Classeq CST Engineer'S Manual Download Page 1

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ENGINEERS MANUAL

CST MACHINES AND DRYER UNIT

Drawn up: 05/10/2018

Document number : 30008893

Page 1 of 48

Revision: C

CST Machines

Summary of Contents for CST

Page 1: ...ENGINEERS MANUAL CST MACHINES AND DRYER UNIT Drawn up 05 10 2018 Document number 30008893 Page 1 of 48 Revision C CST Machines ...

Page 2: ...ENGINEERS MANUAL CST MACHINES AND DRYER UNIT Drawn up 05 10 2018 Document number 30008893 Page 2 of 48 Revision C ...

Page 3: ...ine Specifications 6 4 Installation Instructions 7 5 Know your unit 7 6 Warning and safety information 9 7 Site requirements 10 8 Commissioning Instructions 14 9 Water Systems 18 10 Electrical Component Data 19 11 Changing orientation 20 12 Speed setting 24 13 Setting basket arm 26 14 Machine wiring and layout 27 15 Dryer unit wiring and layout 41 16 Trouble shooting 46 ...

Page 4: ...nuine Classeq spare parts failure to do so could invalidate any warranty and relieve the manufacture of all liability Modification Classeq reserves the right to modify either the appliance or the contents of these instructions without notice CAREFULLY READ THESE INSTRUCTIONS BEFORE INSTALLING AND OPERATING OR REPAIRING THIS APPLIANCE INCORRECT INSTALLATION ADAPTATIONS OR ALTERATIONS COULD RESULT I...

Page 5: ...socket 8 0mm Spanner nut runner socket 10 0mm Spanner nut runner socket 13 0mm Spanner nut runner socket 24 0mm Spanner nut runner socket 32 0mm Spanner nut runner socket 10mm to 18mm Adjustable spanner Pliers 2 5mm Hex key 3mm Hex key No 2 Pozi screw driver Electric screw driver small Flat bladed screw driver large Wire cutters Wire crimpers Multi meter capable of measuring Volts 10V 240V AC Amps...

Page 6: ...evel 170 240mm Required water pressure 2 4 bar Maximum drain height from floor 270 320mm Drain size Ø40 Amps required 3 phase Water fed 40 C 32A Water fed 10 C 45A Total connected load Water fed 40 C 13 74kW Water fed 10 C 25 74kW Operating voltage 380 415V Wash tank element 2x6kW Rinse boiler element 4x6kW Rinse boiler capacity 7Lts Wash pump power 1 1kW Wash tank capacity 80Lts Wash water operat...

Page 7: ...ance is stable with its weight being distributed equally and does not tilt more than 3 in any direction Adjuster feet After removing the machine from the transport pallet ensure all the feet are adjusted to suit the surface where the appliance is being installed For further instructions see installation and operation manual 5 Know your unit Machine layout Take note of safety information regarding ...

Page 8: ...RS MANUAL CST MACHINES AND DRYER UNIT Drawn up 05 10 2018 Document number 30008893 Page 8 of 48 Revision C Dryer unit layout Dryer cassette Blower unit Dryer element Dryer thermostat Blower terminal block TB4 ...

Page 9: ...y the Manufacturer s Warranty Children should be supervised to ensure that they do not play with or operate the machine When disconnecting your machine from the mains electrical supply Machines hard wired i e no plug this must be disconnected in accordance with local and national regulations Classeq recommends this is performed by a qualified electrician Always remove excess food from the dishes b...

Page 10: ...s Dishwashers CST With dyer Machine mm A width mm 1300 2000 B depth Closed mm 810 Open mm 1490 C height mm 1380 1440 1730 1790 Basket size mm square basket 500 Load capacity dishes 18 Load capacity pint glass 30 Basket rate Baskets hour 100 130 Rinse running water temperature 82 C Rinse standby water temperature 60 C Wash water temperature 55 C B C A B ...

Page 11: ...at bottom of the appliance to the rear this is in addition to the earthed electrical supply Prior to connecting the appliance ensure voltage and supply fuse comply with rating plate Electrical rating Note Electrical supply can be either side of the appliance The appliance not supplied with the electrical plugs If the supply cable is damaged it must be replaced by a cable or cord assembly supplied ...

Page 12: ...e pressure harness and choice of chemicals For the longevity of any water related devices and to ensure you get consistently good results it is essential your machine is either fed from a soft water supply or your Classeq appliance is connected to an appropriate water softener Note Water supply can be either side of the machine IMPORTANT All supplier warranties are void if lime scale is present wi...

Page 13: ...ites drain is from the floor surface the machine sits upon MUST be within the following Waste hose must flow down from the waste outlet to the drain Joint between standpipe and waste hose must be water tight If you have any doubts about the drainage system on the machine please contact either Classeq or your dealer agent Terminal block layout Terminal block TB1 configuration Mains supply Drainage ...

