When a connector is disconnected from a Triac the connectors to the righ
30. ection of rotation left hand or right hand sink configuration are critical to receiving the correct part Contact the Power ooak field service department for help DAMAGED IMPELLERS Power Soak 8 1 Assembly Refer to the illustration in Section 10 1for the following description Apply a thin coating of light weight oil such as WD 40 to the outer surface of the Mechanical Seal base 10 and push the base into the Adapter Plate 13 with the white surface of the base oriented to the pump side Apply a thin coating of light weight oil to the interior of the Mechanical Seal 10 and slide the seal onto the Shaft Sleeve 9 with the protruding ceramic face of the seal oriented away from the shoulder on the sleeve The mechanical seal base is installed into the adapter plate with the ceramic white face oriented toward the pump side of the plate The protruding ceramic face of the mechanical seal is to be oriented to contact the white face of the mechanical seal base The shaft sleeve will slide through the mechanical seal oriented so that these two faces make contact with each other Place the adapter plate on the face of the motor with a drain slot aligned with the connection box and the other drain slot oriented as shown for the configuration of the machine This will allow the connection box to be on the bottom side of the motor when the pump and motor are assembled onto the volute pump housing Install the bolts with a 5 16 Allen
31. ective hose with a new hose 2 Unscrew the fitting from the container check the threads and face of the fittings for damage Carefully screw the fitting back onto the container so that the fitting seats properly against the container opening If the trouble shooting procedures do not correct the problem contact Power Soak systems Inc at 800 444 9624 or an authorized service agency Power Soak Power Soak Parts Lists Section 10 5 275 Power Soak 10 1 Motor and Pump Assembly The part numbers for the Volute 1 Impeller 6 and Motor 16 are different for the different configurations of machines Contact the Power Soak Service Department 1 800 444 9624 and provide the serial number of the machine for help with the part numbers 10 1a Parts list Part Number J Description Item Description Volte 9 27481 ShaftSleve Pin partofvolut 10 27480 Mechanical Seal Stud partofvolut 11 27476 Adapter O Ring 27478 Impeller Bolt 12 27483 Motor Bolt 27479 Impeller Washer 13 27525 Adapter Plate Varies Impeller 14 28312 Washer ImpellrKey 15 28264 Nu _ Sleeve O Ring 16 Varies Power Soak 10 16 60 Hz Motor and Impeller _ HP Side Phase Motor Impeller _ 10 1c 50 Hz Motor and Impeller _ HP side Phase Motor Impeller 10 1d Pump Parts Common to all Assemblies 10 1e Seal Kit Description Seal Kit Mechanical Seal O ring sleeve O ring seal plate I
32. el DO NOT attempt to do these procedures without proper training To obtain information for a recommended service agent please call the Power Soak Service Department at 1 800 444 9624 Power Soak 7 1 Pump Motor The pump motor is bolted to a mounting plate that is attached to the pump housing The pump impeller is attached directly to the motor shaft A rotary joint seal is used to separate the water containment area from the front of the motor see section 8 1 for assembly instructions The pump impeller and motor must rotate smoothly without dragging anywhere in the rotation The motor shaft can be turned by hand to verify that the motor is rotating properly and that the pump is not jammed with debris To rotate the motor by hand turn off the electrical power to the machine at the circuit breaker before working on the pump motor Remove the fan cover and turn the fan blade by hand If the fan blade will not rotate easily and or smoothly there is a problem with the motor or the pump The motor will have to be removed from the pump housing to determine the source of the problem see section 8 1 Install the fan cover before turning on the power to the machine The Pump Motor fan cover provides protection from the moving fan blade The power to the machine must be turned off at the circuit breaker in the wall mounted enclosure when working on the pump motor Failure to turn off the power will result in serious injury The Pump Motor is
33. erious injury and possibly death 6 7 Load Sensor The high voltage wire leading to the heater and motor along with the coil wire for the contactor have been placed through the center of a load sensor This device senses the amperage on the electrical supply to the components in order to detect an overload situation In order for the sensor to function properly the smaller wire from the contactor coil must be wrapped three times through the center of the load sensor body A plastic Zip tie is tied around the high voltage wire to keep the senor from sliding down the high voltage wire Load Sensor Contactor Wire tie to keep the sensor from sliding down the high voltage wire Contactor wire must be wrapped 3 loops through the center of the load sensor for proper operation High Voltage Wire Power Soak 6 8 Fuse Holder Terminal Blocks and Jumpers A fuse holder with a 1 amp fuse for the 24VAC contactor control circuit and chemical dispenser pump is nested with the terminal blocks When this fuse is blown or not present the contactor will not connect the high voltage electricity to the pump motor or heater The fuse is accessed by pulling out on the tab at the top edge of the fuse holder The electrical supply wires are to be connected to the terminal blocks Some of the components of the machine are also wired to the terminal blocks A jumper is used to connect specific terminal blocks to the adjacent terminal b
