Jackson Gas Heated Door-Type Dishmachines Tempstar TGP User's Manual
Contents
1. 1 3 Hose 1 2 Heat Exchanger Inlet Assembly not shown 5700 002 17 7 LOWER ASSEMBLY RIGHT SIDE 1 Rinse Tank Assembly 5700 002 17 80 1 Saddle Burner 5700 002 18 74 1 Vent Flue Assembly 5700 002 19 45 1 5700 002 20 50 Air Shield 5700 002 18 27 Locknut 10 24 s s Hex w Nylon Insert 5310 373 01 00 07 Bracket Pump Support Assembly 5700 002 18 08 1 Wash Pump amp Motor Assembly 240v 50hz 1ph 6105 002 19 87 10 1 Bracket Drain Support 5700 002 20 58 8 09 1 Clamp 5 5 8 to 6 4730 011 34 90 11 2 waste 5700 001 17 87 7 12 1 Hose Flex Gas s s Assembly 5700 011 93 95 13 1 Plumbing Drain Assembly 5700 002 21 29 Hose Heat Exchanger Outlet Assembly 5700 002 17 75 INCOMING PLUMBING ASSEMBLY Pa I INCOMING PLUMBING PARTS LISTS ITEM QTY DESCRIPTION MFG NO Pressure Guage 0 100 PSI Ball Valve Test Cock 1 4 Bronze Tee Brass 3 4 X 3 A X 1 4 Pressure Regulator Incoming Plumbing Support Bracket Magnet Reed Switch Reed Switch Conduit 1 2 X 14 Plumbing Assembly Inlet to Rinse Tank Washer Teflon Panel Lower Back Cover Panel Upper Back Cover Locknut 10 24 s s Hex w Nylon Insert Clamp Nylon 1 1 4 Conduit 3 4 X 37 1 2 Plumbing Assembly Outlet From Rinse Tank Clamp Double Pipe Washer 1 4 ID s s Locknut 1 4 20 s s Hex w Ny2. 1 27cm or gas line greater than 16 feet 4 88m reduce pressure may result Ensure 12 VDC to both sides of valve If not check ECO and DSI If yes valve may have failed shut Replace valve Tap on gas supply line between the combination cutoff valve and the modulating valve This tapping helps to free the piston Check wire for continuity Check connection to both the DSI and spark probe Check height of probe above burner should be 1 8 318 CM Check gap between probe ends 1 8 318 CM Ensure probe is not touching burner Disconnect ignition wire from DSI spade connector During ignition a spark should be seen at this spade If none replace DSI If spark exists replace ignition wire Check voltage to modulating valve If greater than 2 0 VDC modulating valve may have been forced out of its operating range Tap on gas supply line between the combination cutoff valve and the modulating valve This tapping helps to free the piston If less than 2 0 VDC replace control board TROUBLESHOOTING SECTION WARNING Inspection testing and repair of electrical equipment should only be performed by a qualified service techni cian Many of the tests require that the unit have power to it and live electrical components be exposed USE EXTREME CAUTION WHEN TESTING THE MACHINE The unit ignites but will to rise above T mid thermistor inoperative Check T mid thermistor readings at control ignition burn board set poin
3. USE EXTREME CAUTION WHEN TESTING THE MACHINE Low rinse temperature low wash temperature High rinse temperature Possible Cause Low inlet water temperature Low gas pressure Improper circulation through system T set needs adjustment Defective T mid thermistor Red LED light may be flashing Defective control board ECB T set needs adjustment ECO failure Overprotection feature is faulty and does not open at 210 F 98 89 C Ensure incoming water is 110 F 43 33 C at incoming point of machine may need to increase the set point of the supply water heater Check gas supply pressure Ensure proper operation of combination gas cutoff valve Ensure manual gas cutoff valve is open Check gas supply pressure Check for kinks in flexible gas supply line Check recirculating pump operation Check for obstructions Ensure set point is approximately 4 25 VDC Check Ohms reading is between 950 and 1150 Ohms when probe is at room temperature Check for frayed wiring Ensure connection to control board Perform auto calibration Ensure power supplied to board is 12 VDC Ensure green LED light is flashing Ensure set point is approximately 4 25 VDC Remove wire from ECO terminal If burner unit turns off ECO may be defective Replace ECO TROUBLESHOOTING SECTION WARNING Inspection testing and repair of electrical equipment should only be performed by a qualified service techni
4. rN Ic DUAL TEMPERATURE GAS HEATED N 5 DOOR TYPE DISHMACHINES One Company Countless Solutions TECHNICAL MANUAL INSTALLATION MANUAL FOR EXPORT UNITS SERVICE MANUAL FOR DOMESTIC UNITS FOR JACKSON MODEL TEMPSTAR TGP Jackson Enc dis Company Jackson MSC Inc P O BOX 1060 HWY 25E BARBOURVILLE KY 40906 June 24 2004 FAX 606 523 9196 P N 7610 001 98 99 Revision C TABLE OF CONTENTS GENERAL Specifications INSTALLATION Unpacking Plumbing Connections Electrical Connections Gas Connection OPERATING INSTRUCTIONS Preparing the Dishes Daily Machine Preparation Washing a Rack of Ware Shut Down and Cleaning OVERVIEW OF OPERATION THERMOSTAT ADJUSTMENT PROCEDURE AUTO CALIBRATION PROCEDURE ELECTRONIC CONTROL BOARD ECB TESTING THERMISTORS CONTROL BOARD LED LIGHT INDICATIONS TROUBLESHOOTING DIMENSIONS TABLE DIMENSIONS PHOTOGRAPHS Main Assembly Control Box Assembly Front View Control Box Assembly Top View Hood Assembly Cantilever Arm Assembly Tub Assembly Back of Tub amp Drain Assembly Lower Assembly Right Side Incoming Plumbing Assembly Gas Pack Assembly Upper Wash amp Rinse Arm Assembly Lower Wash amp Rinse Arm Assembly Steam Coil Assembly Rinse Tank Assembly Electronic Control Drawer Components METRIC CONVERSION SCHEMATICS 208 240 Volt Schematic SPECIFICATIONS OF THE TEMPSTAR TGP PERFORMANCE CAPABILITIES VO
