Service Manual 05/07/2004
Contents
1. BREAKER By others 460 Vac 60 hz Thermal cutoffs 135 F SES 7 ri Sr hs i OVER TEMP SENSOR 1 1 e lo es OVER TEMP SENSOR 1 2 By others 400 VAC HEATER 50Hz AS H1 G L1 L2 L3 G 2 2 M3 M1 G L1 L2 L3 G 2 2 E 3 M1 H3 H1 ee 1A a a BB PB fe su Ke TH il EN C E le Es E w il SIP BROWN t 803 DISPENSING PUMP 24V AC 1 olf el lol lal lo la lal i Pet kO DISPENSING PUMP 24V AC 2 PURPLE P6 07 16 07 o BROWN AE TEMP SENSOR 1 1 ze wee 25 08 TEMP SENSOR 1 2 18 al YELLOW P6 09 16 09 6 o o 1TF4555 YELLOW P6 10 J6 10 x o lt e BROWN 277Vac yellow STP_BRN_ T3 BLUE 1898 16 05 PERISTALTIC PUMP 1 S SIGNAL sa ag L BLK 10 AWG o E qe vaas BROWN 25 06 36 08 DERISTALTIC PUMP 2 W SIGNAL ORG 10 AWG x ja jog BLUE 240Vac sallow STR ORANGE P6 11 161 LEVEL PROBE W L BLU 10 AWG u GREY T1 STR GREEN EsTa 12 EVEL PROBE W H wale BLACK 120Vac orange J29 center STP_YELL2. IS TeoLnooJg APOS 49M0d aseyd ZH 09 1104 017 807 eura BREAKER 208 240 Vac 60 hz By others uN ce 135 F I H OVER TEMP SENSOR 1 1 9 Internal BREAKER TSTAT OVER TEMP SENSOR 1 2 By others 208 240 vac m HEATER HS H1 V G L1 12 L3 G 2 H2 M3 M1 G L1 L2 L3 G 2 H2 F 3 MI H3 H ZE gt o O gt gt gt gt he 5 P6 01 EI N C 7 TE A P6 02 16 02 N C TG TB1 182 183 To T54 TES FR S7P BROWN P6 03 16203 DISPENSING PUMP 24V AC 1 2 2 2 2 2 2 2 27 o el lol fol lo lol lol la AE P6 0t 16 08 DISPENSING PUMP 24V AC 2 PURPLE P6 07 Y6 07 TEMP SE SOR j j GREEN 10 AWG Y a PURPURPLE P6 08 46 08 TEMP SENSOR 1 2 Je 5 A EIER TERE YELLOW P6 09 6 09 7 o YELLOW P6 10 46 10 5 E o 126 e BROWN 277Vac yellow STP_BRN BLUE 26 05 96 05 PERISTALTIC PUMP 1 S SIGNAL BLK 10 AWG 2 lt e el BROWN 25 06 16 05 PERISTALTIC PUMP 2 W SIGNAL ORG 10 AWG F BLUE 240Vac yallaw STP_ORANGE P6 11 J6 11 LEVEL PROBE W L BLU 10 AWG a 2 GREY SIR GREEN Pent SZ LEVEL PROBE W H RED 10 AWG J27 e BLACK 120Vac ene STP YELLOW Pei k 813 EVEL PROBE S L BLK 10 AWG J21 12Vac SIR BLUE 1614 EVEL PROBE S H ORG 10 AWG J22 RED 18 AWG R
3. B wire bottom mount Element 380 volt rev B wire bottom mount not available yet Element 480 volt rev B wire bottom mount Gasket for Accutherm heater Cover rev A front mount 17 Cover rev B angle mount 14 Cover rev C after 02 05 04 12 Bolt heater cover Terminal strip heater Thermistor temperature sensor Thermodisc heater thermal cutoff Sensor pad Heatsink compound Glue dot Power Soak Parts list Control Panel 2 901 2 902 2 903 2 171 2 172 2 920 2 923 2 924 27925 2 928 28923 2 927 2 200 2 922 Control Panel 220 volt single phase Control Panel 220 volt three phase Control Panel 480 volt three phase Contactor Transformer 24 volt UPM Programming Module Terminal Block Grounding Block Din Rail mount for terminal blocks Triac solid state relay Fuse Block Heatsink Overlay start stop membrane Wiring Harness internal to control panel Miscellaneous 23987 23988 2 84 2 848 28065 28066 28669 2 854 2 854 28553 2 855 Liquid Level Sensor Gasket Liquid Level sensor Wiring Harness Wash Wiring Harness Sanitize Wiring Harness Extension 3 ft Wiring Harness Extension 6 ft Utensil Basket Chemical Injector Connector chemical injector Cap chemical injector Gasket Chemical Injector Me TCRAr T Power Soole SS Parts List Optional Chemical Dispenser Dual Pump Chemical Dispenser 2
4. 444 9624 www powersoak com METCRAr T
5. AWG CS1 2 LED5 ERR CODE CS1 BLACK J1 14 P1 14 CSI 1 PE ag LED6 POWER ON CONTACTOR we 1 2V RY1 J1 12 P1 12 RY su 8 WI atu 10 Awe orc L2 V RED 10 AWG Bik H UL Bik 10 AWG a ge lo e 2 ja I 1 SADA All WAT ryi_at A2 ORG ryi_a2 E ker iee ee TEM EE 13910 Kessler Drive nd N GU A O A Grandview MO 64030 Po werSoak Systems LED3 sor METCRAFT INC POWERSOAK CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL HEREIN DISCLOSED IT IS SUPPLIED IN o CONFIDENCE WITHOUT PREJUDICE TO ANY PATENT RIGHTS OF METCRAFT INC AND MAY NOT BE REPRODUCED SHARED OR USED TO MANUFACTURE ANYTHING SHOWN THEREIN WITHOUT METCRAFT INC S WRITTEN PERMISSION LEDI 5 ALL INFORMATION ALWAYS REMAINS THE SOLE PROPERTY OF METCRAFT INC MEMBRANE Power Soak6 is a registered trademark of Cantrell Ind Inc Licensed by Cantrell Ind Inc TITLE O NOTICE THIS DRAWING IS PART OF THE PROPEIETARY ARTICLE HEREIN DISCLOSED OWNED BY RENAU ELECTRONIC LAB THE UNITED STATES OR OTHER PARTY TO PS 200 WIRING DIAG RAM n WHOM FURNISHED OR HAVING POSSESSION HEREOF BY ACCEPTING THIS DRAWING ASSUMES CUSTODY AND CONTROL HEREOF AND AGREES _ BENAU A THE INFORMATION SET FORTH HEREIN IS GIVEN IN CONFIDENCE AND THIS DRAWING WiLL NOT BE 400V 50Hz 3 PH Es ere E E ELECTRONIC COPIED OR RE PRODUCED IN WHOLE OR IN PART NOR ITS CONTENTS REVEALED IN ANY MAN NER TO DRAWN BY Mark C 8 LABORATORIES ANY PERSON EXCEPT TO MEET THE PURPOSE FOR WHICH IT WAS DELIVERED S
