Power Soak PS-200 & PS-201 Service Manual
Contents
1. ASSUMES CUSTOOY AND CONTROL HEREOF AND S CONTROL BOX 3 PH METCRAFT POWER SOAK EN SC ER DISPENSING PUMP 24V AC 1 13840 Kander Oron m PowerSoak systems E EE aa heer Ca TME ps 200 amp PS201 WIRING DIAGRAM 208 230V 60Hz erus ovome SHEET1 OF 1 1 P 460 volt 60 Hz 3 phase P ci we Po MARCANA ara C Tapa M sten UT MET RAPT RL RATA Pe TES TE DIED SHES ano TME PS 200 amp PS 201 WIRING DIAGRAM us Se opija TE 460V 60Hz 3 PH Electrical Schematic European 400 volt 50 Hz 3 phase sk f Jet C Ster 5 O MEIN aaNmywol a Le UN i j d E u i 1 i i SNIMYYO FIVES LON OD ES d FE Hi E i d Hd ZHOS ACOP WVSOVIO ONIHIM LOZ Sd 002 Sd 5 O o m 2 230 volt 50 Hz 3 phase 10830 Kossar Don mi PowerSoak systems Fi tt nd minii i rr AT Lu fi EP 7 casu mre TME PS 200 amp PS 201 WIRING DIAGRAM Pr 220V 50Hz 1 PH SIZE mom A 27894 29 d ee PE poem P Motor and Pump Assembly Exploded View Som ww Casing Nut 9 16 hex Motor Indicates parts included in the seal lat Motor and Pump Assembly amp Disassembly Procedures DISASSEMBLY PROCEDURE 1 Remove 3 nuts from the back of the adaptor plate Slide the pump end out from the volute 2 Holding the impeller to keep it from turning loosen the washer head cap screw and remove the screw and ga2. stripe Sanitize Sink Low LLS Pin 21 White with Yellow stripe Sanitize Sink High LLS Pin 22 White with Blue stripe Ifthe meter shows a reading higher than one Ohm there may be a dirty sensor a broken wire or a loose connection The loose connection may be at the sensor the wiring harness or the 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 the 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 kQ and less than 15k 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 Power Soale Heater Thermodisc Hi Limit or Cutoff Switch The Heater Thermodisc is a protection
3. Power Sodales SERVICE MANUAL PS 200 amp PS 201 Table of Contents Explanation of Warning Messages I I I a 1 i 1 rogo P Ee ja 1 Personil mpe ESQ RA OOR ie NG ntn ien n ada nad ia 1 Marsi Buts ins ER 1 Preventie dim cole AA e m ER ne a an 2 hi mn rr on o mre rr peere rr PR eee 2 oli l ee u EO HA IT 2 lil D L EN 3 Hazard to Untrained or Unauthorized Personnel unies seleksie baci 3 ans g e je e a E E aa anqas 3 IG zw an Pg sede Ge ee 3 R lT o u s 4 Pump works A ER Ee ee 4 Water ee do de not hotenoup uu au a qaqusqa qia qalan 4 EE EA MM stid i SS ka ee ee bao 5 uno gh MV D i A ELEME 5 Component Operation and Checks QA A 7 Liquid Level Sensors a 7 LN RR ui m 7 Heater Thermodisc Hi Limit ar Cutoff Switch anni 8 Ji lil ono pop o orco orn snn n na Aha 8 Triac Thyristor or Solid State Relay asua usu ua uqu ua ve 9 dec I en ere o o n usus 9 Heater Element u E 9 Power Soak goa RL u ee N EE u u ene peer 10 Mole Impeller Pump Assembler aut 10 Motor Impeller Pump Assembly I I ins an aaa 11 Motor Impeller Pump SEE tda 11 EE 13 hu Pl L EO ane ea 14 pok Li MT 14 daa Chemical R jj 15 Bedi TY Obi u u u a Q N dee 16 208 240 volt 60 Hz 1 phase EE N 16 203 230 SVE DU DS yp Su a
4. 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 form J9 and P10 for the Motor Thermodisc reference schematic or Motor Thermodisc for location and description Device should read less than one ohm when closed If the reading is more than one ohm the Thermodisc may be defective Next check for a short to ground If there is a short to ground from either side of the Thermodisc the Thermodisc is either defective or there may be 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 itis imperative to put hear 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 only the motor If the temperature of the motor reaches 180 F the disc opens cutting off power to the UPM and the UPM turns off the power to the motor 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 locatio
5. e marks made in step 7 above line up 3 Install O ring into the groove of the adaptor plate Power Soale 9 Coat the shaft sleeve lightly with lube Install the mechanical seal on the shaft sleeve using your hand to push against the seal face Make sure rubber seal bellows are seated against sleeve shoulder and carbon seal face is 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 squeeze 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 stud and tighten to 23 ft lbs Power Soala Appendix A Thermistor Resistance Temperature Chart o 90 80 70 60 50 40 30 20 PLES FA APH S US S P P SO Temperature degrees Fahrenheit T lt lt o o c s 2 x Power Soala Power Soak Power Soak is a registered trademark of Cantrell Industries I