5. 82 22 C CHECK VALVE CHECK VALVE WASH TANK WATER LEVEL BOOSTER PROBE a TANK THERMOSTAT WASH TANK COILS WASH TEMP 150 165 65 56 73 89 EXCHANGER _ BURNER RECIRCULATING ASSEMBLY PUMP oooooooo _ MODULATING COMBINATION GAS VALVE CUTOFF VALVE The Tempstar TGP heating system is designed to heat and maintain the wash tank water temperature at a minimum of 150 F 65 56 C as well as providing a constant 180 F 82 22 C rinse water temperature Incoming water is supplied at a pressure of 20psi and between 70 140 F 21 11 60 C Incoming gas pressure should be between 4 0 6 0 WCI for town gas The sequence of operation is as follows please refer to the above diagram When the power is turned on at the ON OFF switch the water level control board will sense a low water level in the wash tank and the unit will begin to fill This occurs as the rinse solenoid valve opens allowing connected water to fill the booster tank heat exchanger and the rest of recirculating system once the booster tank is full water will fill the wash tank until the water level control sys tem is satisfied Simultaneously with the fill the rinse recirculating pump and the gas burner assembly is energized to begin heat up of the unit A transformer in the main control box supplies 12vdc to the electronics control drawer location in the lower section of the unit The electronics control board ECB is the
6. 12 6 35 20 1 2 52 07 25 1 4 2 1 4 1 1 2 3 4 B lt A gt lt OPENING TABLE DIMENSIONS CORNER INSTALLATION gt OPENING lt D gt F ROLL TABLE DIMENSIONS CONNECTION TO DISHMACHINE gt lt lt D gt OPENING lt TABLE DIMENSIONS STRAIGHT THROUGH INSTALLATION 64 44 CM MAIN ASSEMBLY r 7 TN Right Side Panel ITEM 7 Vent Hue Assembly 5700 002 19 45 Vent Flue Adapter NOT SHOWN 5700 002 22 70 Bullet Feet 5340 108 02 06 CONTROL BOX ASSEMBLY FRONT VIEW 03 04 05 06 07 08 09 10 11 DESCRIPTION 01 1 ControlBoxCoverDecal 9905 021 91 15 02 1 RinseThermometer 48 Lead 6685 111 68 48 03 1 PowerLight Red 5945 504 07 18 O 04 1 Screw 10 32 X 3 8 Phillips Truss Head 05 1 Delime Manual Wash Switch 5930 301 2118 06 1 On OffPowerSwitch 5930 011 4955 07 1 Delime NormalDecal 9905 011 34 96 08 1 Timer 220v50 8cam o o o 5945 001 99 08 09 1 CycleLight Green 5945 504 08 18 10 1 TimerMountingBracket 5700 021 3454 O 11 8 MicroSwitch 59451116849 O 12 1 Wash Thermometer 96 Lead CONTROL BOX ASSEMBLY TOP VIEW 01 h 1 02 a m LL i 01 2 HeycoPlug 5975 200 40 00 02 1 Fitting Co n
7. FOOT 12 INCHES 0 3048 m 1 SQUARE FOOT ft 0 0929 m 1 YARD 3 FEET 0 9144 m 1 SQUARE YARD 0 8361 m 1 MILE 1760 YARDS 1 6093 km 1 SQUARE MILE 2 59 km TEMPERATURE CONVERSION F C x 1 8 32 Example F 32 C x 1 8 32 89 6 F 32 1 8 Example C 100 F 32 1 8 37 8 FLUID CAPACITY VOLUME IMPERIAL METRIC IMPERIAL METRIC 1 GALLON US 3 785412 L 1 CUBIC INCH 16 3871 1 QUART US 946 3539 mL 1 CUBIC FOOT ft 0 02831 m 1 PINT US 473 1765 mL 1 CUBIC YARD 0 7645549 1 FLUID OUNCE US 29 574 mL IMPERIAL METRIC IMPERIAL METRIC 1 FOOT MINUTE 0 3048 m m 1 GALLON MINUTE 0 0038 m min 1 FOOT SECOND 0 3048 m s 1 GALLON HOUR 1 0515 mL s 1 MILE HOUR 1 609344 km h UNITS OF MEASURE Area Volume Conveyor Speed United States 1 in ft min Metric m min Tempstar TGP ELECTRICAL DIAGRAM 208 240 VOLT 50 HERTZ 1 PHASE
8. If not check circuit chip microprocessor fully inserted If so replace control board Voltage not being sent from control board to Check for 12 VDC at black wire going from DSI control board to DSI Ensure green wire on DSI cable is grounded Green LED flashes but no ignition Igniter ECO defective or not electrically connected Check blue wire from DSI connected to one sparks no gas spade terminal of ECO and another blue wire connected from other spade terminal of ECO and to the combination gas cutoff valve TROUBLESHOOTING SECTION WARNING Inspection testing and repair of electrical equipment should only be performed by a qualified service techni cian Many of the tests require that the unit have power to it and live electrical components be exposed USE EXTREME CAUTION WHEN TESTING THE MACHINE Green LED flashes but no ignition igniter sparks no gas Green LED flashes but no ignition no igniter sparks gas flow and smell present The unit ignites but will not rise above ignition burn Gas flow interrupted Combination gas cutoff valve is closed Modulating valve forced out of normal range and may be stuck common occurrence during shipment Ignition wire loose or broken Improper gap on spark probe Defective DSI Improper operation of modulating valve Check manual gas valve is open Check regulated gas pressure 4 0 6 0 WCI for town gas If gas line diameter is less than 1 2
9. UPPER WASH amp RINSE ARM ASSEMBLY ITEM 5700 071 25 92 os oa Le 8703 8083 2 1 Ri Wash Arm 2 Nut38 16Hex 53102760100 2 Bolt KE JAN 2 Ri 1 LOWER WASH amp RINSE ARM ASSEMBLY ITEM QTY DESCRIPTION 5700 011 35 92 4730 609 04 00 4730 609 05 00 LRinseArm Rinse Manifold Assembly Lower Wash Casting Bolt 3 8 X 11 4 Long Rack Guide Weldment Lower Wash Manifold 07 i gt gt LU A gt lt LU STEAM COIL ASSEMBLY PARTS LISTS ITEM QTY DESCRIPTION MFG NO 5700 002 08 53 5310 374 01 00 5311 174 01 00 5700 041 90 30 5700 001 27 55 5700 001 25 69 5700 002 08 52 4730 609 05 00 5700 021 41 38 5700 001 17 86 5700 002 08 50 5310 374 01 00 5700 001 22 23 5700 001 22 24 5700 002 08 51 5700 111 68 49 Stand D Steam Coil Support Locknut 1 4 20 s s Hex w Nylon Insert Washer s s 1 4 1 0 Tub Weldment Overflow Support Bracket Wash Overflow Weldment Stand C Steam Coil Support Bulk Head Plug Steam Coil Weldment Gasket Steam Coil Stand A Steam Coil Support Locknut 1 4 20 s s Hex w Nylon Insert Suction Strainer Weldment Bracket Suction Strainer Stand B Steam Coil Support Wash Thermometer 96 Lead Thermostat Wash Regulating 78 Deg 5930 121 67 72 Probe High Water 6680 200 02 68 O Ring Vitan 403 218 5330
10. WARNING Inspection testing and repair of electrical equipment should only be performed by a qualified service techni cian Many of the tests require that the unit have power to it and live electrical components be exposed USE EXTREME CAUTION WHEN TESTING THE MACHINE Symptom Low wash water pressure Water leak in the gas booster pack Gas leak CAUTION WHEN CHECKING FOR GAS LEAKS DO NOT USE FLAME Low rinse temperature low wash temperature Wash arms nozzles are clogged Pump impeller worn or broken Loose compression or NPT fitting Compression fitting over compressed NPT fitting cross threaded Loose fitting Bad thread sealer on fitting Defective part has crack hole or break in it Excessive water flow into machine Remove wash arms and clean Replace pump Check all fittings to ensure that they are tight Replace compression fitting Replace the fitting Using an approved leak detector determine which fitting is loose and either tighten or replace Remove fitting and apply an AGA approved thread sealer Replace the part Adjust pressure regulator so that 20 PSI is maintained at gauge Check for leakage past solenoid valve TROUBLESHOOTING SECTION WARNING Inspection testing and repair of electrical equipment should only be performed by a qualified service techni cian Many of the tests require that the unit have power to it and live electrical components be exposed