6. Clean the liguid level sensors These sensors are located on the side walls of the wash and sanitizer tanks They are the white plastic discs with metal centers Clean the sensor faces thoroughly If cleaned regularly a washcloth and soapy water are all that is required If the liquid level sensors are not cleaned regularly the machine may fail to operate or 1t may be possible to run it without water which may cause serious damage to the unit Monthly IMPORTANT Turn off the power to the unit at the main breaker prior to performing the following task After shutting off the power at the system s dedicated breaker 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 rag The motor shroud is the vented cover located at the end of the motor closest to the control panel This will prevent grease and dust from accumulating in the cover s openings which can obstruct the airflow that cools the motor De lime the wash sink Simply add a de liming agent to a sink of warm fresh water and run the system overnight Ask your chemical sales representative to recommend a specific de liming agent There are no other preventive maintenance procedures that you will need to perform on your Power Soak system You need not be concerned about greasing the motor bearings as they are permanently sealed If you have any questions regarding the preventi
7. OR IN PART DATE METCRAFT POWER SOAK AND THE INFORMATION CONTAINED HEREIN UNDER NO CIRCUMSTANCES WLL BE USED IN THE 7 10 2002 A 27894 F MANUFACTURE OR REPRODUCTION OF THE ARTICLE SHOWN AND DELIVERY OF THIS DRAWING SHALL SCALE FSCM NO DWG NO REV NOT CONSTITUTE ANY RIGHT OR LICENSE TO DO SO THIS LEGEND SHLL BE MARKED ON ANY 9Y131 60A6005 D REPRODUCTION HEREOF IN WHOLE OR IN PART DATE REV 1 14 2004 NTS DO NOT SCALE DRAWING SHEET 1 OF 1 OOC Sd Power Soak SD Motor and Pump Assembly Exploded view Description Description Casing shaft Sleeve Cotter pin part of casing Mechanical Seal Stud part of casing Adapter O ring Impeller screw 9 16 hex Motor bolt 5 16 allen Impeller washer Adapter plate Impeller Washer Impeller key Gasing Nut 9 16 hex sleeve O ring Motor Indicates parts included in the seal kit Mc TCRAF T 22 Power Soole SS Motor and Pump Assembly DISASSEMBLY PROCEDURE Remove 3 nuts from the back of the adaptor plate Slide the pump end out from the volute Holding the impeller to keep it from turning loose the washer head cap screw remove the screw and gasket Slide the impeller off of the shaft and remove the key Remove the seal sleeve as a unit by pulling it off of the shaft Some corrosion may prohibit movement and a lubricant may be used to penetrate between the sleeve and motor shaft With the impeller
8. and key removed the shaft sleeve and the mechanical seal assembly can be removed Remove O ring from the shaft sleeve With the shaft sleeve removed the seal rotating assembly can be pulled off of the shaft sleeve Mark the adaptor plate and motor to insure proper re assembly Remove 4 screws from the adaptor plate Take the adaptor plate off the motor Remove o ring from adaptor plate With the adaptor plate removed the seal seat can be removed using a screwdriver or by using your fingers INSPECTION OF THE COMPONENTS With pump end disassembled clean all parts and check for worn and damaged areas Worn or damaged metal parts should be replaced The mechanical seal gasket o ring O ring and washer head cap screw are replacement parts that are provided in the kit All old parts must be discarded and are not to be reused ASSEMBLY PROCEDURE 23 2 J Push the mechanical seal seat squarely into the seal bore of the adaptor plate by using fingers A little lube can be used on the seal bore of the adaptor plate Make sure that ceramic side up and it is fully seated Install the adaptor plate and tighten 4 screws which hold it to the motor face Make sure the marks made in step 7 above line up Install o ring into the groove of the adaptor plate MeTCRAr T Power Soole SS 4 Coat the shaft sleeve lightly with lube Install the mechanical seal on the shaft 2 sleeve using your hand to push against t
9. is 20v 28v across the coil and the contactor does not pull in the contactor 1s defective If there is input voltage across terminals L1 and L2 also L1 L3 and L2 L3 if three phase and the contactor 1s pulled in but no voltage across terminals TI and T2 also T1 T3 and T2 T3 f three phase the contactor is defective Heater Element The heater in a PowerSoak sink is rated at 7000 watts To check operation of the heat element first turn the power off at the breaker Disconnect the H2 wire from terminal H2 and the HI wire from the triac HI and H3 wire from H3 triac 1f 3 phase from the Control Panel Check each heater lead to ground for a short They all should be open to ground Check resistance between each of the combinations of the chart below Connection Heater rated voltage phase Resistance ohms H1 H2 208 230 1 7 56 H1 H2 208 230 3 15 12 H2 H3 208 230 3 15 12 H1 H3 208 230 3 15 12 H1 H2 460 l 32 91 H1 H2 460 3 65 83 H2 H3 460 3 65 83 H1 H3 460 3 65 83 The heater should be within about 10 of the value in the chart If the reading varies significantly from the chart above the heater may be defective or there may be a broken wire or loose connection Electrically the Heater 1s three separate elements each of 2333 watts When replacing note how the existing Heater is wired and refer to the schematic when wiring the new Heater Power Soal Parts List Motor Impeller Pump Assembly 60 Hz self draini