6. ed and refer to the schematic when wiring new heater Power Soale Parts List Motor Impeller Pump Assembly 60 Hz Self Draining Volt Motor Impeller 208 29506 27590 208 29506 27591 230 29500 27590 208 29508 27590 208 29508 27591 e 230 460 29507 27590 RH 3 230 460 29502 27591 208 29507 27592 29507 27593 29501 27592 gt gt gt s gt P A 29501 27593 208 29509 27592 208 29509 27593 230 460 29503 27592 230 460 29503 27593 208 29510 27594 230 460 29504 27594 208 29511 27596 208 29511 27597 230 460 29505 27596 460 29505 27597 Q OO Lu ss N ee HIH w w S co w Motor Impeller Pump Assembly 60 Hz Not Self Draining 7 e LH EIER see 27590 above 230 460 see above Motor Impeller Pump Assembly 50 Hz European ii p ma 1 ze mmi rSn Es As um 3 am mem 27592 H 20 immu i f 220 2513 27594 30 3 so zote 24 RH 3 E NN NNNM XE ANM a 3 Pump Parts Common to all E I 1 r L 28920 27047 27132 Discharge gasket 2748 Mechanical Seal 27476 O ring seal plate 27478 Impeller Bolt i _ 27481 o 2743 28262 These items are contained in seal kit 28920 Power Soale Heater 29243 Element 208 volt rev B wire bottom mount not availab
7. 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 5 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 6 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 Power Soale Component Operation and Checks The following checks should only be performed by qualified 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 Using and Ohm meter measure the resistance between the face of the LLS and the appropriate pin of the white connector The meter 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
8. le yet 27930 Element 230 volt rev B wire bottom mount 29244 Element 380 volt rev B wire bottom mount not available yet Power Soala Control Panel Control Panel 220 volt single phase Control Panel 480 volt three phase Contactor EES LE Transformer 24 volt 27920 UPM Programming Module Terminal Block Din Rail mount for terminal blocks Fuse Block Overlay start stop membrane 27922 Wiring Harness internal to control panel Miscellaneous 27854 Chemical Injector 27854 Connector chemical injector 28553 Cap chemical injector 27855 Gasket chemical injector Power Soale Optional Chemical Dispenser Dual Pump Chemical Dispenser Electrical Schematic 208 240 volt 60 Hz 1 phase 13910 Kesler Orive a mu PowerSoak systems ENO A ck ee EE ME las rd do Ren OR LGED TO MAMUFACT RE ANYTHING DOWN THERE M WITHOUT METORAFT INC S WRITTEN PERMESS IOM eg E 7 a EE EE EE MAGE EE ONES BY RENA SE LAN ME EE TME PS_200 amp PS 201 WIRING DIAGRAM gen 208 240V 60Hz 1 PH BUS prvo vano MER TO ECR DW REV bare moza a azaoa T DATE REV 1 14 2004 PTS DO NOT SCALE DRAWING SHEET 1 OF 1 IN ANT MAN ANTE P 208 230 volt 60 Hz 3 phase NOTICE THS DRAWING IS PART OF THE PROPOETARY ARTICLE HEREIN DISCLOSED OWNED BY RENAU ELECTRONIC LAB THE UNITED STATES OR OTHER PARTY TO WHOM FURNISHED OR HAVING POSSESSION HEREOF BY ACCEPTING THIS DRAMNG
9. n 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 resistance between J9 and P10 reference schematic these are the black Thermodisc wires The device should read less than one ohm when closed If the reading is more than one ohm the Thermodisc may be defective Next check for a short to ground If there is a short to ground from either side of the Thermodisc the Thermodisc is either defective or there may be water on the Thermodisc This condition will keep the UPM from operating correctly On some of the Power Soak motors the Thermodisc is built in to the motor which is not replaceable On others it is 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 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 the 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 Tra
10. nc 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 34773 Rev A Rev Date 12 19 13 Power Soale
11. nce procedures please contact the factory at 800 444 9624 Power Soale Troubleshooting Hazard to Untrained or Unauthorized Personnel The following procedures are provided for use 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 Power Soak Service Department 800 444 9624 When performing trouble shooting procedures the authorized service agency will need to open the electrical enclosure on the Power Soak machine The control panel must be properly closed before reconnecting the power to the machine Pump leaks Look for Correction 1 Defective ADAPTER O RING Replace 2 Defective PUMP SEAL Replace Intermittent running See Pump does not work below Power Soala 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 proper water 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 temperatures to 115 with ice or cold water See N
12. nsformer The reading should be 24 volts across the outputs and 12 volts between the center tap and each of the other outputs These voltages can be verified at the three wire nuts on the internal wiring harness near the Transformer Note the wire colors on the schematic for each wire nut Power Soala Triac Thyristor or Solid State Relay The Triac is a three terminal semiconductor for controlling current in either direction The Triac in the Power Soak 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 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 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 are labeled identically 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 the gate voltage has been applied by the UPM If the light is on the Triac should be closed and terminal 1 of the Triac should be supplying power to the respective device If
