Jackson RackStar 44 Installation, Operation And Service Manual Download

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RACKST

RackStar

Manual • Rev B • 07610-004-33-05 • Issued: 9-21-2016 • Revised: 10-25-16

INSTALLATION, OPERATION,

AND SERVICE MANUAL

RACKSTAR

SERIES CONVEYOR DISHMACHINES

Summary of Contents for RackStar 44

Page 1: ...RACKSTAR RackStar Manual Rev B 07610 004 33 05 Issued 9 21 2016 Revised 10 25 16 INSTALLATION OPERATION AND SERVICE MANUAL RACKSTAR SERIES CONVEYOR DISHMACHINES...

Page 2: ......

Page 3: ...mproper installation if serial number has been removed or altered or if unit is used for a purpose other than originally intended TRAVEL LIMITATIONS Jackson WWS limits warranty travel time to 2 two ho...

Page 4: ...B 10 25 16 JH N A Corrected delime instructions Corrected P Ns for item 6 on pg 42 Updated pg 13 to change the pressure regulator from standard to optional Updated Miscellaneous Electrical Components...

Page 5: ...ical support staff Please have this manual with you when you call so that our staff can refer you if necessary to the proper page Technicalsupportisnotavailable on holidays Contact technical support t...

Page 6: ...uench Kit Instructions 19 Operating Instructions 21 Display Instructions 24 Delime Instructions 25 MAINTENANCE Preventative Maintenance 26 TROUBLESHOOTING Common Problems 27 Display Programming 29 Fau...

Page 7: ...ng Coil Assembly 58 Booster Heater Option Electric 59 Frame Assembly 60 Door Assemblies 61 Miscellaneous Parts 62 SCHEMATICS Booster Heater 3 Phase 63 Booster Heater 1 Phase 12 kW 64 Booster Heater 1...

Page 8: ...eference data plate important note i caustic chemicals ABBREVIATIONS ACRONYMS ANSI American National Standards Institute CFM Cubic Feet per Minute GHT Garden Hose Thread GPM Gallons per Minute GPG Gra...

Page 9: ...nection Provided on both sides of unit 2 Water Inlet 1 2 NPT 180 F 3 Drain Connection 1 1 2 NPT 4 Vent Connections Including Dampers 4 101 6 mm 4 101 6 mm ADJUSTABLE FROM 51 1 2 TO 54 1308 1 mm TO 137...

Page 10: ...ion Provided on both sides of unit 2 Water Inlet 1 2 NPT 180 F 3 Drain Connection 1 1 2 NPT 4 Vent Connections Including Dampers 5 127 0 mm 8 203 2 mm 4 101 6 mm 4 101 6 mm ADJUSTABLE FROM 51 1 2 TO 5...

Page 11: ...1740 mm 4 MIN 102 mm 31 15 16 811 mm 63 1600 mm 61 3 8 1559 mm 4 3 4 120 mm 6 11 16 169 mm 18 5 16 465 mm 28 7 16 722 mm 25 1 4 642 mm 3 1 2 4 4 5 5 1 2 3 ADJUSTABLE FROM 73 1 2 76 1867 1930 mm 1 Ele...

Page 12: ...FDQ EH LQFUHDVHG 1 3 4 using the machine s adjustable feet 68 1 2 1740 mm 4 MIN 102 mm 31 15 16 811 mm 63 1600 mm 61 3 8 1559 mm 4 3 4 120 mm 6 11 16 169 mm 18 5 16 465 mm 28 7 16 722 mm 25 1 4 642 m...

Page 13: ...E LOADER DRAIN HOSE SIDE LOADER DRAIN HOSE 23 L R UNHOODED SIDE LOADER 23 R L UNHOODED SIDE LOADER VENTILATION SCOOP VENTILATION SCOOP VENTILATION COWL WITH CUTOUT FOR R L UNITS VENTILATION COWL WITH...

Page 14: ...1 1 8 in 22 in 33 8 in 193 8 in 201 8 in 285 8 in 201 4 in W1 S W2 PS PW 33 69 11 3 8 in 22 in 71 2 in E E E E MAIN ELECTRICAL CONNECTION 7 8 DIA HOLE W1 MAIN INLET WATER CONNECTION 3 4 NPT F W2 WATER...

Page 15: ...6 35 6 35 6 Pre Wash Tank N A 15 8 N A 15 8 Electrical Loads as applicable Wash Motor HP 3 0 3 0 3 0 3 0 Drive Motor HP 0 25 0 25 0 25 0 25 Pre Wash Motor HP N A 2 0 N A 2 0 Wash Heater kW 15 15 N A N...