11. a series of steps Watch the readings of your multi meter They will run approximately 11 9 VDC 23 VDC for the TGP at the highest flame step down to about 6 0 VDC 12 VDC for the TGP and then step down again slightly to 5 7 to 5 8 VDC 11 4 to 11 6 VDC for the TGP before shutting the burner off This whole process takes about 1 2 Minutes Once the burner goes out turn dishmachine OFF Wait one minute Replace jumper on control board in the exact same place it came off Turn the dishmachine back ON TEST di HB AUCH TURA TETI TM t EHTHOMAKE TER SET SCRE Figure 1 Figure 2 ELECTRONICS CONTROL BOARD ECB THERMISTER TEST POINT TEST POINT 12 CONNECTIONS T OUT 4 GROUND POWER SUPPLY ORANGE CONNECTION INDICATION LIGHTS ALTO CALIBRATION JUMPER TEST POINT T MID CONTROL YELLOW CHIP TEST POINT T SET BLUE POTENTIOMETER SETSCREW TEST POINT BROWN NOT USED DS BOARD MODULATING CONNECTION CONNECTION VALVE NOT USED CONNECTION Testing and Setting the Set Point Temperature The Control Board regulates the temperature of the water in the heat exchanger system This water is also used as the rinse water for the rinse cycle of the dishwasher It does this by regulating the flame of the burner by increasing or decreasing the voltage to the modulating valve The modulating valve in turn increases or decreases the gas pressure going to the burner manifold de
12. cian Many of the tests require that the unit have power to it and live electrical components be exposed USE EXTREME CAUTION WHEN TESTING THE MACHINE High wash tank temperature Defective thermostat If wash tank temperature is greater than 170 F 76 67 C back thermostat CCW one full turn and restart unit When cycle completes set thermostat to 170 F 76 67 C by turning CW Leak in wash tank heating coil allowing hot Empty wash tank and observe coils with recirculating system water to enter tank recirculating system on No Green LED flash and the recirculating New control board placed into system and Perform auto calibration pump is running or the Green LED stays on not calibrated but does not flash Power to control board interrupted Check 12 VDC to control board Voltage should be between 10 8 and 14 4 VDC Make sure the transformer in main control box is energized CAUTION REVERSE POLARITY WILL DAMAGE THE CIRCUIT BOARDS Circuit chip microprocessor pins not fully Check for bent pins Ensure chip fully inserted into its sockets inserted by gently pressing with thumb Green LED flashes but no ignition attempt T mid thermistor reading incorrectly May Check T mid voltage reading at test points no igniter no gas be sensing non existing high temperature control board Ignition relay on control board inoperative Place finger on ignition relay and turn power on Should hear or feel the relay actuating
13. the stabilization temperature the gas flow is slowly reduced until the minimum burn is attained The software will keep the unit in minimum burn until the heat exchanger temperature exceeds stabilization tempera ture when the gas will be shut off Over many minutes the software will turn the burner off and on repeatedly until all the water in the System reaches the stabilization temperature At this point the software will only turn the burner on every 1 2 minutes to maintain the stabilization temperature Now the unit is ready for operation As the dishwasher pulls water from the tank the water is replaced with cooler water The need to heat the new water is sensed by the software and the burner is turned on The software will modulate the gas flow between minimum and maximum gas flow attempt ing to recover the stabilization temperature and always keeping the tank temperature above the required temperature The stabilization temperature may be adjusted by means of a potentiometer located on the ECB This is referred to as the T set normally 4 25vdc The recirculating pump draws water from the rinse booster tank and circulates it through the wash tank coils where it will heat the water residing in the wash tank The water then returns to the heat exchanger where it is reheated This hot water then flows back to the rinse booster tank and repeats the cycle The thermostat in conjunction with the wash temp relay is used during idle times to preven
14. 00 031 50 67 4 Washerss14 ID 5311 174 01 00 4 Locknut 14 20 s s Hex w Nylon Insert O 5310 374 01 00 6 Wear Button 1 2 Dia UHMW O 5700 001 98 69 2 SprngRod 5700 001 28 18 2 Cantilever Arm Support Bracket 5700 031 88 00 2 Yoke Assembly 5700 000 75 78 1 Hood Assembly 5700 041 90 56 TUB ASSEMBLY ITEM QTY DESCRIPTION Bracket Reciculating Pump 5700 002 14 85 5311 275 01 00 5305 275 09 00 5700 002 17 77 5700 011 73 77 Thermostat Wash Temperature Over Limit 78 Deg 5930 121 67 72 Clamp 5 8 Nylon 4730 011 39 01 4730 206 08 00 6685 111 68 49 6680 200 02 68 5700 002 18 85 Clamp Reg Range 1 5 16 2 1 4 4730 719 01 37 5700 002 18 77 6105 002 19 87 7 BACK OF TUB amp DRAIN ASSEMBLY 07 08 01 1 TubWeldment 1 5700 002 1877 02 1 VentFlueAssembly 57000021945 03 1 Wash Pump amp Motor Assembly 240w 50hz iph 1 6105 002 1987 04 1 FrameWeldment 1 5700002878 05 1 Plumbing DrainAssembly 1 57000022129 06 1 Bracket Drain Support 57000022058 07 1 3 4 Recirculating Pump Suction 08 2 Elbow 90 Deg 1 2 Street Brass 09 2 Bolt CantileverHangerEye3 8 16 1 5306 956 05 00 10 2 BulkHead 47305090550 11 1 1 2 Recirculating Pump Discharge 1 5700 002 17 71 12 2 Spring 53401090200 13 2 Rod Spring