34. fold Start wash cycle and check the operating temperature of the water The water should heat to approximately 115 F within two hours The heating element access cover must be installed while the pump is operating Failure to install the heating element access cover will allow objects to enter the pump suction and damage the pump impeller Power Soak 8 3 Sensor Pad 8 3a Disassembly To access the contents of the Sensor Pad unbolt the mounting bracket that holds the sensor pad and remove the sensor pad from the back side of the wash tank Lift the retainer plate out of the rubber pad and then remove the electrical components Heat sink Thermistor compound Is used on these faces Thermo disc Retainer plate The sensor pad is located on sensor pad removed from wash tank the back side of the wash tank 8 3b Inspection Examine the wires for damage to the insulation Test each of the components for proper function Unplug the spade connectors from the tabs on the thermo disc and use an Ohm meter to measure the resistance across the tabs of the thermo disc If this measurement shows more than one ohm of resistance it will keep the UPM from operating correctly Individually check each tab connection for continuity to the mounting flange Continuity to the flange would indicate a defective thermo disc that will need to be replaced Check the operation of the Thermistor as described in section 7 5 8 3c Assembly
35. he motor 3 Turn off the power to the machine at the circuit breaker in the wall mounted electrical enclosure and change the wiring connection for the motor This must be done by a qualified electrician Power Soak 9 3 Motor starts but no water flows in the wash tank Possible Cause 1 The key that drives the impeller has fallen out of the motor shaft keyway 2 The pump impeller is broken or not connected to the motor shaft 3 The motor is rotating the in the wrong direction only occurs when motor is first installed or replaced Solution 1 amp 2 Turn off the power to the machine at the circuit breaker in the wall mounted electrical enclosure and remove the motor assembly see sections 7 1 amp 8 1 3 Turn off the power to the machine at the circuit breaker in the wall mounted electrical enclosure and change the wiring connection for the motor This must be done by a certified electrician 9 4 The control circuit fuse blows when the power is turned on Possible Cause 1 There is a short circuit in the chemical dispensing pump not all machines have chemical dispensing pump 2 coil in the contactor is drawing too much current Solution 1 Disconnect the cable on the back of the chemical dispenser and try a new fuse If the fuse does not blow then have the chemical dispenser checked by a qualified service person 2 Turn off the power to the machine at the circuit breaker in the wall mounte
36. ion 7 6 Liquid Level Sensor Temperature Sensor Error When the UPM receives a signal from the thermistor see Section 7 5 Thermistor that is outside the range of the UPM programming the temperature sensor error will actuate Over Current Error If any of the high voltage components begin drawing excessive current the current sensor will send a signal to the UPM to start the Over Current Error and deactivate the contactor which turns the power off to the machine see Section 6 6 Contactor amp Section 6 7 Load Sensor Over Temperature Error If the fluid temperature the wash tank exceeds 135 it will activate this error message and stop the machine This error code cannot be reset until the fluid is drained below the low level sensor in the wash tank Current Sensor Error The UPM must receive a signal from the current sensor to verify that it is connected and working If it does not receive the signal the UPM program will stop the machine and give this error code see Section 6 7 Load Sensor Power Soak Membrane Error In the event that one of the control panel buttons sends a constant signal to the UPM the program will recognize that the membrane is defective and display this error code see Section 6 9 Push Button Membrane Please have the Error Code information and serial number of the machine available when calling Power Soak Systems for telephone assistance 1 800 444 9624 The machine serial number wi