Page 14: ...al block is provided on right hand side of the wash tank for connecting the electrics of the chemical pumps Note Isolate the machine prior to the access and connection of the chemical pump terminal block WARNING Only rinse aids and detergents developed for commercial glass and dishwashers are to be used rinse aids must be suitable for water temperatures down to 40 C Terminal block configuration Ch...

Page 15: ...ut have been pre set to Dryer air temperature ST4 60ºC The manual reset safety thermal trips on the machine are set to the following values and cannot be adjusted Wash tank 85 C Rinse boiler 95 C Air blower 85 C Table end limit switch It is very important that the table end limit switch be installed at the end of the exit table and the arm adjusted so that it is activated by the basket before it r...

Page 16: ...018 Document number 30008893 Page 16 of 48 Revision C This switch will stop the machine when activated allowing the operator time to remove the clean baskets before more baskets are pushed through the machine Min 50mm Adjustable 20 70mm Cable gland Terminal block ...

Page 17: ...the rinse boiler and reduces the current required Cold fill 45A per phase Hot fill 32A per phase Installing the splash guard only if not dryer fitted Once the machine has been installed and all tabling has been aligned the splash guards should be fitted to the exit of the machine Remove the 3x M5 screws on either side of the exit and use these to fasten the splash guard in place Align the splash g...

Page 18: ...ENGINEERS MANUAL CST MACHINES AND DRYER UNIT Drawn up 05 10 2018 Document number 30008893 Page 18 of 48 Revision C 9 Water Systems Rinse system Also used for filling the wash tank Wash system ...

Page 19: ...0 leg 26 42 leg Wash elements 2 x 3x2kW 230 50 60 8 7 leg 2000 leg 26 42 leg Rinse pump 220 240 50 1 2 Running 250 Wash pump 380 415 50 2 8 1100 Drive motor 380 415 50 1 23 370 Contactors 220 240 50 Timer 220 240 50 Relays Finder 220 240 50 Indicator lamps White LED 220 240 50 60 Amber 220 240 50 60 Blue 220 240 50 60 Red 220 240 50 60 Air pressure switches 220 240 50 60 Temperature display 220 24...

Page 20: ...om panels in order to get access to wash and rinse hoses When changing the direction of the CST care must be taken not to misplace or damage the sealing O rings 11 1 Changing wash and rinse arms system Remove the wash arms and cassette from the machine Remove wash arm brackets and fixing tubes Take note shorter fixing tubes used at bottom and longer fixing tube used at top Remove rinse arm hose fr...

Page 21: ...nd fasten into place Fit rinse hose to rinse bushes and tighten jubilee clips Fit blanking covers into remaining holes Fit rinse and wash arm brackets Note fixing ring orientation Fit wash arms Move curtain bracket to front edge of entry side of machine 5 The below image shows the orientation of the wash arms rinse arms and blanking covers for both directions of travel Caution Classeq recommend th...

Page 22: ...tations in the machine as show below Orientation 1 Pointing directly down Orientation 2 Tilted slightly inward from entrance Orientation 3 Pointing directly up Orientation 4 Tilted slightly outward towards entrance The above orientations are used in the assembly of the wash arms as below Top wash arms shown with entrance to the left Bottom wash arms shown with entrance to the left Left to right Ri...

Page 23: ...o move the baskets in the required direction Remove the nuts holding centre plate Relocate the centre plate to opposite side of cassette assembly and fasten it with nuts Ensure centre plate is fitted to the correct speed setting 10 Place cassette assembly back into machine and fasten into place with the fixing screws Fit the curtains back into machine Turn on all electrical supplies to your machin...

Page 24: ...ng remove cassette assembly from the machine and follow the steps below Step 1 Remove 4x M5 nuts holding centre plate F then re locate centre plate F to the correlating stud and tighten it back with the 4 x M5 nuts Step 2 Loosen the 2 nuts attached to the slot of speed adjustment plate G on each side Then remove socket button head screws M5x12 and M5 nuts from the hole and re locate it to required...

Page 25: ...ed setting onto drive plate J and tighten the bolt I Rotating cap J Drive plate Step 4 Place cassette assembly back into the machine as follow Ensure centre plate F fits onto rotating cap I and plastic guides H sit into the drive rail K properly K Drive rail Caution It is very important to follow the steps failure to it will lead to potential damage to the cassette assembly If in doubt then contac...

Page 26: ... by the machine or are causing the machine to stop in the cylce then the arm can be adjusted to suite these At the right hand side of the basket arm is a bracket to allow for adjustment 1 Isolate the machine 2 Insert the off sized basket into the centre of the machine 3 Remove the M3 screw and nylock nut 4 Rotate the magnet arm so that the hooked end is in line with the bend in the cabinet 5 Find ...