Page 16: ...mum Rinse Temperature 120 120 120 120 Incoming Water Temperature 12 kW Booster 80 80 N A N A 18 kW Booster 50 50 N A N A No Booster 120 120 120 120 Other Water Requirements Water Flow Pressure PSI 15...

Page 17: ...umes incoming voltages will be either 208 230 or 460 Volts Some of the heating elements used in our machines are actually rated for other voltages such as 240 or 480 Volts Always verify the amperage d...

Page 18: ...0 1 60 10 0 1 8 59 9 71 7 208 3 60 8 6 1 1 41 6 51 3 230 3 60 8 4 1 1 34 6 44 1 460 3 60 4 2 0 6 17 3 22 1 44 Volts Phase Hz Wash Motor Amps Drive Motor Amps Total Load 208 1 60 10 0 1 8 11 8 230 1 60...

Page 19: ...10 0 1 8 22 0 230 1 60 9 4 10 0 1 8 21 2 208 3 60 6 2 8 6 1 1 15 9 230 3 60 9 4 10 0 1 1 20 5 460 3 60 3 2 4 2 0 6 8 0 66 Steam Volts Phase Hz Rinse Heater Amps 208 1 60 57 7 230 1 60 47 9 208 3 60 33...

Page 20: ...ng the incoming water lines are flushed of debris before connecting to the machine Note that chips and materials from cutting processes can become lodged in the solenoid valves and prevent them from o...

Page 21: ...e load and serial number If a data plate has been damaged and cannot be read contact the manufacturer The main power terminal blocks for the dishmachine and for the rinse booster heater if applicable...

Page 22: ...EM For the dishmachine to operate correctly connect it to a third party chemical dispenser that meets the requirements of NSF Standard 29 Contact a chemical supplier about connecting a dispenser to th...

Page 23: ...lkhead Opening for Conductivity Probe Drain Connection Adjustable Feet Drain Connection Booster Heater Electrical Opening provided on both sides of unit Detergent Connection Point Main Electrical Open...

Page 24: ...EN MACHINE POWER SWITCH IS ON LIVE WHEN RINSE VALVE IS OPEN LIVE WHEN WASH PUMP MOTOR IS ON L1 L2 3 AMP MAX L1 L2 3 AMP MAX L1 L2 3 AMP MAX TIMER L1 L2 N Contactor customer provides Fuse Block Exhaust...

Page 25: ...L S XL Load Unload IMPORTANCE OF PROPER CURTAIN PLACEMENT The curtains inside the dishmachine must be installed properly for the machine to operate correctly Curtains are used to control air currents...

Page 26: ...might be required in some areas Turn off the power supply and place the dishwasher disconnect if applicable in the off position Lockout tag out to prevent the power supply from being turned back on ac...

Page 27: ...ater to inlet side of solenoid valve DRAIN QUENCH SYSTEM IF THERE ARE ANY ISSUES AFTER INSTALLATION PLEASE CONTACT TECHNICAL SERVICE AT 1 888 800 5672 5 Secure all electrical ensure connection is to 1...

Page 28: ...for the mode of operation the wash heater will energize Refer to the machine data plate for a better understanding of the minimum temperatures needed to operate the unit correctly It might take sever...

Page 29: ...ne This dishmachine is designed to wash ware that is placed in a rack Materials should not be placed in the unit unless they are properly secured in a dish rack To start the cycle gently push the rack...

Page 30: ...e removed and debris scooped out Do not hit strainers to remove debris this can cause them to warp and not seat correctly Rinsing the strainer under water should remove the rest of any debris trapped...

Page 31: ...h the rinse section 1 When main power is first connected to the unit the digital display will sequence through its LEDs to show all are functional 2 The unit will then go into Standby Mode blank displ...

Page 32: ...for the length of time recommended by the chemical supplier 5 Press the START button to shut the unit off 6 Wait five minutes then inspect the inside of the machine If the machine is not delimed run a...

Page 33: ...f reasons why your water temperature could be too low 2 Ensure that all strainers are clean and in place laying flat before operating the machine When cleaning out strainers do NOT beat them on waste...

Page 34: ...ash motor contactor faulty 1 Verify that the wash motor is getting power if so replace the motor 2 Check for continuity if contacts are open replace the contactor Dishmachine runs continuously in the...