37. ion The beacon will flash when the fluid temperature in the wash tank is above 120 F indicating that the wash fluid temperature is uncomfortable for human contact Error Purple All lights are turned off 3 37109 PS 275 Light Sequence xlsx Power Soak 5 3 Green Status Light Off Power to the machine is turned off or an over temperature situation has occurred Status Estatus C Slow Flashing POWER system is energized and ready to fill the wash tank Solid Illumination OPERATING wash tank is full START button has been pressed the program is running Note if the Stop button is pressed the program is still running even if the wash action is stopped pressing the START button will start the wash action The wash solution must be drained from the wash tank to exit the operating program Flashing with another light indicating a message see the chart in section 5 2 Flashing a repeating long amp short pattern error has been detected see error codes in section 5 5a 5 4 Power Light ON Electrical power is connected to the PS 275 em and the transformer inside the control panel Power Poder is producing the appropriate 24 VAC OFF The power supply to the PS 275 is turned off or the transformer inside the control panel has failed 5 5 Error Light The error light is used to flash a code that indicates the type of failure that has been dete
38. ll be used to identify the configuration of the machine The serial number is 5 6 digits long and located on the identification tag which is on the lower corner of the wash tank close to the control panel enclosure Note There are periods of unstable power from the incoming power source that can cause a false error Turning the electrical power off and on can reset the program if it is a power source fluctuation that caused the error Locate the wall mounted circuit breaker box turn the circuit breaker for the Power Soak machine off pause for 15 seconds turn the circuit breaker back on and then check to see if the error code has cleared 5 6 Blue Wash Tank Light Solid Illumination CHANGE WASH SOLUTION the Wash Tank Tanque de Lavado wash cycle will be stopped until the wash tank is completely drained and refilled Slow to Fast Flashing wash solution life is expiring 15 HDI Feet uy minute warning prior to solid illumination Flashing with Green Status light occurs when tank is filling with water indicating near full rapid flashing indicates that the tank is full NOTE the fill indication feature is an option that must be selected in the UPM settings see programming manual 37193 5 7 Red Sanitizer Tank Light Solid Illumination FILL SANITIZER TANK sanitizer tank Tanque Para must be filled to the waterline Saneamiento O R Solid Fill Encendida Lienar Solid Illumination
39. lock so that wires connected to either terminal block are all connected together The jumpers are arranged according to the electrical requirements for the heater and motor This jumper is used Fuse Jump Holder on all assemblies This jumper is used for single phase electrical connections DO NOT use this jumper with three phase electrical connections Connect the incoming electrical supply wires to the terminal blocks Connecting the electrical supply wires to any other location will void the warranty TERMINAL BLOCK ASSEMBLY The incoming electrical supply wires must be connected to the terminal blocks Connecting the electrical supply wires to any other location will void the warranty Power Soal 6 9 Push Button Membrane The buttons and lights on the front of the control panel are made into a plastic membrane that is sandwiched between the plastic overlay and the sheet metal face of the enclosure cover Multiple ribbon cables attach to the buttons and lights The ribbon cables fit through a slot in the sheet metal door on the control panel and the cables pug into the Membrane Encoder see section 6 1b to allow the buttons to signal the UPM for the Start Stop and Unload functions The large connector ribbon cable allows the UPM to illuminate the lights on the membrane The membrane and overlay are bonded to the sheet metal with an adhesive If the membrane malfunctions the overlay and the membrane will both have to be re
40. mage Hazard Will result in property or equipment damage 2 3 Chemical Hazard Will result in serious injury or death Instructions labels and Material Safety Data Sheets MSDSs are to be supplied with all detergents and sanitizing chemicals The manufacturers importers and distributors of the cleaning chemicals are responsible for providing this information Power Soak Systems Inc is not a chemical manufacturer importer or distributor Power Soak Systems Inc can assist the chemical representative but will not make specific brand recommendations 2 4 Personal Injury Hazard Hazard from sharp objects Will result in serious injury or death gt Power Soak Detergents and Sanitizer Section 3 3 1 Detergents Power Soak machines require a low foaming and recommend a metal aluminum safe detergent The detergent should have good grease cutting abilities and pH level that is safe for human contact Improper detergents may damage the equipment Use of the correct detergent in the Power Soak PS 275 is critical to its washing performance If there are problems with cleaning results please contact Power Soak Systems 1 800 444 9624 Detergents with high or low pH level will damage the equipment and be harmful to human contact Consult with a chemical manufacturer representative for recommendations on the selection of detergents 3 2 Sanitizers A chemical sanitizing method is used in the Power Soak sy