10. 115 F with ice or cold water See No Power Pump works Heater does not work Look For Correction 1 Water temperature lt 110 F Check Heater and replace as necessary Check Triac s and replace as necessary 2 Water temperature between 110 F and 120 F Normal operating temperature 3 Water temperature gt 120 F Water too hot reduce temperature to 115 F with ice or cold water Water too hot or not hot enough Look For Correction 1 Water temperature lt 110 F Check Heater and replace as necessary Check Triac s and replace as necessary 2 Water temperature between 110 F and 120 F Normal operating temperature 3 Water temperature gt 120 F Check Thermistor and replace as necessary Too much soap can cause excessive heat buildup Power Soak gt Troubleshooting PS 200 No Power Look For Correction 1 Incoming voltage between L1 and L2 L1 L2 Check Heater and replace as necessary Also L1 L3 L2 L3 if 3 phase 2 Less than 10 volts to UPM Water too hot above 135 F empty sink and refill with 115 F water leave UPM plugged in during check Tighten the External Wiring Harness on back of Control Panel Check transformer and replace as necessary Check thermal cutoff for heater and replace as necessary Check thermal cutoff for motor and replace as necessary Error Codes Represents a long flash X Represents a short flash Look For Correction This indicates a Water Level p
11. 14 2004 SCALE NTS DO NOT SCALE DRAWING SHEET1 OF 1 oseyd ZH 09 H04 09 H 11199 Yos ed peua OOC Sd APOS 49M0d Do gt H 11199 aseyd ZH OS W04 OOP UIS ED CAPOS 19MOG neua ueadommg BREAKER By others 400 Vac 50 hz Thermal cutoffs 135 F s gt 5 7 T 2 pr OVER TEMP SENSOR 1 1 BREAKER CG TSTAT OVER TEMP SENSOR 1 2 By others 400 VAC HEATER 50Hz H3 H1 V N G LI L2 LS G 2 H2 M3 M1 N G L1 2 3 G 2 H2 F 3 MI H3 H1 Ia 1A 5 5 gt A o o a 5 a P6 01 ee N C 14 A P6 02 8 02 N C 18 Te Tet 182 183 TG TBA TBS FR S IRZBROWN u 8 05 DISPENSING PUMP 24V AC 1 2
12. 8900 283 0 29233 29230 29231 29232 29235 29234 2806 29236 29237 29238 29239 29240 29241 29242 28 03 28 04 Chemical Dispenser Dual Pump Generic Chemical Dispenser Dual Pump Kay Chemical Timer solidstate Button Guard metal Switch MOM N O metal Rectifier bridge Lock Key Motor 24 volt 120 rpm Wiring Harness soap dispenser Hook 4 Loop Screw 48 32 x 1 2 flat phillips s s Spring Cone Screw 1410 24 x 1 3 4 pan phillips s s Pump 2 cc power wash Tape double sided foam Key Screw 6 32 s s Nut hex 46 32 s s 103 014 Nut Sert 10 24 tsn 2 858 28557 28901 29145 28999 Gasket soap dispenser PS 200 Overlay soap dispenser Kay Chemical Overlay soap dispenser generic Terminal Fork 22 18 8 Insulated Decal Overlay Metcraft service MeETCRAr T pa I ONI BREAKER By others 208 240 60Hz Thermal x cutoffs 135 F Air m OVER TEM
13. D3 LIQ LEV W H ye 47 lt lt P17 NEG LED4 LIQ LEV W L gt t ei LED5 ERR CODE BLACK 41 14 P1 14 re Er CS1 1 LEDS POWER ON CONTACTOR NG E a 31 2V RY1 41 12 Pp1 12 RY LS ma W L2 v ORG RED 10 AWG cst BLK EI U BLK 10 AWG a la e la la a L bh Ja JA la Jo A A MAT Ryi at A2 ORG Ryi a3 e fe le la ERRE 13910 Kessler Drive LED MEMBRANE LED2 Grandview MO 64030 PowerSoak Systems METCRAFT INC POWERSOAK CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL HEREIN DISCLOSED IT IS SUPPLIED IN CONFIDENCE WITHOUT PREJUDICE TO ANY PATENT RIGHTS OF METCRAFT INC AND MAY NOT BE REPRODUCED SHARED OR USED TO MANUFACTURE ANYTHING SHOWN THEREIN WITHOUT METCRAFT INC S WRITTEN PERMISSION ALL INFORMATION ALWAYS REMAINS THE SOLE PROPERTY OF METCRAFT INC Power Soak is a registered trademark of Cantrell Ind Inc Licensed by Cantrell Ind Inc HEREOF BY ACCEPTING A THE INFORMATION SE B WTHOUT THE WRITTEN CO AND THE INFORMATION CON RENAU tore LABORA TORIES CONTROL 1 PH 208 240V 60Hz METCRAFT POWER SOAK oy 34 DWG NO 60A6001 D REPRODUCTION HEREOF IN WI OTICE THIS DRAWING IS PART OF THE PROPEIETARY ARTICLE HEREIN D WHOM FURNISHED OR HAVING POSSESSION H S TA MANUFACTURE OR REPRODUCTION