15. 400 05 00 N 01 02 02 03 04 05 06 08 09 10 o 12 13 14 15 16 128 RINSE TANK ASSEMBLY NOTE THESE UNIONS ARE NOT INCLUDED WITH THIS ASSEMBLY 1 RinseTankAssemblIy 5700 002 1780 01 2 Union Brass Comes With Incoming Plumbing Assy 7 4730 212 0500 02 2 2 473020746900 O 03 1 Valve 3 4 NPT Female Check High 04 3 Nipple 3 4 NPT 1 3 8 Close Brass 05 2 Elbow 3 4 Street Brass 06 1 RinseTankWeldment 5700 002 17 81 07 1 Elbow 90 Deg 1 2 Street Brass 08 1 Valve 3 4 NPT Female Check 09 1 Circulating Return Tube NOT SHOWN 1 5700 021 92 39 o vc ELECTRONIC CONTROL DRAWER COMPONENTS le muc RED GREEN LED LED 1 Electronic Control Drawer Assembly 5700 002 21 10 1 Wiring Harness ThermistorCable 5700002 12 34 1 Electronic Control Board ECB 66800021226 1 Wiring Harness DSICable 57000024256 1 Wiring Harness Power Supply Cale 57002002425 1 Wiring Harness Modulating Valve TGP 1 570000227 1 Direct Spark Ignition Board DS 6680 0021225 1 ligniionCable 570000422 1 Circuit Breaker 3 amp 07 METRIC CONVERSIONS LENGTH IMPERIAL METRIC IMPERIAL METRIC 1 INCH 2 54 cm 1 SQUARE INCH in 6 4516 cm 1
16. HIS MACHINE ENSURE THAT THE AREA WHERE THIS MACHINE IS TO BE INSTALLED IS WELL VENTILATED TO PREVENT THE BUILD UP OF COMBUSTIBLE GASES ENSURE THAT ALL LOCAL HEALTH FIRE AND BUILDING CODES ARE BEING ADHERED TO WHEN INSTALLING THIS MACHINE VERIFY WITH LOCAL OFFICIALS IF THERE ARE ANY QUESTIONS INSTALL A SHUT OFF VALVE AT THE GAS SOURCE AND SUPPLY THE MACHINE USING A 1 2 LINE CONNECT TO THE 1 2 NPT FITTING ON THE MACHINE OPERATION INSTRUCTIONS PREPARATION Before proceeding with the start up of the unit verify the following 1 The pump intake and wash tank strainers are in place and is clean 2 The drain stopper is installed 3 That the wash and rinse arms are screwed securely into place and that their endcaps are tight The wash and rinse arms should rotate freely POWER UP To energize the unit turn on the power at the service breaker The voltage should have been previously verified as being correct If not the voltage will have to be verified FILLING THE WASH TUB Ensure that the delime switch is in the NORMAL position and place the power switch into the ON posi tion The Tempstar TGP should fill automatically and shut off when the appropriate level is reached just below the wash tank strainer Verify that the drain stopper is preventing the wash tub water from pouring out excessively There will probably be some slight leakage from the drain hole Verify that there are no other leaks on the unit before pr
17. LTS OPERATING CAPACITY RACKS HOUR 208 240 RACKS PER HOUR DISHES PER HOUR WATER REQUIREMENTS GLASSES PER HOUR INLET TEMPERATURE 70 140 F INLET TEMPERATURE OPERATING CYCLE SECONDS GALLONS PER HOUR WASH TIME LITERS PER HOUR RINSE TIME WATER LINE SIZE 1 5 Minimum DWELL TIME WATER LINE SIZE 1 5 Minimum TOTAL CYCLE TIME DRAIN LINE SIZE I P S Minimum DRAIN LINE SIZE I P S Minimum TANK CAPACITY GALLONS FLOW PRESSURE P S I Optimum WASH TANK MINIMUM BOOSTER TANK 1 GAS REQUIREMENTS BTU INPUT RATE TANK CAPACITY LITERS INLET LINE PRESSURE TowN Gas WASH TANK MINIMUM MANIFOLD PRESSURE MINIMUM BOOSTER TANK MAXIMUM WASH PUMP CAPACITY FRAME DIMENSIONS GALLONS PER MINUTE WIDTH 25 3 4 LITERS PER MINUTE WIDTH 65 4 CM DEPTH 25 1 4 TEMPERATURES DEPTH 64 14 CM WASH F MINIMUM HEIGHT 56 3 4 WASH C MINIMUM HEIGHT 144 15 CM RINSE F STANDARD TABLE HEIGHT 34 RINSE C STANDARD TABLE HEIGHT 86 36 CM MAXIMUM INSIDE CLEARANCE 17 1 4 ELECTRICAL REQUIREMENTS MAXIMUM INSIDE CLEARANCE 43 82 CM WASH PUMP MOTOR HP CIRCULATOR PUMP MOTOR HP RACKS DISH 20 X 20 50 8 CM X 50 8 CM OPTIONAL GLASS amp SILVER 20 X 20 50 8 CM X 50 8 CM OPTIONAL INSTALLATION INSTRUCTIONS VISUAL INSPECTION Before installing the unit check the con tainer and machine for damage A damaged container is an indi cator that there may be some damage to the machine If there is damage to both the contain
18. PECTION Based upon usage the wash tank strainer may become clogged with soil and debris as the workday progresses Operators should regularly inspect the wash tank strainer to ensure it has not become clogged If the strainer does it will reduce the washing capability of the machine Instruct oper ators to clean out the wash tank strainer at regular intervals or as required by work load SHUTDOWN AND CLEANING At the end of the workday close the doors When the unit completes the cycle turn the power switch to the OFF position and open the doors Manually remove the drain stopper from the tub and allow the tub to drain NOTE the wash tank water will be hot so caution is advised Once the wash tub is drained remove the wash tank strainer and the pump suction strainer Remove soil and debris from the strainer and set to the side Unscrew the wash and rinse arms from their mani folds Remove the endcaps and flush the arms with water Use a brush to clean out the inside of the arms If the nozzles appear to be clogged use a toothpick to remove the obstruction Wipe the inside of the unit out removing all soil and scraps Reassemble the wash and rinse arms and replace them in the unit The arms only need to be hand tight do not use tools to tighten them down Reinstall the strainers and close the doors OVERVIEW OF OPERATION PRESSURE GAUGE VACUUM BREAKER REGULATOR FILL RINSE SOLENOID RINSE TEMP RINSE ARM gt 180 F
19. ack Thermister Conversion a Voltage DC a 9 Temperature F CONTROL BOARD LED LIGHT INDICATIONS The Electronic Control Board ECB has two LED light indicators that can be seen at its upper left hand corner The following conditions for each light may be seen during operation of the unit 1 Green LED is off A Dishmachine is turned off therefore no power to ECB B Wash thermostat has cycled off therefore breaking power to 12 volt transformer in the main control box This will also disrupt power to the ECB C ECB may have never recieved an AUTO CALIBRATION D ECB may be damaged due to high voltage E Control chip in ECB may be misaligned not fully inserted or damaged 2 Green LED is a illuminated and steady A ECB has been damaged in some form 3 Green LED is illuminated and flashing A This is the normal operating condition whether the LED flashes rapidly or at a slower rate 4 Red LED is off A This is the normal operating condition 5 Red LED is illuminated and steady or flashing A This is an indication of a malfunction of the T MID Thermistor Thermister may be unplugged grounded have frayed wiring or other damage TROUBLESHOOTING SECTION WARNING Inspection testing and repair of electrical equipment should only be performed by a qualified service techni cian Many of the tests require th