41. mpeller Bolt Fiber Washer Power Soak 10 2 Heater amp Sensor Block Heating Element Heating Element Gasket P Terminal Block sensor Pad Thermistor Thermodisc Retainer Plate Power Soak JUMPER 10 3 Control Panel TRANSFORMER Ex TERMINAL BLOCK Lo GROUND BLOCK N FUSE HOLDER e DIN RAIL 2207 USB PORT WIRING HARNESS HEAT SINK ALERT LIGHT TRIAC PROGRAMMING INTERFACE UPM USB INTERFACE MEMBRANE ENCODER The control panel is shown without the sheet metal enclosure for clarity Some variations of the control assembly do not contain all of the components shown Parts Description 33552 Contactor 296 Jumper 00 5 27172 Transformer 24 volt 208 220 33716 AlertLight green 31659 Transformer 24 volt 415 480 7 33715 AlertLight red 36457 Programming Module 33536 Alert Light blue 27923 Terminal Block 36206 Alert Light orange 27924 Grounding Block 34823 USB Pot 27925 DinRail mount for terminal blocks 34822 058 Cable 27928 Triac solidstate relay 34815 USB Interface 28923 Fuse Holder 7 34147 Programming Interface 27927 HeatSink 33507 Overlay L R machines 32394 EndStp 7 33508 Overlay R L machines __ Wiring Harness internal to control a Power Filter Use with 50 panel Hz only not shown Lad ins IPM S not shown
42. nect the output wires and check again If the voltage returns to 24VAC then check other components for a connection to ground short circuit Transformer up 4 Fuse Block le olo i B i SE Contactor Terminal Blocks Load Sensor The transformer is connected to high voltage electricity The power to the machine must be turned off at the circuit breaker in the wall mounted enclosure when working on the transformer Failure to turn off the power will result in serious injury and possibly death Power Soak 6 6 Contactor A mechanical contactor is used to disconnect the high voltage electrical supply from the Triacs when the UPM detects a problem with the pump motor or wash tank heater The contactor is located on the left side of the mounting plate in the control enclosure The contactor is defective if there is 20vac 28vac across the coil and the contactor does not pull the center button into the core When the center button is pulled into the core and there is input voltage across terminals L1 and L2 also L1 L3 and L2 L3 if three phase but no voltage across terminals 1 and T2 also T1 T3 and T2 T3 if three phase the contactor is defective The contactor is connected to high voltage electricity The power to the machine must be turned off at the circuit breaker in the wall mounted enclosure when working on the contactor Failure to turn off the power will result in s
43. omponents Section 7 Authorized Personnel 25 emer renee UU rE UU UU 26 Te IMIOLOL IHMC 26 7 3 Heating 27 7 4 Heating Element 29 CN MTM 29 7 6 Liquid Level Sensors 5 5 5 30 Assembly Procedures Section 8 Authorized Personnel Only 31 VIO TOR 32 8 1a Disassembly _ _______ ______ 32 STDS DECOT peer r E 32 8 1 33 8 2 Heating 34 9 29 istum an aes 34 1 8 eee ee trees eee tet cs Sede ede ine eel lee 34 35 9 5 DENSON Pad 36 Power Soak 8 3a 36 8 36 36 __ 36 8 4 Chemical Dispenser 36 Troubleshooting Section 9 37 9 1 The pump will not start when the green START button is pushed 38 9 1a Control panel white POWER light is not on 38 9 1b Control panel white POWER light is on 1 38 9 1c Control panel POWE
44. oward the center of the case and then pull the outer case away from the front face Power Soak Tabs To separate the interface unit for mounting squeeze the tabs on the end of the case and pull on the back edge of the mounting flange Back edge of the mounting flange Separated for mounting 6 16 Membrane Encoder The membrane encoder is located next to the UPM and is used to translate inputs and outputs between the control panel overlay and the UPM The ribbon cables from the overlay and a four pin connector Four pin routed from the UPM harness plug into the face of the connector encoder The four pin connector is keyed so that it will only insert into the socket if it is oriented correctly The ribbon cables from the overlay can be installed incorrectly and must be properly oriented as described Keeping the ribbon cables flat no twists in the cable the large connector onto the inner row of pins making sure that the connector slides over all the pins The middle size connector slides onto the outer row of pins and connects to the first four pins that are closest to the outer edge of the encoder see illustrations Large connector slides over all the pins on the inner row The smallest connector attaches to a two pin Middle size connector slides connector that is part of the wiring harness The over pins on outer row orientation of the two pin connection is not important Membrane
45. placed The adhesive is strong enough that the membrane and overlay cannot be removed without damage to both components The following illustrations show how to check the operation of the push buttons Disconnect the large and middles size ribbon connectors and apply the leads of an ohm meter to the middle size connector as shown If the ohm meter does not show continuity when the button is pressed and a break in continuity when the button is released then the membrane must be replaced Ohm meter probes Ribbon connector disconnected from the encoder START BUTTON First and second from the right side of the connector as viewed in this photo STOP BUTTON UNLOAD BUTTON First and third from the First and fourth from the right side of the connector right side of the connector as viewed in this photo as viewed in this photo The large connector is unplugged to allow access to the middle size connector The large connector carries the signals to all the lights in the membrane except the POWER light The small connector carries the 24VAC to the POWER light The small connector is plugged into the wire harness which is not part of the Membrane Encoder Orientation of the small connector to the wiring harness connector is not important Power Soal Power Soak Electrical Components Section 7 Authorized Personnel Only AUTHORIZED SERVICE AGENCY This section contains procedures that are to be performed only by authorized service personn