14. ED 0 Vac orange WHITE GREEN Thermal cutoffs 130 C Jag al al a a ol el al 8 I I I I I I I I I ll I 5 5 5 5 2 5 5 5 5 5 5 lt 5 e zZ z z 4 M3 H3 M1 H o of w 2 a Y e 8 1 P8 1 J8 1 1272 J7 1 1 P4 1 J4 1 AR 4 P3 1 J3 1 E ld E x 4 er Ja o kri ON O E RW J T J I BE E O ane P8 3 gt J8 3 ne P7 3 gt J7 3 JA P4 3 gt J4 3 IB 2 aa a 5V a ae 2 a y E 7 n w o gt e gt gt EN gt ina P3 3 J3 3 11 17 Piaty HEATER A x x Una a add n bi 3 3 3 3 31 18 P1 18 0 P u m gt gt gt a a ta LED LIQ LEV SCH pump Se 2 48 5 e one aH oo nen LED2 LIQ LEV S L 92 O SIP RED L a Lp i Li LED3 LIQ LEV W H STP_BLK pos Wie 1 7 P1 7 NEG LED4 LIGLEV W L BLACK 41 15 P1 15 SEES CS1 2 LED5 ERR CODE est BLACK J1 14 P1 14 u C51 1 LED6 POWER ON CONTACTOR Me 3 J 2V RY1 12 P1 12 RY1 piu lL W Buu 10 AWG ORG L2 V RED 10 AWG BLk E U BLK 10 AWG le Beg LAS KA NA E A fo SAI A WAT Rya A2 ORG elles Je Se Mes ie t s 5 5 5 5 5 13910 Kessler Drive P s va KI aa Grandview MO 64030 O We r O a k ystems LED3 sor METCRAFT INC POWERSOAK CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL HEREIN DISCLOSED IT IS SUPPLIED IN o CONFIDENCE WITHOUT PREJUDICE TO ANY PATENT RIGHTS OF METCRAFT INC AND MAY NOT BE REPRODUCED SHARED OR USED TO MANUFACTURE ANYTHING SHOWN THEREIN WITHOUT METCRAFT INC S WRITTEN PERMISSION Z LED LED2 ALL I
15. G L1 N G 2 H2 M1 BRN 14 AWG e G L1 N G A F M H m s o JA 5 P6 01 ge N C O O O 2 PO O2 46 02 N C p F me A os Ki SIRZEROWN 26 03 96 03 DISPENSING PUMP 24V AC 1 ol fol la fol la al a MALE PEA DISPENSING PUMP 24V AC 2 PURPLE P6 07 J6 07 TEMP SENSOR 1 1 GREEN 10 AWG 2 R PURPLE P6 08 J6 08 TEMP SE SOR 1 2 Mi gt L YELLOW P6 09 d6 09 N o 2 1784555 YELLOW P6 10 6 10 1 lt g o jas e BROWN 277Vac yellow STP_BRN BLUE 28 05 K lt PERISTALTIC PUMP 1 S SIGNAL BLK 10 AWG Ni we BREAN PLE PERISTALTIC PUMP 2 W SIGNAL ORG 10 AWG a BLUE 240Vac wallow STP_ORANGE EGEL 0 LEVEL PROBE W L 2 GREY STP GREEN P6 12 6 12 LEVEL PROBE W H e BLACK 120Vac orange J29 center STP_ YELLOW P6 13 46 13 LEVEL PROBE S L 12Vac STP_BLUE P6 14 J6 14 LEVEL PROBE S H BLK 10 AWG 2 RED 0 Vac orange _ WHITE GREEN Thermal cutoffs 130 C J30 x alo A 2 S a 8 5 5 5 5 5 5 5 5 5 5 5 S l T4 UNE ee gil Ja aoid 24 74 79 943437 7 1 food Mio a a af al al al al al af al al a a 2 TY3 TY4 RED 41 16 P1 16 O TN O dm amp ce OAB P4 3 J4 3 5V E SE u o 23535 2 gt gt Sy 2 a i N gt cu vV S P3 3 J3 3 MOM OV EATER ALAN apo 4 4 v Li 2 A m D O see 2 53 7 o LED LIQ LEV S H lt lt PUMP a zZ SE zn u E no U KE LED2 LIQ LEV S L RED ES te n 0 a a Lil a 3 LED3 LIQ LEV W H STP_BLK E 6 ne 177 P1 7 NEG LED4 LIQ LEV W L BLACK SP ESI LEDS Y ER
16. IZE ECR DWG REV CONTROL BOX 3 PH SOHZ B WITHOUT THE WRITTEN CONSENT OF RENAU ELECTRONIC LAB THIS DRAWING IN WHOLE OR IN PART DATE 7 10 2002 A 2 890 F METCRAFT POWER SOAK AND THE INFORMATION CONTAINED HEREIN UNDER NO CIRCUMSTANCES WILL BE USED IN THE E E MANUFACTURE OR REPRODUCTION OF THE ARTICLE SHOWN AND DELIVERY OF THIS DRAWING SHALL SCALE ESC NO DWG NO Rev NOT CONSTITUTE ANY RIGHT OR LICENSE TO DO SO THIS LEGEND SHLL BE MARKED ON ANY 9Y131 60A6006 D REPRODUCTION HEREOF IN WHOLE OR IN PART DATE REV 1 14 2004 NTS DO NOT SCALE DRAWING SHEET 1 OF 1 OOC Sd KO pa 9SEYd ZH OS H04 OFZ H 11199 yos ed neua APOS 49M0d uvodomy BREAKER By others 230 50Hz Thermal x cutoffs 135 F E e a Gr OVER TEMP SENSOR 1 1 gt ier i i or TSTAT OVER TEMP SENSOR 1 2 te AN H1
17. NFORMATION ALWAYS REMAINS THE SOLE PROPERTY OF METCRAFT INC MEMBRANE O Power Soak is a registered trademark of Cantrell Ind Inc Licensed by Cantrell Ind Inc TITLE i NOTICE THIS DRAWING IS PART OF THE PROPEIETARY ARTICLE HEREIN DISCLOSED OWNED BY RENAU ELECTRONIC LAB THE UNITED STATES OR OTHER PARTY TO PS 200 WIRING DIAG RAM A WHOM FURNISHED OR HAVING POSSESSION HEREOF BY ACCEPTING THIS DRAWING ASSUMES CUSTODY AND CONTROL HEREOF AND AGREES E aa A THE INFORMATION SET FORTH HEREIN IS GIVEN IN CONFIDENCE AND THIS DRAWING WILL NOT BE COPIED 208 240V 60Hz 3 PH E PAI BE ELECTRONIC OR RE PRODUCED IN WHOLE OR IN PART NOR ITS CONTENTS REVEALED IN ANY MAN NER TO ANY PERSON DRAWN BY Mark C LABORATORIES EXCEPT TO MEET THE PURPOSE FOR WHICH IT WAS DELIVERED SIZE ECR DWG REV CONTROL BOX 3 PH 60H Z B WITHOUT THE WRITTEN CONSENT OF RENAU ELECTRONIC LAB THIS DRAWING IN WHOLE OR IN PART DATE 7 10 2002 A 2 905 G METCRAFT POWER SOAK AND THE INFORMATION CONTAINED HEREIN UNDER NO CIRCUMSTANCES WILL BE USED IN THE A A MANUFACTURE OR REPRODUCTION OF THE ARTICLE SHOWN AND DELIVERY OF THIS DRAWING SHALL NOT SCALE FSCM NO DWG NO Rev CONSTITUTE ANY RIGHT OR LICENSE TO DO SO THIS LEGEND SHLL BE MARKED ON ANY REPRODUCTION 9Y131 60A6003 C HEREOF IN WHOLE OR IN PART DATE REV 1 14 2004 NTS DO NOT SCALE DRAWING SHEET 1 OF 1 OOC Sd pa NO ONI