13. o 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 Normal operating temperature 120 F 3 Water temperature gt 120 F Check Thermistor and replace as necessary Too much soap can cause excessive heat buildup 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 Normal operating temperature 120 F 3 Water temperature gt 120 F Check thermistor and replace as necessary Too much soap can cause excessive heat buildup Power Soale No Power Look for Correction 1 Incoming voltage between L1 and L2 L1 Check Heater and replace as necessary L2 Also L1 L3 L2 L3 if 3 phase 2 Less than 10 volts to UPM leave UPM plugged in during check Water too hot above 135 F empty sink and refill with 115 F water 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 Represents a short flash Look for Correcti
14. on 1 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 toa coating of debris or a broken disconnected wire that is preventing the signal to the UPM Acontinuous 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 Power Soala 2 em tt Temperature Sensor Error When the UPM receives a signal from the thermistor that is outside the range of the UPM programming the temperature sensor error will actuate The UPM will signal an error ifit reads a resistance greater than 430 k and less than 15 k Check and replace Thermistor as necessary dp qa P 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 Checkand replace the transformer motor and or heater as necessary 4 Over Temperature Error If the fluid temperature in the wash tank exceeds 135 F it will activate this
15. sis to ensure that your system remains reliable Daily Clean the liquid 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 Dirty sensors may create a situation that will allow the machine to run without water which can 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 Ifa brush and vacuum are unavailable clean the shroud with a damp soapy rag The motor shroud is the vented cover located at the end ofthe 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 Note The motor bearings do not need to be greased because they are permanently sealed If you have any questions regarding the preventive maintena
16. sket 3 Slide the impeller off of the shaft and remove the key 4 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 and key removed the shaft sleeve and the mechanical seal assembly can be removed Remove O ring from the shaft sleeve 6 With the shaft sleeve removed the seal rotating assembly can be pulled off of the shaft sleeve 7 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 8 Remove O ring from adaptor plate 9 With the adaptor plate removed the seal seat can be removed using a screwdriver or by using your fingers q 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 1 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 the ceramic side is up and it is fully seated 2 Install the adaptor plate and tighten 4 screws which hold it to the motor face Make sure th
17. the LED is off there should be virtually no current on the output side of the Triac Contactor If there is a 20v 28v across the coil and the contactor does not pull in the contactor is defective If there is input voltage across terminals L1 and L2 also L1 L3 and L2 L3 if three phase and the contactor is pulled in but no voltage across terminals T1 and T2 also T1 T3 and T2 T3 if three phase the contactor is defective Heater Element The heater in a Power Soak sink is rated at 7000 watts To check operations of the heat element first turn the power off at the breaker Disconnect the H2 wire from terminal H2 and the H1 wire from the triac H1 and H3 wire from H3 triac if 3 phase from the Control Panel Check each heater lead to ground for short They all should be open to ground Check resistance between each of the combinations of the chart below Connection Heater Rated phase Resistance ohms Voltage 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 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 a 10 variance of the value of 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 is three separate elements each of 2333 watts When replacing note how the existing Heater is wir
18. to id apa ai pu b 17 460 volt 60 Hz 3 phase corn 18 Electrical Schematic European see ee ie ie ee NE ee bee II 19 400 volt S0 EIER pha naina hahahahah ee aaa ika 19 230 volt 50 Hz 3 phase 20 Motoran Fi ifo PD 21 diclo M 21 Motor and Pump Assembly amp Disassembly Procedures 22 RT UR A mapi do uuu ann mens QE EAR me 22 INSPECTION OF THE COMPONENTS EQ 22 ASSEMBLY PROCEDURE l dodas nn 22 iro air o VER 24 Power Soak Explanation of Warning Messages 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 of 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 Soala Preventive Maintenance Power Soak machines require minimal routine preventive maintenance As such the following should be done on a routine ba
Download Pdf Manuals
Related Search