Page 35: ...the seal 2 Close or tighten 3 Tighten the hose clamps Will not rinse 1 Defective rinse solenoid 2 Faulty timer 3 No water to the machine 1 Repair or replace the rinse solenoid 2 Replace timer 3 Verif...

Page 36: ...terrupt the process The programming Keys Up arrow Down arrow and Select are hidden on the display and are shown below outlined with red dots 1 Press and hold the I and II Keys until Program starts fla...

Page 37: ...of the IO module and UI board 3 Use the Up arrow Key to cycle through the categories will be flashing Language Wash Offset Temperature Scale Rinse Offset Wash Temperature Boost Offset Boost Temperatur...

Page 38: ...re probe T1 1 Check for welded contacts Verify that output from IO module turns off when above the set temperature 2 Substitute a 1 2 k resistor for T1 and verify that wash heater turns off If not rep...

Page 39: ...33 05 B FAULT CODES TROUBLESHOOTING TABLE 1 RESISTANCE TO TEMPERATURE VALUES R k F 11 58 69 8 10 37 75 2 9 30 80 6 7 78 89 6 3 05 140 0 2 54 150 8 2 18 159 8 1 58 179 6 1 45 185 0 1 33 190 4 1 16 199...

Page 40: ...ntrol 05945 004 47 81 5 4 Relay KUP14AT5 120 P B 3PO TP MO 05945 111 72 51 6 1 Timer Universal Digital Multi timer 05945 004 22 78 7 1 Overload 05945 111 68 40 8 2 Contactor Wash Motor 05945 111 68 38...

Page 41: ...L COMPONENTS PARTS ITEM QTY DESCRIPTION PART NUMBER 1 4 Nut Thumb 6 32 Nylon 05310 002 83 12 2 1 Board Populated Circuit 05945 004 36 33 3 4 Spacer Display Board 05999 004 19 75 4 1 Panel with Display...

Page 42: ...1 Gasket Suction Casting 05330 003 75 89 4 1 Gasket Pump Suction 05330 003 75 87 5 1 Gasket Heater 05330 200 02 70 6 1 Heater Box Rails 05700 003 74 72 7 1 Wash Pump Suction Weldment 05700 003 77 63...

Page 43: ...5330 003 75 89 2 1 Gasket Pump Suction 05330 003 75 87 3 1 Pre Wash Pump Suction Weldment 05700 003 82 27 4 1 Strainer Pre Wash Pump 05700 003 81 28 4 1 3 2 PUMP SUCTION ASSEMBLY PARTS Pump Suction As...

Page 44: ...21 79 31 05945 002 24 70 460 3 18 04540 121 79 32 05945 002 24 70 SERVICE NOTES When replacing wash heaters it is highly recommended to change the gasket as well Once installed gaskets become compress...

Page 45: ...rass 04730 207 15 00 4 2 Solenoid Valve 1 2 04810 003 71 55 5 1 Tee 1 2 Brass 04730 211 27 00 6 1 Y strainer 04730 217 01 10 7 2 Elbow 1 2 NPT 04730 011 42 96 8 2 Adapter 1 2 Fitting X Male 04730 011...

Page 46: ...Nipple 1 2 Brass 2 Long 04730 207 19 00 7 2 Adapter 1 2 Fitting X Male 04730 011 59 53 8 2 Elbow 1 2 04730 406 31 01 9 1 Union 1 2 04730 412 05 01 10 1 Solenoid Valve 1 2 04810 003 71 55 11 1 Fitting...

Page 47: ...55 4 2 Nipple 1 2 Brass 2 Long 04730 207 19 00 5 1 Vacuum Breaker 1 2 04820 003 06 13 6 1 Elbow 90 degree 1 2 Street Brass 04730 206 08 00 7 1 Wash Fill Injector 05700 003 77 56 8 1 Gasket Rinse Mani...

Page 48: ...41 07610 004 33 05 B 1 2 4 5 4 6 7 13 8 9 14 14 10 11 11 10 12 14 13 3 PARTS WASH MANIFOLD ARM ASSEMBLY 16 15 Mechanical Pump Seal 05330 002 34 22...

Page 49: ...73 66 10 1 Wash Arm Weldment Top right 05700 003 75 79 11 1 Wash Arm Weldment Top left 05700 003 75 80 12 12 Cap Threaded 04730 603 12 00 13 3 O Ring Silicone 103 Dia 2 1 2 x 2 11 16 OD 05330 003 73...