18. NOT CONSTITUTE ANY RIGHT HO OR NED HEREIN UNDER LE OR IN PART ENT OF RENAU ELECTRONIC LAB OF THE ARTICLE SHOWN LICENSE TO DO SO SCLOSED OWNED BY RENAU ELECTRONIC LAB S DRAWING ASSUMES CUSTODY AND CONTROL HEREOF AND AGREES FORTH H OR RE PRODUCED IN WHOLE PERSON EXCEPT TO MEET THE IT WAS DELIVERED THIS DRAWING IN WHOLE OR IN NO CIRCUMSTANCES WILL BE USED IN THE EREIN IS GIVEN IN CONFIDENCE AND THIS DRAWING WILL NOT BE COPIED OR IN PART NOR ITS CONTENTS REVEALED IN ANY MAN NER TO ANY PURPOSE FOR WHICH PART AND DELIVERY OF THIS DRAWING SHALL THIS LEGEND SHLL BE MARKED ON ANY THE UNITED STATES OR OTHER PARTY TO DRAWN BY Mark C TITLE PS 200 WIRING DIAGRAM 208 240V 60Hz 1 PH DATE 7 10 2002 SIZE ECR DWG 27904 REV DATE REV 1 14 2004 SCALE NTS DO NOT SCALE DRAWING SHEET1 OF 1 aseyd ZH 09 OA 017 807 neua YS omod 00c Sd APOS 49M0d pa 00
19. OW P6 13 J6 13 LEVEL PROBE S L RED 10 AWG 12Vac STP BLUE P6 14 J6 14 LEVEL PROBE S H ORG 10 AWG 122 RED 18 AWG RED 0 Vac orange WHITE 72 GREEN Thermal cutoffs 130 C 130 A a a e z R l 1 1 I I I I I I 1 I 5 5 5 5 2 5 5 5 5 5 2 5 2 Zz z zZ 74 M3 H3 M1 H a of of of wo FF S al N e 7 2 u P8 1 gt J8 1 con P7 1 gt gt J7 1 1 P4 1 J4 1 amp P3 1 J3 1 z n z 2 z A E E 4 gt E 5 ve N 3 O Mm J E J TE aas a a in EEE a a be a Li p lt sv lt L35 l T L e P3 3 3 3 91247 El HEATER a oa u Ev oe oka SS A ES 3 3 3 3 aaa la Rn a gt EE 2 DB 2 LED LIQ LEV S H a e UMP a eri Te SE am ks ii LED2 LIQ LEV S L gt STP_RED S 2 Ao a9 an a E u LED3 LIQ LEV W H E ya HET P1 7 NEG LED4 LIQ LEV W L El ate an A on LED5 ERR CODE CSI BLACK J1 14 P1 14 m Yl 1 LED6 POWER ON CONTACTOR VE lt 1 2V RY 41 12 P1 12 RY1 BLU L M atu 10 Awe ore L2 V RED 10 AWG Buk H UL BLK 10 AWG a la e a jee k N UN u a KAA A MAT Rym A2 ORG Ry _a2 O ol ea ler les ale arm 13910 Kessler Drive Grandview MO 64030 P O WE rS O a k Systems LED1 MEMBRANE LED2 METCRAFT INC POWERSOAK CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL HEREIN DISCLOSED IT IS SUPPLIED IN CONFIDENCE WITHOUT PREJUDICE TO ANY PATENT RIGHTS OF METCRAFT INC AND MAY NOT BE REPRODUCED SHARED OR USED TO MANUFACTURE ANYTHING SHOWN THEREIN WITHOUT METCRAFT INC
20. P SENSOR 1 1 Internal T u 2 gt TSTAT OVER TEMP SENSOR 1 2 PAK Hai 5 H1 V G L L2 G 2 H2 M1 BRN 14 AWG 5 G L L2 L2A G 2 H2 E M1 H1 wy s 1A e 2 2 el o e e Jel o e TA AAN O E pe Te ks kalu DE hd STP BROWN P6 03 16 03 DISPENSING PUMP 24V AC 1 ol lol lo fol fol fol lo lo WHITE P04 8 0 DISPENSING PUMP 24V AC 2 o PURPLE P6 07 J6 07 TEMP SE SOR GREEN e m PURPLE P6 08 46 08 TEMP SENSOR 1 2 EBE o YELLOW P6 09 J6 09 E o ze 2 1TF 4555 YELLOW P6 10 J6 10 a lt g 0 176 e BROWN 277Vac yellow STP_BRN BLUE 28 08 96 05 PERISTALTIC PUMP 1 S SIGNAL BLK 10 AWG wu FR po PEE PERISTALTIC PUMP 2 W SIGNAL ORG 10 AWG m BLUE 240Vac yellow ORAN P6 11 6 11 EVEL PROBE W L ta GREY STP GREEN PS 12 46 12 EVEL PROBE W H A BLACK 120Vac orange J29 center STP YELLOW P6 13 46 13 LEVEL PROBE S L 12Vac STP_BLUE P6 14 J6 14 LEVEL PROBE S H BLK 10 AWG 222 RED 0 Vac orange WHITE GREEN Thermal cutoffs 130 C 150 al al al 2 4 wl a 8 A 8 I i I i I I I I I I 5 Ss sf 5 e s Ss s 5 s 5 e s e E gt gt 74 M1 H N a lt wo 8 N R 2 18 p ein EI an ap DR DD DR ae TY3 TY4 RED 416 Pis OT NO ME J7I47 amp co0 2 P4 3 gt J4 3 2 T 5V ES Bu z EA amp gt gt DN A Z p3 3 J3 3 we ATI EATER N Sm Sa dd sd 3 5 J1 18 P1 18 a La 5 gt S gt gt b 7 H LED LIQ LEV SCH a lt lt PUMP zZ Sa i E 2 Ea O ne G E LED2 LIQ LEV S L IL pn a E 2 S E GS LE
21. Power Soak Service Manual Power Soole SS Revised 5 7 04 Power Soole SS Table of Contents Preventive Maintenance Routine Preventive Maintenance Daily Monthly Notes Troubleshooting Component Operation amp Checks Parts List Electrical Schematic Pump and Motor Assembly Appendix Notes METCR ri Page 2 3 Pages 4 6 Pages 7 10 Pages 11 15 Pages 16 19 Pages 21 25 Page 26 Power Soole SS Explanation of Warning Messages Be sure to read understand and follow all DANGER WARNING and CAUTION messages located in this guide and on the equipment Danger Personal Injury and Property Damage hazard May result in serious injury or death May cause extensive equipment damage Warning Property Damage Hazard May result in property or equipment damage Personal Injury Hazard Hazard from sharp objects May result in serious injury or death Chemical Hazard May result in serious injury or death Instructions labels and Material Safety Data Sheets MSDSs should be supplied with all detergents and sanitizing chemicals The manufacturers importers and distributors of your cleaning chemicals are responsible for providing this information Power Soole SS Preventive Maintenance Your system reguires minimal routine preventive maintenance As such the following should be done on a routine basis to ensure that your system remains reliable Daily