Page 27: ... layout Rinse heater contactors CT1 CT2 Wash heater contactors CT3 CT6 Rinse heater contactors CT4 CT5 Three phase breakers 1 3 25A Three phase breaker 4 6A Breaker 5 6A Timer TM1 On Off relay RL1 Door relay RL2 Wash pump relay RL3 Machine full relay RL4 Basket present relay RL5 Drive motor relay RL6 Wash heater relay RL7 Timer TM2 Control Panel RC Filter Timer TM3 ...

Page 28: ... 48 Revision C Front panel Z On Off switch On Off lamp L1 Double Red Double Blue Pump running lamp L2 Heating lamp L3 Error lamp L4 Purple Brown Double Blue Double Blue Brown Brown Double Blue Orange L N Wash temperature Double Red Double Blue L N Rinse temperature Double Red Double Blue Orange Brown ...

Page 29: ... motor relay RL6 25A Breaker 1 Incoming wire from terminal block TB1 Out going wire to heating contactor CT1 Incoming wire from Terminal block TB1 Out going wire to heating contactor CT1 Incoming wire from Terminal block TB1 Out going wire to heating contactor CT1 Breaker 2 Incoming wire from Terminal block TB1 Out going wire to heating contactor CT2 Incoming wire from Terminal block TB1 Out going...

Page 30: ...be used Default 2m 2 minutes Time Adjust time within time segment Default 20 Full Timer type Select type of timer Default BE On delay DO NOT CHANGE Delay timer TM2 A2 Neutral from Terminal block TB1 A1 Incoming wire from Door relay RL2 B1 Incoming wire from Basket switch Sw4 18 To Basket pressent relay RL5 15 From timer TM2 Time segment Select time segment to be used Default 2m 2 minutes Time Adju...

Page 31: ...Neutral from Terminal block TB1 A1 From CB5 B1 From on off switch 18 To Basket pressent relay RL5 16 To Control circuit 15 From timer TM2 Time segment Select time segment to be used Default 20s 20 seconds Time Adjust time within time segment Default 5 Quarter 5 Seconds Timer type Select type of timer Default BE On delay DO NOT CHANGE ...

Page 32: ...s Rinse heating contactor CT1 Rinse heating contactor CT2 Wash heating contactor CT3 Red Blue Brown Black Grey Brown Black Grey Red Blue Brown Black Grey Brown Black Grey Red Blue Brown Black Grey Brown Black Grey A1 A2 2T1 4T2 6T3 14NO 1L1 3L2 5L3 13NO A1 A2 2T1 4T2 6T3 14NO 1L1 3L2 5L3 13NO A1 A2 2T1 4T2 6T3 14NO 1L1 3L2 5L3 13NO ...

Page 33: ...ing contactor CT4 Rinse heating contactor CT5 Wash heating contactor CT6 Grey Blue Brown Black Grey Brown Brown Black Grey Red Grey Brown Black Grey Brown Brown Black Grey Red Purple Brown Black Grey Brown Brown Black Grey Red A1 A2 2T1 4T2 6T3 14NO 1L1 3L2 5L3 13NO A1 A2 2T1 4T2 6T3 14NO 1L1 3L2 5L3 13NO A1 A2 2T1 4T2 6T3 14NO 1L1 3L2 5L3 13NO ...

Page 34: ... pump Relay RL3 Red cover Black cover White cover Green cover Purple Purple Red Blue White Black Orange Red Purple Purple Brown Orange Blue Black Grey Grey Black Purple Purple Grey Blue 22 32 24 34 21 31 12 14 11 A1 A2 22 32 24 34 21 31 12 14 11 A1 22 32 24 34 21 31 12 14 11 A1 A2 Normally closed Normally open Common Coil A2 Red cover Black cover White cover Green cover ...

Page 35: ...lay RL1 Purple Purple Brown Blue White Grey Orange Black Black Brown Brown White Blue Black Grey Grey Black Purple White White Blue Red White 22 32 24 34 21 31 12 14 11 A1 A2 22 32 24 34 21 31 12 14 11 A1 22 32 24 34 21 31 12 14 11 A1 A2 Normally closed Normally open Common Coil A2 Red cover Black cover White cover Green cover Red cover Black cover White cover Green cover Blue Brown White From SW3...

Page 36: ...Document number 30008893 Page 36 of 48 Revision C Machine Filters 1 Suppression filter 4 Amp 2 RC Filters Brown Blue Black Blue P P1 N1 N E Yellow Earth CT4 CT5 Rinse heating contactor CT6 Wash heating contactor Grey Purple Blue Blue To CB5 From TB1 From TB1 From TB1 ...