Page 50: ...43 07610 004 33 05 B Mechanical Pump Seal 05330 002 34 22 PARTS PRE WASH MANIFOLD ARM ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 12 13 10 5 7 2 8...

Page 51: ...ing Silicone 139 Dia 2 1 4 ID x 2 1 2 OD 05330 003 73 72 9 1 Pre wash Arm 05700 003 75 79 10 4 Cap Threaded 04730 603 12 00 11 1 Pre wash Arm Lower 05700 003 80 96 12 1 Gasket Pump Discharge 05330 003...

Page 52: ...45 07610 004 33 05 B PARTS RINSE ASSEMBLY 1 2 3 4 5 6 7 8 9 10 11 12 13 8 9 3 6 14 16 15 17 18 17 13 14 19 20 20 21...

Page 53: ...er Male 04730 401 03 01 9 2 Elbow 607 1 2 IN CTOC 04730 406 01 01 10 1 Union 1 2 04730 412 05 01 11 1 Elbow 1 2 NPT 90 Brass 04730 011 42 96 12 1 Fill Injector 05700 004 32 61 13 2 Rinse Manifold 0570...

Page 54: ...5311 004 29 35 4 7 Rack Catch Left 05700 004 15 70 5 7 Rack Catch Right 05700 004 15 71 6 14 Bolt Shoulder 3 8 DIA x 1 4 1 4 20 05306 004 29 34 7 14 Rivet Flat Head 05320 107 21 00 8 1 44 Pawl Bar Wel...

Page 55: ...Nut Lock 1 4 20 Hex w Nylon Insert 05310 374 01 00 3 2 Washer 1 4 20 I D 05311 174 01 00 4 1 End cap Magnet Tube 05700 002 21 36 5 1 Magnet 05930 003 31 63 6 1 End cap Paddle Switch 05700 011 60 92 7...

Page 56: ...49 07610 004 33 05 B PARTS DRIVE ASSEMBLY 10 12 8 7 7 13 6 2 15 4 9 14 17 18 21 23 11 12 13 14 15 16 17 18 19 20 21 22 Drive Assembly 05700 004 29 95 1...

Page 57: ...Drive 3 4 x 3 4 06105 004 29 41 10 1 Drive Plate Cover 05700 004 29 49 11 1 Washer Bonded Sealing 1 4 x 3 4 05311 002 77 79 12 1 Collar Shaft Drive 05700 004 29 45 13 1 Motor Plate 05700 004 19 38 14...

Page 58: ...L ITEM QTY DESCRIPTION PART NUMBER 1 2 Ventilation Cowl 05700 004 34 01 2 2 Ventilation Scoop 05700 004 29 68 3 2 Ventilation Duct Adapter 05700 003 75 73 4 2 Damper Ventilation Scoop 05700 003 74 76...

Page 59: ...Spring 05311 274 01 00 10 3 Bolt 1 4 20 x 1 2 Long 05305 274 02 00 To attach the curtain and rod to the Ventilation Cowl ensure that the curtain is oriented as depicted and follow the steps below 1 I...

Page 60: ...TORS Overloads are specified for 3 phase units only For GE brand MT03 series overloads the process for setting is as follows Determine the FLA for the drive motor Set the overload at the closest setti...

Page 61: ...icts a 23 Right to Left Unhooded Side Loader Differences in parts for the 23 Left to Right and both directions of the 30 Side Loaders are reflected in the parts list NOTE NOTE NOTE Order lengths of Ho...

Page 62: ...16 B 7 16 DETAIL B 21 24 24 20 14 16 14 16 23 16 22 This illustration depicts a 23 Right to Left Unhooded Side Loader Differences in parts for the 23 Left to Right and both directions of the 30 Side L...

Page 63: ...9 14 16 Washer 1 4 S S 05311 174 01 00 15 4 Bolt 1 4 20 x 1 2 Long 05305 274 02 00 16 39 Locknut 1 4 20 Hex w Nylon Insert 05310 374 01 00 17 2 Roller 05700 011 68 16 18 2 SRackStar 1 4 20 x 1 3 4 Lon...

Page 64: ...Pawl Dog w Wing 05700 021 86 79 4 3 Locknut 3 8 16 w Nylon Insert 05310 011 72 55 5 3 Bolt 3 8 16 x 1 3 4 Long Hex Head 05306 011 36 94 6 6 Spacer Pawl Bar Dog 05700 011 71 45 7 3 SRackStar 1 4 20 x...