22. R CODE e esi LED6 POWER ON J1 3 P1 3 CONTACTOR NR i 2V RY1 J1 12 P1 12 RY1 BM W O L2 V ORG RED 10 AWG CS1 BLK H U BLK 10 AWG aja ga a e 2 lis kl SAA AL MAT RYA A2 ORG Ry 42 E oli oan FREE EE poa 13910 Kessler Drive recom O Grandview MO 64030 Po Wer oak Systems 7 LED LED2 METCRAFT ING POWERSOAKO CLAIMS PROPRIETARY RIGHTS IN THE MATERIAL HEREIN DISCLOSED IT IS SUPPLIED IN O MEMBRANE CONFIDENCE WITHOUT PREJUDICE TO ANY PATENT RIGHTS OF METCRAFT INC AND MAY NOT BE REPRODUCED SHARED OR USED TO MANUFACTURE ANYTHING SHOWN THEREIN WITHOUT METCRAFT INC S WRITTEN PERMISSION ALL INFORMATION ALWAYS REMAINS THE SOLE PROPERTY OF METCRAFT INC Q yel Na isa ered A Cara Ind e ee Cantrell Ind Inc a TITLE NOTICE THIS DRAWING IS PART OF THE PROPEIETARY ARTICLE HEREIN DISCLOSED OWNED BY RENAU ELECTRONIC LAB THE UNITED STATES OR OTHER PARTY TO PS 200 WIRING DIAG RAM WHOM FURNISHED OR HAVING POSSESSION HEREOF BY ACCEPTING THIS DRAWING ASSUMES CUSTODY AND CONTROL HEREOF AND AGREES Bean A THE INFORMATION SET FORTH HEREIN IS GIVEN IN CONFIDENCE AND THIS DRAWING WILL NOT BE COPIED 230V 50Hz 1 PH A ELECTRONIC OR RE PRODUCED IN WHOLE OR IN PART NOR ITS CONTENTS REVEALED IN ANY MAN NER TO ANY DRAWN BY Mark C LABORATORIES PERSON EXCEPT TO MEET THE PURPOSE FOR WHICH IT WAS DELIVERED SIZE ECR DWG REV CONTROL 1 PH 230V 50Hz B WITHOUT THE WRITTEN CONSENT OF RENAU ELECTRONIC LAB THIS DRAWING IN WHOLE
23. S WRITTEN PERMISSION ALL INFORMATION ALWAYS REMAINS THE SOLE PROPERTY OF METCRAFT INC Power Soak is a registered trademark of Cantrell Ind Inc Licensed by Cantrell Ind Inc NOTICE THIS DRAWING IS PART OF THE PROPEIETARY ARTICLE HEREI WHOM FURNISHED OR HAVING POSSESSION HEREOF BY ACCEPTING T A THE A 5 ONE COPIED LABORATORIES CONTROL BOX 3 PH 60Hz METCRAFT POWER SOAK ON a OY 31 DWG NO 6048004 B WTHOUT THE WRITTEN CO MANUFACTURE OR REPRODUC REV NOT CONSTITUTE ANY RIGHT D REPRODUCTION HEREOF IN WH INFORMATION SET FOR OR RE PRODUCED ANY PERSON EXCEPT TO MEET INFORMATION CONT S A 0 LE OR IN PART DISCLOSED OW IS DRAWING AS IH HEREIN IS GIVEN WHOLE OR IN PART THE PURPOSE FOR WHICH ENT OF RENAU ELECTRONIC LAB NED HEREIN UNDE ON OF THE ARTICLE SHOWN OR LICENSE TO DO SO ED BY RENAU ELECTRONIC LAB SUMES CUSTODY AND CONTROL HERE IN CONFIDENCE AND THIS DRAWING WILL NOT BE NOR ITS CONTENTS REVEALED IN ANY MA IT WAS DELIVERED THIS DRAWING IN WHOLE OR R NO CIRCUMSTANCES WILL BE USED IN THE AND DELIVERY OF THIS DRAW THIS LEGEND SHLL BE MARKED ON ANY TH NER TO IN PART NG SHALL E UNITED STATES OR OTHER PARTY TO OF AND AGREES DRAWN BY Mark C TITLE PS 200 WIRING DIAGRAM 460V 60Hz 3 PH DATE 7 10 2002 SIZE ECR DWG REV 27906 G DATE REV 1
24. es can be veritied at the three wire nuts on the internal wiring harness near the Transformer Note the wire colors on the schematic for each wire nut Triac Thyristor or Solid State Relay The Triac is a three terminal semiconductor for controlling current in either direction Our use for the Triac is 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 a 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 MI motor leg 1 and Hl heater leg 1 On a three phase Control Panel there are four Triacs two for the Heater and two for the Motor Two are labeled 1dentically to a single phase Panel The two others 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 signals whether gate voltage has been 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 virtually no current on the output side of the Triac Power Soole SS Component Operation and Checks Contactor If there
25. external wiring harness may not be tight at the back of the Control Panel Thermistor The Thermistor is a temperature sensor The UPM measures the resistance through the Thermistor and associates that resistance to a temperature To check operation first unplug the white connector from the UPM Next measure the resistance across the Thermistor This reading can be attained at the white UPM connector reference UPM for pin layout between pin 8 and pin 9 If your reading varies significantly from the Temperature Resistance chart in Appendix A the Thermistor may be defective The UPM will signal an error if it reads a resistance greater than 430 k and less than 15 kQ The Thermistor is located close to the Heater inside the Sensor Pad When replacing a Thermistor it is helpful to use a glue dot to hold it in place while reattaching the Sensor Pad to the sink Also it is imperative to put heat sink compound on the side of the Thermistor that will be against the sink and the Heater Thermodisc as well to help ensure good heat transfer METCRAr T Power Soole SS Component Operation and Checks Heater Thermodisc Hi Limit or Cutoff Switch The Heater Thermodisc 1s a protection device If the temperature at the Thermodisc reaches 135 F the disc opens cutting off power to the UPM To check operation first shut off the circuit breaker to the sink Next unplug the connectors P9 and J10 from J9 and P10 for the Motor Thermod