46. reas on the surface of the coil Replace any defective part with a new part Power Soak 8 2c Assembly Place the gasket on the bottom surface of the heating element mounting plate Insert the heating element though the opening in the back wall of the wash tank Push the wires through the center opening and align the studs with the mounting holes on the bottom surface of the tank Install the nuts on outside surface of the tank to secure the heating element to the bottom of the tank Tighten the nuts to pull the mounting base snug against the bottom surface of the tank and then turn the nut another 1 2 turn to secure the element Fill the tank with a few inches of water and check for leaks around the heating element mounting holes Connect the heater wires to the terminal block Machines that have three power supply wires L1 L2 L3 attached to the terminal block will use the three phase connection and machines that only have two power supply wires L1 L2 attached to the terminal block will use the single phase connection L1 L2 L3 WIRING CONNECTION FOR 3 WIRING CONNECTION FOR SINGLE EE EAA EE EE PHASE HEATING ELEMENT TERMINAL ON WIRING BLOCK a 1 L1 L2 q P WIRE FROM HEATING ELEMENT 127 a NW f WW Install the cover over the heater access opening inside the wash tank Be sure that the cover is seated well with no gaps around the edges that will allow debris to enter the pump suction mani
47. ries with the heating element thermo disc see the schematic for wiring information 7 5 Thermistor The Thermistor is a temperature sensor located close to the Heater inside the Sensor Pad that is mounted to the outside of the wash tank see section 8 3 for location The UPM measures the resistance through the Thermistor and associates that resistance to temperature The temperature measurement is used to turn the heating element on and off for controlling the wash solution temperature To check the Thermistor unplug the white connector from the UPM and using an Ohm meter measure the resistance across the violet colored wires connected to pin 8 and pin 9 of the cable connector refer to section 6 0 for pin layout The UPM will signal an error if it reads a resistance greater than 430 k and less than 15 k Replace the Thermistor if the reading indicates that it is defective Power Soak 7 6 Liquid Level Sensors There are two Liquid Level Sensors in the side wall of the wash tank and two in the side wall of the sanitize tank if equipped with a sanitize tank The sensor located at the bottom of the tank is used to detect when the tank has been drained and the sensor at the top of the tank is used to determine when the tank is full check operation unplug the white connector from the UPM Measure the resistance between the face of the liquid level sensor and the appropriate pin of the white connector see section 6 0 in this manu
48. stem There are a number of products on the market that work well in this application A chemical sales representative should assist in selecting the proper sanitizer for each application Check with a cleaning chemical provider to determine the detergent concentration sanitizer parts per million ppm and sanitizer submersion times that will meet local health codes 3 3 Factory Assistance lf a chemical sales representative is having difficulty selecting a detergent or sanitizer or if there are poor results with the chemicals that have been recommended please contact a Power Soak representative at 1 800 444 9624 Power Soak Power Soak Preventative Maintenance Section 4 Power Soak 4 0 Maintenance Power Soak machines require minimal preventive maintenance To ensure that the Power soak PS 275 remains reliable the following tasks should be completed at the intervals shown in this section 4 1 Daily 4 1a Clean the liquid level sensors The liquid level sensors are located on the side walls of the wash and sanitizer tanks see section 7 4 They are white plastic discs with metal centers The faces of the sensors need to be cleaned with a washcloth and soapy water Regular cleaning will prevent a build up of difficult to remove chemicals and debris The liquid level sensors must be cleaned regularly in order for the machine to operate correctly Dirty sensors can allow the pump motor to operate without