20. anitize as well to destroy all of the bacteria that could be harmful to human beings In order to do this ware must be properly prepared prior to being placed in the machine DAILY MACHINE PREPARATION Refer to the section entitled PREPARATION at the top of this page and follow the instructions there Afterwards check that all of the chemical levels are correct and or that there is plenty of detergent available for the expected workload WARM UP CYCLES For a typical daily start up it is recom mended to run the machine through 3 cycles to ensure that all of the cold water is out of the system and to verify that the unit is operating correctly To cycle the machine ensure that the power is on and that the tub has filled to the correct level Lift the doors and the cycle light will illuminate When the light goes out close the doors the unit will start run through the cycle and shut off automatically Repeat this two more times The unit should now be ready to proceed with the washing of ware WASHING A RACK OF WARE To wash a rack open the doors completely being careful for hot water that may drip from the doors and slide the rack into the unit Close the doors and the unit will start automatically Once the cycle is completed open the door again watching for the dripping hot water and remove the rack of clean ware Replace with a rack of soiled ware and close the doors The process will then repeat itself OPERATIONAL INS
21. at the unit have power to it and live electrical components be exposed USE EXTREME CAUTION WHEN TESTING THE MACHINE Symptom Dishmachine will not run No power to the unit Dishmachine will not run There is power to the unit Machine runs but there is not water Dishmachine fills continuously even when the machine is off Dishmachine fills continuously only when the power is on Service breaker tripped Incoming power lines not installed in control box Incoming power lines connections not tightened Door switch shorted out or is disconnected Misadjusted or faulty cycle reset cam microswitch No water supply to machine Incoming water supply solenoid not operating Incoming water supply solenoid not operating Incoming water supply solenoid not operating Reset breaker If breaker trips again immediately contact an electrician Install power lines Tighten connections Check to ensure door switch wires are connected correctly If so replace door Switch Replace microswitch Check to ensure that all water valves are open and that water is being supplied to the machine at 20 PSI Check to ensure that valve is wired correctly If so replace valve Check to ensure that valve is wired correctly If so replace valve Check to ensure that valve is wired correctly If so replace valve TROUBLESHOOTING SECTION WARNING Inspection testing and repair of electrical equipment
22. ational plumbing codes The plumber is responsible for ensuring that the incoming water line is thoroughly flushed prior to connecting it to any com ponent of the dishmachine It is necessary to remove all foreign debris from the water line that may potentially get trapped in the valves or cause an obstruction Any valves that are fouled as a result of foreign matter left in the water line and any expenses resulting from this fouling are not the responsibility of the manu facturer CONNECTING THE DRAIN LINE The drain for the Tempstar TGP is a gravity discharge drain All piping from the 1 1 2 FNPT connection on the waste accumulator must be pitched 1 4 per foot 2 083 cm per meter to the floor or sink drain All piping from the machine to the drain must be a minimum 1 1 2 and shall not be reduced There must also be an air gap between the machine drain line and the floor sink or drain If a grease trap is required by code it should have a flow capacity of 5 gallons 18 93 liters per minute WATER SUPPLY CONNECTION Ensure that you have read the section entitled PLUMBING THE DISHMACHINE above before proceeding Install the water supply line 3 4 pipe size minimum to the dishmachine line strainer using copper pipe It is recom mended that a water shut off valve be installed in the water line between the main supply and the machine to allow access for ser vice The water supply line is to be capable of 20 PSI flow pr
23. brain of the system The ECB receives various inputs and determines the amount of heating required When energized the ECB receives input from the T mid thermistor indicating a low water temperature in the recirculating sys tem The ECB will power the ignition relay on the board which in turn provides 12vdc to the direct spark ignition board DSI The DSI sends 12vdc to the combination gas cutoff valve to open it This will supply gas to the burner assembly The DSI begins sparking the igniter probe and monitors the flames presence If the flame is not sensed during the ignition attempt then the DSI will lockout until the software resets the DSI approximately 60 seconds later OVERVIEW OF OPERATION CONTINUED The operator may turn the power off at the ON OFF switch for approximately 5 seconds and then back on This will also reset the ECB and the DSI If flame is lost during normal burn the DSI will attempt a reignition The ECB monitors the 12vdc signal from the DSI to the combination gas cutoff valve The software in the ECB also reads the temperature at the middle of the heat exchanger with the T mid thermistor After the 5 5 second ignition time the software will increase gas flow to the burner to minimum burn by increasing voltage to the modulating valve MV If the heat exchanger temperature is far away from the stabilization temperature the software will increase gas flow to maximum burn Once the heat exchanger temperature nears