Page 65: ...Gasket Steam Coil 05700 001 17 86 9 2 Washer Steam Coil Adapter 05700 001 17 87 10 2 Nut Steam Coil Adapter 05310 011 17 85 11 2 Reducer 3 4 x 1 2 Black Iron 04730 911 02 34 12 2 Union 3 4 Black Iron...

Page 66: ...40 V 3 Phase 04540 004 29 77 18 kW 70 F Rise 480 V 3 Phase 04540 004 30 77 18 kW 70 F Rise 208 V 1 Phase 04540 004 29 76 18 kW 70 F Rise 240 V 1 Phase 04540 004 30 78 ITEM QTY DESCRIPTION PART NUMBER...

Page 67: ...eft to Right Machine 05700 004 30 60 3 1 Display See Miscellaneous Electrical Components page 4 1 Front Dress Panel RackStar 44 05700 004 30 44 5 1 Adjustable Foot 05340 011 71 74 6 1 Left Dress Panel...

Page 68: ...ASSEMBLIES ITEM QTY DESCRIPTION PART NUMBER 1 1 Left Door Assembly 04420 002 43 94 2 1 Right Door Assembly 05306 002 89 27 3 4 Bearing Flanged Sleeve 03120 004 39 92 4 2 Door Seal 09330 004 17 41 1 2...

Page 69: ...il Only shown 05700 004 26 87 Rear Rack Rail Entire Assembly 05700 004 26 86 Rail Only shown 05700 004 22 95 Curtain Bracket End 05700 004 21 24 Curtain Bracket Middle 05700 004 32 75 Strainer Wash Ta...

Page 70: ...WING BOOSTER HEATER OPTIONS 208V 60Hz 3 Phase 12 kW 40 Rise 230V 60Hz 3 Phase 12 kW 40 Rise 460V 60Hz 3 Phase 12 kW 40 Rise 208V 60Hz 3 Phase 18 kW 70 Rise 230V 60Hz 3 Phase 18 kW 70 Rise 460V 60Hz 3...

Page 71: ...64 07610 004 33 05 B USE THIS SCHEMATIC FOR THE FOLLOWING BOOSTER HEATER OPTIONS 208V 60Hz 1 Phase 12 kW 40 Rise 230V 60Hz 1 Phase 12 kW 40 Rise BOOSTER HEATER 1 PHASE 12kW SCHEMATICS...

Page 72: ...65 07610 004 33 05 B USE THIS SCHEMATIC FOR THE FOLLOWING BOOSTER HEATER OPTIONS 208V 60Hz 1 Phase 18 kW 70 Rise 230V 60Hz 1 Phase 18 kW 70 Rise BOOSTER HEATER 1 PHASE 18kW SCHEMATICS...

Page 73: ...66 07610 004 33 05 B STEAM BOOSTER HEATER SCHEMATICS...

Page 74: ...K9 K12 K11 P1 P2 P3 P4 P5 P6 P7 P9 P8 P10 P11 P12 P13 P14 P15 R E D B L K B L K 09905 004 35 19 E Programming header Temperature Sensor inputs T4 spare T2 Rinse Injector GRY BLU T1 Wash RED WHT AC sig...

Page 75: ...t AC power in K 1 K2 L1 L2 N Input Assignments I1 Wash I2 Cycle I3 Float I4 Rinse I5 Chemicals BLK DC RTN RED 24 VDC WHT BLK DC RTN 24 VDC CORRESPONDING CONNECTOR TO DISPLAY PCB PN 05945 004 36 33 B L...

Page 76: ...t AC power in K 1 K2 L1 L2 N Input Assignments I1 Wash I2 Cycle I3 Float I4 Rinse I5 Chemicals BLK DC RTN RED 24 VDC WHT BLK DC RTN 24 VDC CORRESPONDING CONNECTOR TO DISPLAY PCB PN 05945 004 36 33 B L...

Page 77: ...70 07610 004 33 05 B SCHEMATICS RACKSTAR SIDE LOADER...

Page 78: ...05 B This page can be copied and the display templates cut out Lay the cut out over the display and use the Up arrow Down arrow and Select Buttons to locate the hidden programming buttons ADDENDUM DI...

Page 79: ......

Page 80: ...73 73 Jackson WWS Inc 6209 N US Hwy 25E Gray KY 40734 USA 1 888 800 5672 www jacksonwws com RackStar Manual Rev B 07610 004 33 05 Issued 9 21 2016 Revised 10 25 16...

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