26. he seal face Make sure rubber seal bellows are seated against sleeve shoulder and carbon seal face 1s not scratched or chipped Slide the shaft sleeve onto the motor shaft and install the O ring on the groove of the sleeve Using lube or grease on the O ring will help hold the ring in place temporarily until the impeller is secured Install the key on the motor shaft and place the impeller on the motor shaft engaging the key Put the gasket on the washer head cap screw Install the impeller cap screw by holding the impeller push the impeller back against the sleeve and the other hand tighten the screw to 23 ft lbs of torque Do not over tighten as this could cause the gasket to sgueeze out become deformed and not seal properly Slide the pump end on the 3 studs of the volute The motor junction box should be at the bottom 10 Install 3 nuts on the studs and tighten to 23 ft lbs Power Soole SS Appendix A 150 140 130 120 110 100 90 60 70 60 90 40 30 20 Resistance K ohms Thermistor Resistance Temperature Chart EN ESER P P HOP PH AHP v0 Temperature degrees Fahrenheit MeTCRAr T Power Soole SS Power Soak is a registered trademark of Cantrell Industries Inc The Power Soak design and concept is fully patented 13910 Kessler Drive Grandview MO 64030 Phone 816 761 3250 Fax 816 761 0544 800
27. isc reference schematic or Motor Thermodisc for location and description Measure the resistance between J10 and the center tap of the transformer reference schematic or Transformer for location Device should read less than one ohm when closed If you read more than one ohm the Thermodisc may be defective Next check for a short to ground If you find a short to ground from either side of the Thermodisc the Thermodisc is either defective or you may have water in the sensor pad This condition will keep the UPM from operating correctly The Thermodisc is located close to the Heater inside the Sensor Pad When replacing a Thermodisc it is helpful to use a glue dot to hold it in place while reattaching the Sensor Pad to the sink Also it is imperative to put heat sink compound on the side of the Thermodisc that will be against the sink and the Thermistor as well to help ensure good heat transfer Motor Thermodisc Hi Limit or Cutoff Switch The Motor Thermodisc is a protection device If the temperature at the Thermodisc reaches 180 F the disc opens cutting off power to the UPM To check operation first shut off the circuit breaker to the sink Next unplug the connectors P9 and J10 from J9 and P10 for the Motor Thermodisc reference schematic for location and description These connectors plug the two Thermodisc wires black to two yellow wires coming out of the internal wiring harness of the Control Panel Measure the resista
28. ja 2 2 2 2 2 2 27 WATTE MA DISPENSING PUMP 24V AC 2 ol 2 O O O PURPLE P6 07 8 07 TEMP SENSOR 1 1 2 BROWN 14 AWG PURPLE P6 08 36 08 zo TEMP SENSOR 1 2 jE 5 ll YELLOW P6 09 JB 09 6 o o a 1TF 4355 YELLOW P6 10 6 10 x o lt o J26 Le BROWN 277Vac yellow o STP BRN 73 BLUE PCS PERISTALTIC PUMP 1 S SIGNAL BLK 10 AWG 9 Ebe ue tong BROWN 76 06 28 08 PERISTALTIC PUMP 2 W SIGNAL ORG 10 AWG o 3 BLUE 240Vac Vali STP ORANGE P6 11 511 EVEL PROBE W L BLU 10 AWG m a GREY T STP GREEN P6 12 J6 12 LEVEL PROBE W H lai BLACK 120Vac orange J29 center STP YELLOW P6 13 46 13 LEVEL PROBE S L RED 10 AWG 12Vac SIP BLUE amil S4 EVEL PROBE S H ORG 10 AMG 422 RED 18 AWG RED 0 Vac orange WHITE 72 GREEN Thermal cutoffs 130 C gt 5 w a 8 a N t I I I I I 1 I I I 5 5 5 5 S 5 5 5 5 5 5 S 5 S l T4 M3 H3 Mi H al ol e ul 2 8 al gf 2 ef e 8 P8 1 J8 1 CX P7 1 7 1 1 ES amp PS 1 SS 33 1 gi gi dl gi dl od dod od Jd a EYI TY2 TY3 TY4 RED 41 16 P1 16 OT NO QO YN OS P8 3 J8 3 P7 3 J4 3 P4 3 J4 3 lt lt 5V lt y 5 gt 2 TT a Gi gt gt 1 17 P1 17 gt e EN En 4 50 E P3 3 J3 3 HEATER AL NUDO g aa 4 4 n y e vE Eu a LED LIQ LEV S H 3 a 3 3 4 18 P1 18 PUMP Z gt m gt o 4 u DL gt 2 x lt en Mm A Di m LED LIQ LEV S L SIP RED s E E OZ e LED3 LIO LEV W H STP_BLK ne 7 PI 7 NEG LED4 LIQ LEV W L BLACK J1 15 P1 15 RED 10
29. nce between J9 and P10 reference schematic these are the black Thermodisc wires The device should read less than one ohm when closed If you read more than one ohm the Thermodisc may be defective Next check for a short to ground If you find a short to ground from either side of the Thermodisc the Thermodisc is either defective or you may have water on the Thermodisc This condition will keep the UPM from operating correctly On some of our motors the Thermodisc is built in to the motor which is not replaceable On others it 1s located in the wiring box of the Motor which is replaceable When replacing it is imperative to put heat sink compound on the side of the Thermodisc that will be against the motor to help ensure good heat transfer METCRAr T Power Soole SS Component Operation and Checks Transformer The Transformer reduces the incoming power supply voltage to 24 volts with a 12 volt center tap The transformer has acceptable inputs of 120 240 and 277 volts It should already be wired to the specifications of Control Panel refer to schematic To test the Transformer first verify the input voltage This can be done between the L2 terminal and the down stream transformer side of the fuse The fuse holder can be found on the end of the terminal strip Next verify the output voltage of the Transformer You should get 24 volts across it and 12 volts between the center tap and each of the other outputs These voltag