24. d adjusts the burner pressure by way of the Modulating Valve according to how far away that temperature is away from the set point temperature Thermistors are devices that change their resistance value with changes in temperature By running a constant voltage through the thermistor one can read the change of voltage caused by the change of resistance thus determining the temperature of the thermis tor There are test points on the control board see above that can be read with a multi meter on the Direct Current Volt DCV scale for each thermistor To test the temperature at the T in Thermistor There is a BLACK test point along the top edge of the control board on the right side of center This is where the NEGATIVE Common Black probe of a multi meter is inserted There is an ORANGE test point along the top edge of the control board on the left side of center This is where the POSITIVE Red probe of a multi meter is inserted A DC voltage reading is then taken Find the voltage on the chart below and find the corresponding temperature To test the temperature at the T Mid Thermistor Using the same BLACK test point with the NEGATIVE probe of the multi meters in testing the T in thermistor above also find the YEL LOW test point on the left side of the board just under the large plug see above Insert the positive probe of the multi meter and read DC Volts Since the two thermistors have the same values the same chart is used Gas P
25. duit Non Metalic 3 4 x 45 5975 011 47 74 03 1 Groundlug 5940 200 76 00 04 1 Terminal Block 2 pole 05 1 Contactor 2 Pole 220v 20amp Wash Motor 06 1 Contactor 2 Pole 220v 20amp Wash Temperature 07 1 Timer 220v 50hz 8 Cam 5945 001 9908 08 1 FuseHolder 5920 401 03 14 09 1 Relay Control240v 50 60hzTopMount 5945 111 47 51 10 1 LiquidLevelControl 20v 6680 200 08 21 11 1 Inner Control Panel Assembly TGP 205 501 5700 00221 06 12 4 TransformerMounting Bracket 5700 002 1895 13 1 Transformer 100 240vac to24vdC 5950 002 1988 14 1 Transformer 100 240vacto i2vdc 55000247 2 15 1 Fitting Conduit Non Metalic 1 2 x 90 HOOD ASSEMBLY ITEM Double Door Guide Left Front 5700 021 33 20 Double Door Guide Right Front 5700 021 33 19 Locknut 1 4 20 s s Hex w Nylon Insert 5310 374 01 00 Door Guide Left Rear 5700 021 84 71 Hood Weldment 5700 002 18 76 Door Guide Right Rear 5700 021 84 70 EN 28 Screw 1 4 20 x 172 28 wase sis tin EN CANTILEVER ARM ASSEMBLY a sh ITEM QTY DESCRIPTION 1 MagnetReedSwitch 5930 111 51 68 1 DoorGuide RightRear 5700 021 84 70 1 Door Right Side Assembly 5700 002 21 33 2 5340 011 35 00 2 CantileverArmConnector 5700 011 90 99 1 57
26. er and machine do not throw away the container The dishmachine has been inspected and packed at the factory and is expected to arrive to you in new undamaged condition However rough handling by carriers or others may result in there being damage to the unit while in transit If such a situation occurs do not return the unit to Jackson instead contact the carrier and ask them to send a representative to the site to inspect the damage to the unit and to complete an inspection report You must contact the carrier within 48 hours of receiving the machine Also contact the dealer through which you pur chased the unit UNPACKING THE DISHMACHINE Once the machine has been removed from the container ensure that there are no missing parts from the machine This may not be obvious at first If it is dis covered that an item is missing contact Jackson immediately to have the missing item shipped to you LEVEL THE DISHMACHINE The dishmachine is designed to operate while being level This is important to prevent any dam age to the machine during operation and to ensure the best results when washing ware The unit comes with adjustable bullet feet which can be turned using a pair of channel locks or by hand if the unit can be raised safely Ensure that the unit is level from side to side and from front to back before making any connec tions PLUMBING THE DISHMACHINE All plumbing connections must comply with all applicable local state and n
27. es sure at the recommended temperature indicated on the data plate In areas where the water pressure fluctuates or is greater than the recommended pressure it is suggested that a water pressure reg ulator be installed Do not confuse static pressure with flow pressure Static pressure is the line pressure in a no flow condition all valves and services are closed Flow pressure is the pressure in the fill line when the fill valve is opened during the cycle It is also recommended that a shock absorber not supplied with the Tempstar TGP model be installed in the incoming water line This prevents line hammer hydraulic shock induced by the sole noid valve as it operates from causing damage to the equipment PLUMBING CHECK Slowly turn on the water supply to the machine after the incoming fill line and the drain line have been installed Check for any leaks and repair as required All leaks must be repaired prior to placing the machine in operation ELECTRICAL POWER CONNECTION Electrical and grounding connections must comply with the applicable portions of the National Electrical Code ANSI NFPA 70 latest edition and or other electrical codes Disconnect electrical power supply and place a tag at the discon nect switch to indicate that you are working on the circuit The dishmachine data plate is located on the right side and to the front of the machine Refer to the data plate for machine operat ing requirements machine
