Antares Warewash Dispensing System
Antares Warewash Dispensing System
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 1 Reference Manual Antares Series Preface This manual has been written and illustrated to present the basic installation, operation, and servicing instructions of the Antares Warewash Dispensing System. Guidelines will be suggested in reference to the preferred method of installation, however, the variety of equipment and the surrounding environment will dictate the actual installation of the Antares. Antares Warewash Dispensing System Online and downloadable Product Manuals and Quick Start Guides are available at www.HydroSystemsCo.com Please check online for the latest version of this Reference Manual.
WARNING: The Antares dispensing system is intended to be installed by experienced installers, in accordance with all applicable electrical and plumbing codes. All dish machine and dispenser power must be disconnected during installation and/or any time the dispenser cabinet is opened. NOTE: Always use proper lockout tagout procedures when servicing the dispenser. Antares DM-6000
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 2 Table of Contents 1 Product Benefits . . 4 2 System Specifications . . 4 3 Mechanical Installation Overview .
. 5 Wall Mounting . . 6 Probe Mounting . . 6 Rinse Injection Fitting . . 7 Detergent Bulkhead Fitting . . 7 Probe Kit Wiring Guides . . 8 . Rinse and Detergent Supply and Discharge Tubes . . 9 Solenoid Water Feed . . 9 4 Electrical Installation Overview . . 10 Probe Wiring . . 10 Electrical Connections . . 11 Main Power Wiring . . 11 Detergent Signal Wiring . . 11 Rinse Signal Wiring . . 12 5 Operating Modes . . 12 Overview . . 12 6 Operating Modes: Probe Operation Mode Detergent Control . . 12 Rinse Control . . 12 Conveyor Machines . . 13 Door Machines . . 13 Pulse Feed . . 13 7 Operating Modes: Probeless Operation Mode Initial Charge .
. 14 Detergent Dose . . 14 Low Detergent Alarm Threshold . . 15 Rinse Control . . 15 Rack Counts . . 15 Rinse Delay Time (Door Machines Only . . 15 Rinse Saver (Door Machines Only . . 15 Rinse Feed Option (Door Machines Only . . 15 Tank Change Interval . . 15 8 Programming Menus, Screens, and Setup Start-up Splash Screen . . 16 Language Selection . . 16 Date and Time Set . . 16 Home Screen . . 17 Keypad, Menus, and Symbols . . 17 Navigation to User/Program Menus . . 18 Power Saver . . 18 User Menus . . 18 User Prime Pumps . . 18 De-Lime Cycle . . 19 Max Detergent Time . . 19 Manual Initial Charge .
. 19 Manager Reports . . 20 Download Productivity Report . . 20 Installer Password . . 20 Configuration Settings . . 21 Detergent Control . . 21 Machine Type . . 21 Detergent Type . . 21 Pulse Feed Settings . . 21 Alarm Options . . 22 Set Units of Measure . . 22 Auto Switch Mode . . 22 Conveyor Rack Time . . 22 Initial Charge . . 22 Display Live Conductivity . . 23 Display Live Rinse Temperature . . 23 Third Product Run . . 23 User Prime . . 23 Program Settings (Probe Mode Only . . 24 Detergent Set Point . . 24 Manually Add Product . . 24 Enter Set Point . . 24 Use Tank Reading . . 24 Rinse Pump Speed (Probe Mode .
. 25 Third Product Pump Speed (Probe Mode . . 25 Rinse Feed Option (Probe Mode . . 25 Rinse Delay Time (Door Machines Only . . 26 Program Settings (Probeless Mode Only . . 26
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 3 Table of Contents 8 Programming Menus, Screens, and Setup (cont’d.) Detergent Initial Charge . . 26 Detergent Dose . . 27 Detergent Dose Interval . . 27 Rinse Pump Speed (Probeless Mode . . 27 Third Product Pump Speed (Probeless Mode . . 28 Rinse Feed Option (Probeless Mode . . 28 Rinse Delay Time (Door Machines Only . . 28 Low Detergent Alarm Threshold . . 28 Alarm Settings Menu . . 29 Low Detergent Alarm Delay/Detergent Overfeed . . 29 Stop Alarm . . 29 Machine Clean Alarm Setting (Probed and Probeless .