30. ng o HP Side Phase Volt Wet End Motor Impeller 1 5 LH 208 1 5 RH 208 1 5 LH 230 1 5 RH 230 1 5 LH 208 1 5 RH 208 1 5 LH 230 460 1 5 RH 230 460 2 0 LH 208 2 0 RH 208 2 0 LH 230 2 0 RH 230 2 0 LH 208 2 0 RH 208 2 0 LH 230 460 2 0 RH 230 460 208 230 460 208 208 230 460 230 460 EEE WE WW 0D 0 WH WWW OOD 60 Hz non self draining 208 230 27548 see above 208 230 27554 see above 230 460 27558 see above 230 460 27566 see above Power Soole SS Parts List Motor Impeller Pump Assembly 50 Hz European o HP side Phase Volt Wet End Motor Impeller 1 5 1 5 1 5 1 5 2 0 2 0 3 0 3 0 9 0 5 0 LH RH LH RH E EE 0D 0D 0D 0D Pump Parts Common to all 28920 2 886 2 047 2 132 27480 27475 27476 27477 27478 27479 2 481 27483 28262 Seal Kit Thermodisc motor thermal cutoff Intake gasket Discharge gasket Mechanical Seal O ring sleeve O ring seal plate Key Impeller Bolt Fiber Washer Sleeve Cap Screw seal plate Dowel Pin Me TCRAr T Power Soole SS Parts List Heater 27743 2 144 2 839 29243 2 930 29244 2 939 2 934 2 7 02 2 934 29654 2 934 18797 2 926 28454 2 322 28928 28881 Element 230 volt rev A ribbon rear mount Element 460 volt rev A ribbon rear mount Gasket for Chromolox heater Element 208 volt rev B wire bottom mount not available yet Element 230 volt rev
31. roblem Turn off breaker to sink Drain sink clean sensors refill sink Turn on breaker to sink This indicates a Temperature Sensor problem Tighten the External Wiring Harness on back of Control Panel Check and replace Thermistor as necessary This indicates an Over Current problem Check and Replace motor and or heater as necessary Check and Replace UPM or CT as necessary Power Soole SS Component Operation and Checks The following checks should only be performed by gualified technicians using extreme caution Electrical hazard to untrained personnel may result in electrical shock burns or death Liquid Level Sensors There are two Liquid Level Sensors LLS in the wash sink and two more in the sanitize sink if equipped with a sanitize sink To check operation first unplug the white connector from the UPM Measure the resistance between the face of the LLS and the appropriate pin of the white connector You should read less than one ohm Refer to the chart below for the appropriate pins Description UPM pin number Wire color Wash Sink Low LLS Pin 19 White with Orange stripe Wash Sink High LLS Pin 20 White with Green stripe Sanitize Sink Low LLS Pin 21 White with Yellow stripe Sanitize Sink High LLS Pin 22 White with Blue stripe If you read higher than that you may have a dirty sensor a broken wire or a loose connection The loose connection may be at the sensor on your wiring harness or the
32. ve maintenance procedures please contact the factory at 800 444 9624 METCRAr T Power Soole SS Troubleshooting Hazard to untrained or unauthorized personnel The following procedures are provided for use only by an authorized service agency No facility owner manager employee or other unauthorized person should attempt to perform any of these procedures To obtain the name of a recommended service agent in your area please call the Metcraft Inc Power Soak Service Department at 800 444 9624 When performing troubleshooting procedures the authorized service agency will need to open the Power Soak system s main electrical enclosure Properly close the control panel before reconnecting the circuits Power Soole SS Troubleshooting PS 200 Pump leaks Look For Correction 1 Defective ADAPTER O RING replace 2 Defective PUMP SEAL Replace Intermittent running See Pump does not work below Pump does not work Look For Correction 1 Slow Flashing Green Light Clean Liquid Level Sensors Fill sink with water to proper level Tighten the External Wiring Harness on back of Control Panel 2 Solid Blue Light Clean Liquid Level Sensors Drain sink and refill with water to proper level 3 Error LED on UPM Record the pattern See Error Codes 4 Red Green Blue lights blinking together Low power to UPM See No Power 5 No indicator lights at all Water too hot reduce temperature to
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