49. t of that connector will not operate The Iriac relays are bolted to the heat sink which is mounted on the back of the control enclosure When replacing a Triac relay be sure that the mounting surface is clean and then apply thermal paste provided with new triac to the contact surface of the heat sink The thermal paste will conduct heat in order to get the proper cooling of the relay 6 5 Power Transtormer The power transformer located in the upper left corner of the control enclosure is used to convert the incoming high voltage to 24VAC with a 12VAC center tap The 12VAC is used for the thermal protection circuit while the 24VAC is used for control functions and the chemical dispenser The transformer has multiple input voltage connections and must be connected for the correct voltage that is supplied to the machine Three of the wire connections are made using a crimp connector When replacing a transformer new crimp connectors or wire nuts will be required To test the transformer verify that the input voltage is correct This can be done between the L1 and L2 terminal connections Verify the output voltage of the transformer by reading 24 volts across the yellow and orange output wires and 12 volts between the center tap grey connected to black amp white wires and each of the other outputs These voltages can be verified at the three wire nuts on the internal wiring harness near the Transformer If a low voltage reading occurs discon
50. t when the green START button is pushed 9 1a Control panel white POWER light is not on Possible Cause 1 The power supply to the machine is turned off 2 The transformer has failed Solution 1 Restore power to the machine check the circuit breaker in the wall mounted enclosure 2 Check the transformer output See section 6 5 9 1b Control panel white POWER light Is on Possible Cause The Wash Tank is empty Solution Fill the wash tank with water and detergent according to the instructions in the operators manual 9 1c Control panel POWER white light is on STATUS green light is on and WASH TANK blue light is on Possible Cause The Wash Tank is empty or the wash solution life cycle has expired Solution Fill the wash tank with water and detergent according to the instructions in the operator s manual If the wash tank is full the life of the wash solution has expired the tank must be drained and re filled 9 1d Control panel POWER white light is on STATUS green light is on and SANATIZER TANK red light is on Possible Cause The Sanitize Tank is empty or the sanitize solution life cycle has expired Solution Fill the sanitize tank with water and sanitize solution according to the instructions in the operator s manual If the sanitize tank is full the life of the sanitize solution has expired the tank must be drained and re filled Power Soak 9 1d Control panel STATUS light and
51. to the motor which is not replaceable On other motor styles it is located in the wiring box of the Motor which is replaceable When replacing the Thermo disc it is imperative to put heat sink compound on the side of the Thermo disc that will be against the motor to ensure good heat transfer NOTE The heating element thermo disc is wired in series with the motor thermo disc see the schematic for wiring information Conduit fitting from Yellow wires from motor connection wiring harness Unplug the connectors to check continuity Check continuity across the motor thermo disc wires 7 3 Heating Element Most Power Soak pot washing machines are built with the heating element option The heating element is located under the removable plate in the slanted surface of the back wall of the wash tank The heating element will only operate if the wash tank is full and the pump motor 15 running The element will cycle on and off as necessary to keep the wash solution at the preset operating temperature The operating temperature is adjustable with a setting in the UPM The temperature setting is described in the UPM programming manual number 37193 Heating elements have been made in a variety of styles that have different appearance but all work the same Each of the different styles use the same mounting flange and are interchangeable for the same performance in heating the fluid in the wash tank Power Soak There are three heating
52. tor lights for troubleshooting POWER ON UU lt POWER ON Light is on when operating lt ERROR CODE ERROR CODE lt LIQUID LEVELWAL 1 Flash sequence indicates error See section 5 5a for error codes A S A lt LIQUID LEVEL S H Error Codes can only be re the main power off be n then on LIQUID LEVEL W L Light is on when wash tank low level sensor is activated LIQUID LEVELW H 0 Light is on when wash tank high level sensor is activated LIQUID LEVEL S L Light is on when sanitizer tank low level sensor is activated LIQUID LEVEL S H Light is on when sanitizer tank high level sensor is activated Removed from the machine for clarity The UPM is replaced by unplugging the cables and removing the mounting screw in each corner of the mounting flange The two white cable connectors have a hook that keeps them secured to the socket The back edge of the hook must be depressed to allow the connector to be separated from the socket The white connectors are manufactured so that they only plug into the socket when oriented correctly Press the back edge of the hook to unplug the connector from the socket Power Soak Identification of the UPM connector terminals is helpful for troubleshooting Disconnecting the wiring harness connector and conducting voltage or ohm measurements on the terminals in the connector will help determine the condition
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