Page 37: ...ng Rinse standby thermostat ST1 Rinse run thermostat ST2 Wash thermostat ST3 Grey Orange 2 4 1 2 Grey Black Red cover Normally Closed Black cover Normally Open White cover Common 4 1 Red cover Black cover White cover Red cover Black cover White cover 2 4 1 Red cover Normally Closed Black cover Normally Open White cover Common Purple White ...

Page 38: ...n C Machine options Selection Table end switch CC4 and CC5 connector plug Basket present switch SW4 connector plug Motor clutch switch SW2 connector plug Door switch SW3 connector plug Purple Black Grey Blue Brown Red Red Red Brown Red Grey Red Brown Common Air break Pressurised Purple Brown Brown Grey Red White ...

Page 39: ...let Solenoid Valve Rinse safety Thermostat 95 C Wash safety Thermostat 85 C Wash Air pressure Switch Rinse Air pressure Switch Rinse Pump Wash pump Drive motor 11 14 12 22 24 21 Purple Black Blue Wire White Crimp Grey wire White Crimp Blue Wire White Crimp Double blue Wire White Crimp Blue Wire White Crimp Double blue Wire White Crimp 11 14 12 22 24 21 Grey Red Red Brown U1 V1 W1 U1 V1 W1 Purple B...

Page 40: ...ent wiring 6kW Rinse elements using LM CST HEATING Element 1 2 3 4 6kW Wash elements using LM CST HEATING Element 5 6 Temperature probes Brown wire Thick Black wire Thick Grey wire Thick Brown wire Thick Black wire Thick Grey wire Thick Temperature gauge Running temperature 82 85 degrees Standy Temperature 55 58 degrees ...

Page 41: ...DRYER UNIT Drawn up 05 10 2018 Document number 30008893 Page 41 of 48 Revision C 15 Dryer unit wiring and layout Dryer control panel layout Tempraure rdfd Air heater relay RL8 Heater safety relay RL9 Blower relay RL10 Dryer breaker CB6 ...

Page 42: ...ND DRYER UNIT Drawn up 05 10 2018 Document number 30008893 Page 42 of 48 Revision C Dryer terminal block TB3 Earth 1 5mm Black 0 5mm Orange 0 5mm White 0 5mm Grey 0 75mm Black 0 75mm Brown 0 75mm White 1 5mm Purple 1 5mm Brown 1 5mm ...

Page 43: ... 7 8 9 10 11 12 13 14 15 Blue Brown Black White White Earth Red Grey Orange To blower motor Dryer breakers Type Breaker size Breaker number Wire colour Connection configuration 16A Breaker 6 3 phase breaker Incoming wire from Terminal block TB3 Out going wire to Drive motor relay RL8 Incoming wire from Terminal block TB3 Out going wire to Drive motor relay RL8 Incoming wire from Terminal block TB3...

Page 44: ...d cover Black cover White cover Green cover Brown Brown Black Blue Purple White White Purple Brown Brown Black Blue Black Grey Grey Black Brown Brown Orange Blue Grey White 22 32 24 34 21 31 12 14 11 A1 A2 22 32 24 34 21 31 12 14 11 A1 22 32 24 34 21 31 12 14 11 A1 A2 Normally closed Normally open Common Coil A2 Red cover Black cover White cover Green cover Orange White 1 Red cover White cover 2 P...

Page 45: ... Page 45 of 48 Revision C Dryer safety thermostat Rinse safety Thermostat 100 C Dryer elements 6kW Delta connection Red Wire White Crimp Black Wire White Crimp Dryer Element 2 E8 Dryer Element 1 E7 White wire from TB3 Purple wire from TB3 Brown wire from TB3 Black wire Brown wire Grey wire ...

Page 46: ...heck water supply tap is fully open Check water supply hose is not trapped or kinked Check water supply pressure and remove any pressure regulator or reducer Check and clean rinse jets located on the rinse arms within the machine Check drain plug securely fitted and sealing Check the correct flow restrictors are fitted o Purple 4l min in rinse hose o Orange 8l min in solenoid IV Machine not heatin...

Page 47: ...ff relay RL1 X Basket not moving Check for obstructions on the drive rail and at the drive plate Check cassette is fitted correctly and flat Check that machine error lamp is not illuminated Check breaker 4 is ON Check both timers are opperating Check drive motor relay RL5 XI Machine stopping and starting while in a cycle Check water supply hose is not trapped or kinked Check water supply tap is fu...

Page 48: ...05 10 2018 Document number 30008893 Page 48 of 48 Revision C Classeq Ltd Winterhalter House Roebuck Way Knowlhill Milton Keynes MK5 8WH Spares department 0844 225 9252 spares classeq co uk Service department 0844 225 9245 service classeq co uk Classeq Ltd ...

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