28. lon Insert Gasket Vellumoid Union Brass 3 4 Elbow 3 4 90 Deg Street Brass Rinse Injector SDS Weldment Plug 1 8 NPT Brass Vacuum Breaker 3 4 Solenoid Valve 3 4 240v Close Nipple 3 4 Brass 6685 111 88 34 4810 011 72 67 4730 211 04 00 6685 011 58 22 5700 021 34 02 5930 111 51 68 5930 111 41 70 5700 011 46 97 5700 002 18 87 5330 200 11 00 5700 002 17 99 5700 002 17 98 5310 373 01 00 4730 011 51 16 5700 002 19 08 5700 002 18 90 5700 002 23 89 5311 174 01 00 5310 374 01 00 5330 111 42 81 4730 212 05 00 4730 206 04 34 5700 021 47 65 4730 209 07 37 4820 300 08 00 4810 100 03 18 4730 207 34 00 07 01 02 03 04 05 06 07 08 09 10 o 12 13 14 15 16 18 18 19 20 21 22 23 24 25 26 GAS PACK ASSEMBLY 1 M ITEM QTY DESCRIPTION 1 GasPak TOWNGAS 57000021983 O 01 1 Hose Flex Gas s s Assembly 57000119395 02a 1 Cover Electronics Drawer w Sight Glass 5700 00218 62 02b 1 Electronics Control Drawer Assembly 5700 022 0 03 1 T MidThermisterAssembly 857000021222 04 1 Solenoid Combination Cut Off 4810 002 20 11 05 1 T InThermister Assembly 57000021223 O 06 1 Valve Modulating 24v 48100022012 O 07 1 Spark Probe Igniter 668000212204 08 1 Heat Exchanger coppe 5700 002 2 50
29. oceeding any further The wash tub must be completely filled before operating the wash pump to pre vent damage to the component Once the wash tub is filled the unit is ready for operation The water level was set at the factory If the water level is not at the level noted above it will require adjustment Check to ensure that the recommended water pressure is being supplied to the machine 20 PSI If the water pressure is correct then the fill valve will need adjustment Use the following steps to adjust the cam Turn power off at the machine circuit breaker Open the control box cover Locate the timer fill valve cam Cam 4 from the timer motor Locate the spanner wrench taped to the electrical panel The spanner wrench is used to adjust the cam WARE PREPARATION Proper preparation of ware will help ensure good results and less re washes not done properly ware may not come out clean and the efficiency of the dishma chine will be reduced It is important to remember that a dishma chine is not a garbage disposal and that simply throwing unscraped dishes into the machine simply defeats the purpose altogether of washing the ware Scraps should be removed from ware prior to being loaded into a rack Pre rinsing and pre soaking are recomended especially for sil verware and casserole dishes Place cups and glasses upside down in racks so that they do not hold water during the cycle The dishmachine is meant not only to clean but to s
30. orresponds to the machine data plate This machine is equipped with a 1 2 female line for connection of gas The gas line used should be of the type approved for use with natural gas or propane depending on the gas selected to be used in this machine The gas line should be sized to carry the maximum flow of 55 000 BTUs Too small of a gas line will result in poor performance A manual gas shut off valve must be installed in the gas line located within an accessible area of the machine The gas line should be kept as short as possible and installed in a way to protect it from damage When making pipe connections use an AGA approved pipe dope being careful not to use excessive amounts as to foul the gas valve or clog the gas line When tightening the gas line always support the gas valve to avoid damage to the gas train When making the connection to the booster unit take care to start the gas line fitting by hand and tighten by hand to avoid cross thread ing Tighten fitting with a wrench taking care not to damage any internal components of the unit After making a final connection of gas with power to the unit turned off check all gas line fittings for leaks using a liquid test solution WARNING ENSURE THAT THERE IS NO ELECTRICAL POWER APPLIED TO THE MACHINE WHEN MAKING GAS CONNECTION CHECK ALL GAS CONNECTIONS FOR LEAKS PRIOR TO APPLYING POWER THE GASES USED FOR COMBUSTION IN THIS DISH MACHINE ARE HIGHLY FLAMMABLE DO NOT SMOKE AROUND T
31. pending on the voltage it is getting from the control board From time to time it may be necessary to check or adjust the setting of this water tem perature To test the setting or to reset the temperature of the rinse water make sure the unit is on and the green LED on the board is flashing steadily Insert the NEGATIVE Black Common probe of a multi meter set on DC volts in the BLACK test point see above Insert the POSITIVE Red probe of the multi meter in the BLUE test point The reading will indicate the set point temperature The fac tory setting is 4 25 VDC which corresponds to 198 F 92 C Adjustments to the set point are made on the BLUE POTENTIOMETER directly below the BLUE test point With a very small slotted screwdriver rotate the trim screw on the potentiometer clockwise CW to increase the voltage and Temperature and counterclockwise to decrease TESTING THE THERMISTORS TEP Fl CONMECDOHE TOUT X Te E GEL ERA IK TE bud BLUE AL FMECDON Vue pad AME There are two thermistors that are used in controlling the temperature of the water in the heat exchanger system The T in that sam ples the temperature of the water going into the heat exchanger and the T Mid that samples the temperature halfway through the heat exchanger The Control Board constantly monitors the temperature at the T Mid Thermistor an
32. should only be performed by a qualified service techni cian Many of the tests require that the unit have power to it and live electrical components be exposed USE EXTREME CAUTION WHEN TESTING THE MACHINE Symptom Dishmachine fills continuously only when the power is on Dishmachine runs with the door open Low wash water pressure Faulty fill microswitch Cam timer stalled in fill position Shorted out ON FILL switch Shorted defective liquid level control board or probe Door switch shorted out wired incorrectly Faulty wash relay wash relay welded closed Faulty control relay Water level is too low Pump intake strainer is clogged Replace microswitch If cam timer is not rotating check the voltage to the motor If voltage is correct replace timer Check the voltage across the switch If the voltage is incorrect replace the switch Check voltage going to each component and ensure they are wired correctly If satisfactory replace the defective part Check the wiring of the door switch if correct replace the door switch Turn machine off if wash relay doesn t release replace contactor Measure the continuity between terminals 6 and 9 If there is no continuity replace the relay Check to ensure that the drain stopper is in and has an O ring Check to ensure that the LLC board and probe are functioning properly Remove and clean strainer TROUBLESHOOTING SECTION
