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DUAL TEMPERATURE, GAS HEATED
DOOR-TYPE DISHMACHINES
TECHNICAL MANUAL
INSTALLATION MANUAL FOR EXPORT UNITS
SERVICE MANUAL FOR DOMESTIC UNITS
FOR JACKSON MODEL:
TEMPSTAR TGP
An Company
Jackson MSC, Inc.
P.O. BOX 1060
HWY. 25E
BARBOURVILLE, KY. 40906
FAX (606) 523-9196
June 24, 2004
PHONE (606) 523-9795
P/N 7610-001-98-99 (Revision C)
www.jacksonmsc.com
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TABLE OF CONTENTS GENERAL PAGE Specifications ............................................................................................. 1 INSTALLATION Unpacking................................................................................................... 2 Plumbing Connections................................................................................ 2 Electrical Connections................................................................................ 2 Gas Connection............
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SPECIFICATIONS OF THE TEMPSTAR TGP PERFORMANCE/CAPABILITIES VOLTS PHASE AMPS OPERATING CAPACITY (RACKS/HOUR) 208 - 240 1 6.7 RACKS PER HOUR 57 DISHES PER HOUR 1425 WATER REQUIREMENTS GLASSES PER HOUR 1425 INLET TEMPERATURE 70 -140°F INLET TEMPERATURE 21.11-60°C OPERATING CYCLE (SECONDS) GALLONS PER HOUR 52.0 WASH TIME 45 LITERS PER HOUR 196.84 RINSE TIME 11 WATER LINE SIZE I.P.S. (Minimum) 3/4” DWELL TIME 2 WATER LINE SIZE I.P.S. (Minimum) 1.9 CM TOTAL CY
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INSTALLATION INSTRUCTIONS VISUAL INSPECTION: Before installing the unit, check the con- In areas where the water pressure fluctuates or is greater than the tainer and machine for damage. A damaged container is an indi- recommended pressure, it is suggested that a water pressure reg- cator that there may be some damage to the machine. If there is ulator be installed. damage to both the container and machine, do not throw away the container. The dishmachine has been inspected and packed at Do not
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GAS CONNECTION It is very important that the type and inlet pressure of the gas used corresponds 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
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OPERATION INSTRUCTIONS PREPARATION: Before proceeding with the start-up of the unit, WARM-UP CYCLES: For a typical daily start-up, it is recom- verify the following: 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 1. The pump intake, and wash tank strainers are in place operating correctly. To cycle the machine, ensure that the power and is clean. is on and that the tub has filled to the correct level. Lift the d
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OVERVIEW OF OPERATION PRESSURE VACUUM BREAKER GAUGE REGULATOR FILL / RINSE SOLENOID RINSE TEMP T >180 °F (82.22 °C) RINSE ARM CHECK VALVE CHECK VALVE WASH TANK WATER LEVEL BOOSTER WL PROBE TANK TS THERMOSTAT WASH TANK T COILS WASH TEMP 150-165 °F (65.56 - 73.89 °C) ECO T-MID HEAT EXCHANGER BURNER RECIRCULATING ASSEMBLY PUMP 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
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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 w
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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 Gauge 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
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AUTO-CALIBRATION PROCEDURE Model: TEMPSTAR GP, & TEMPSTAR TGP This procedure must be completed every time you replace either a control board or a modulating valve. AUTO - CALIBRATION 1. Turn the unit OFF at the main power switch and let stand for one minute. 2. Remove the lower front panel and set aside. 3. Remove the cover of the rectangular control box. 4. Locate the control board (see figure 1). 5. Locate and remove the jumper labeled ACAL (see figure 1) from the control board. Be careful
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ELECTRONICS CONTROL BOARD (ECB) 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 depending on the voltage it is gettin
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TESTING THE THERMISTORS 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 and adjusts the burner pressure by way of the Modulating Valve according to how far away that temperature is away from th
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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 CAL
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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. Symptom Possible Cause Action Dishmachine will not run. No power to the Service breaker tripped. Reset breaker. If breaker trips again, unit. immediately contact an electrician. Incoming power lines n
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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. Symptom Possible Cause Action Dishmachine fills continuously, only when Faulty fill microswitch. Replace microswitch. the power is on. Cam timer stalled in fill position. If cam timer is not rotating,
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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. Symptom Possible Cause Action Low wash water pressure. Wash arms (nozzles) are clogged. Remove wash arms and clean. Pump impeller worn or broken. Replace pump. Water leak in the gas booster pack. Loos
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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. Symptom Possible Cause Action Low rinse temperature/low wash Low inlet water temperature. Ensure incoming water is 110 F (43.33 C) at temperature. incoming point of machine, may need to increase the
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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. Symptom Possible Cause Action 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 cyc
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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. Symptom Possible Cause Action Green LED flashes, but no ignition (igniter Gas flow interrupted. Check manual gas valve is open. sparks, no gas). Check regulated gas pressure. (4.0 -6.0
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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. Symptom Possible Cause Action The unit ignites, but will to rise above T-mid thermistor inoperative. Check T-mid thermistor readings at control ignition burn. board set points. T-set too low. Check T