33. t wash tank temperature from exceeding 170 76 67 C during normal operation the wash tank will self regulate between 150 165 65 56 73 89 However when idle the temperature in the wash tank will slowly rise towards booster tank temperature until the temperature reaches 170 F 76 67 C The wash tank thermostat will cycle the heat exchanger amp recirculating pump off When the wash tank temperature lowers the heat exchanger and recirculating pump will energize This will continue during all idle time At any time that the unit is placed into operation the wash temp relay will energize and immediately power the heat exchanger and the recirculating pump regardless of the thermostats position Excessive high temperatures in the system are avoided by the following 1 high temperature limit control by input from T mid thermistor 2 energy cutoff temperature lockout ECO by means of a bi metallic switch independent of the microprocessor which will break voltage to the combination gas cutoff valve if temperature in the system exceeds 210 F 98 89 Excessive high pressures that potentially could be created in the system are vented directly to atmosphere by means of the rinse booster tank and rinse arms THERMOSTAT ADJUSTMENT PROCEDURE 1 Start up unit 2 Allow to fill and start warm up 3 Turn thermostat trim screw Counter Clockwise CCW 2 full revolutions 4 Allow wash temperature to reach 170 F on Wash Temperature Ga
34. ts T set too low Check T set is at 4 25 VDC Obstruction in gas burners or gas nozzles Remove burner manifold and check for obstructions Control board damaged Replace control board Exhaust contains dark smoke Incorrect gas nozzles for type of gas being Remove burner manifold and check correct used nozzle orifice size Gas leak may be present Check for localized large yellow flame or a flame located above the burner Obstruction in heat exchanger vent or air Check for obstructions intake Ignition attempt with flame already burning Flame proofing not occurring Check ignition wire Check that lights above connection point to DSI are dimly lit proofing signal is present Heat exchanger and recirculating pump de Failure or incorrect setting of thermostat Back thermostat CCW one full turn and energize at end of rinse cycle with wash restart unit When cycle completes set tank temperature below 170 F 76 67 C thermostat to 170 F 76 67 C by turning CW DIMENSIONS DIMENSIONS LEGEND LETTER DIM IN DIM CM LETTER DIM IN DIM CM 6 15 24 LEGEND A DRAIN 1 1 2 1 5 B WATER INLET 3 4 I P S C ELECTRICAL CONNECTION D STANDARD WALL CLEARANCE WITH DISHTABLE IS 4 10 16cm E GAS INLET 2 1 2 6 35 2 1 2 6 35 cC IO0Ommoou ANDOVOZSEFA TABLE DIMENSIONS DIM IN DIM CM 4 MIN 10 16 MIN 2
35. uge 5 Turn thermostat trim screw Clockwise CW until flashing Green LED on control board turns off The recirculating pump will also turn off 6 To ensure that the trim screw has not been turned too far CW turn CCW very slowly until Green LED turns on and once again turn CW very slowly until Green LED goes out 7 Start normal operation and monitor wash tank temperature 8 If readjustment is needed repeat steps 5 7 until wash tank temperature maintains at 170 F 76 67 C during idle time AUTO CALIBRATION PROCEDURE Model TEMPSTAR GP amp TEMPSTAR TGP This procedure must be completed every time you replace either a control board or a modulating valve AUTO CALIBRATION Turn the unit OFF at the main power switch and let stand for one minute Remove the lower front panel and set aside Remove the cover of the rectangular control box Locate the control board see figure 1 Locate and remove the jumper labeled ACAL see figure 1 from the control board Be careful to remove metal jumper not just the plastic insulator Make a note of the exact position the jumper was located Set jumper aside for later reinstallation With your multi meter set on DC volts attach to the molex plug going to the modulating valve NOTE Do not disconnect molex plug Insert probes in the rear of one side so the contact is made with the metal pins inside of the plug see figure 2 Turn dishmachine ON Burner will ignite and run through
36. voltage total amperage load and seri al number To install the incoming power lines open the control box This will require taking a phillips head screwdriver and removing the one 1 screw on the front cover of the control box Install 3 4 conduit into the pre punched holes in the back of the control box Route power wires and connect to power block and grounding lug Install the service wires L1 amp L2 to the appropriate terminals as they are marked on the terminal block Install the grounding wire into the lug provided Tighten the connections and perform the pull test The tightened wires should remain in place after giving the wires a moderate pull to see if they will come loose It is recommended that DE OX or another similar anti oxidation agent be used on all power connections VOLTAGE CHECK Ensure that the power switch is in the OFF position and apply power to the dishmachine Check the incoming power at the terminal block and ensure it corresponds to the volt age listed on the data plate If not contact a qualified service agency to examine the problem Do not run the dishmachine if the voltage is too high or too low Shut off the service breaker and mark it as being for the dishmachine Advise all proper personnel of any problems and of the location of the service breaker Replace the control box cover and tighten down the screws GAS CONNECTION It is very important that the type and inlet pressure of the gas used c
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