. 29 Conductivity Probe Range Setting (Probe Mode Only . . 30 Change Tank Alarm . . 30 Change Squeeze Tube Time . . 30 Low Rinse Temp Setting . . 30 Installer Service . . 30 Service Pumps . . 31 View Pump Configuration . . 31 Name Pumps . . 31 Prime Pumps . . 31 Pump Calibration . . 32 View Calibration . . 32 Calibrate Pumps (Non-Solenoid . . 32 Calibrate Pumps (Solenoid . . 32 Enter Product Cost . . 33 Tube Replacement Date . . 33 Set Pump Type . . 34 Set Pump Product . . 34 Set Pump Install . . 34 View Amount Pumped . . 34 Clear Data Log . . 35 Initial System Setup . . 35 Edit Installer Password .
. 35 Edit Manager Password . . 35 Edit Account Name/Edit Machine Name/Edit . . 36 Company Name . . 36 Set LCD Contrast . . 36 Set Date & Time . . 36 Clear Settings . . 36 View Software ID . . 37 View Serial Number . . 37 Signal Display Enable . . 37 External Solenoid Enable . . 37 Electric Cost/KWH . . 37 Water Unit Cost . . 37 Full KW Power Usage . . 37 Idle KW Power Usage . . 38 Water Volume/Wash . . 38 Data Transfer . . 38 Write Reports . . 39 Read Setup . . 39 Write Setup . . 40 Update Firmware . . 40 9 Alarm Messages Detergent Overfeed Stop Alarm . . 41 Machine Clean Alarm . . 41 Conductivity Probe Faulty Alarm .
. 41 Squeeze Tube Change Alarm . . 41 Change Tank Alarm (Probeless Mode . . 41 Low Rinse Temperature Alarm . . 41 Pump Jam Alarm . . 42 Probe Not Calibrated Alarm . . 42 10 Reports Productivity Report . . 43 Settings Report . . 44 Activity Report . . 46 Diagnostic Report . . 48 11 Maintenance and Service Spare Parts Listing . . 49 12 Specifications and Warrant Specifications . . 51 13 Index . . 52
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 4 Product Benefits Advanced Design The Antares uses surface mount electronic components to provide powerful features in a small package. A multi-line LCD screen allows intuitive programming of all options. Reliability The gasket-enclosed Antares Warewash Dispenser is highly water resistant and the electronics are protected within the enclosure. The readout gives confirmation of detergent and rinse signals. Versatility The Antares can be configured as a conductivity probe controlled unit or as a probeless, time-based dispenser.
It can accept a 100-249VAC nominal - 10% fluctuation) main power input at 50 or 60 Hz. Rinse and Detergent control signals are universal “machine interface” types that are capable of accepting any voltage from 24 to 240 VAC nominal - 10% fluctuation) or 24 VDC - 10% fluctuation). Antares can control either capsule or liquid detergents.
Cost Savings A special Rinse Saver Feature prevents rinse additive waste during fills of the washer. Digital electronics ensure accurate detergent control and minimize overuse. The Antares contains energy management features which can be used to track water and power usage and cost per rack over time. Reports indicate percentage of racks washed successfully and racks where alarms occurred. Intelligence The Antares includes a rack counter as a “standard” feature. A unique “De-Lime” mode allows for safe washer cleaning without detergent waste.
Choice of Options A full range of programmable options are included, such as Rinse Delay, Variable Alarm Volume, and Manual Prime for both rinse and detergent.
Hardware options include detergent tank and rinse probe temperature. Easy Service/Repair The Antares features convenient front access for all services. No internal access to the cabinet is required for installation and routine maintenance. Spare parts are available in modular form for fast, convenient repairs. System Specifications Detergent input signal 24 to 250VAC 50/60 HZ 20mA Rinse input signal 24 to 250VAC 50/60 HZ 20mA Tank fill input signal 24 to 250VAC 50/60 HZ 20mA Motor/solenoid drive outputs for detergent and rinse External solenoid output signal for rinse dissolver 24v DC Out Conductivity probe for tank Included Optional temperature probe for rinse and wash tank Separate kit(s) required Audible alarm within controller (single volume level) and external output for alarm (On/Off, no levels) USB type A, used for USB drive storage and Flash programming LCD display, 8 line by 20 character with adjustable contrast.
Multiple system configurations are available. Contact Hydro Systems customer service for more information.
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 5 Mechanical Installation Overview This chapter describes the hardware installation of the Antares. In this chapter, you will: • Wall-mount the Antares • Mount and install the probe (if applicable) • Mount and install the rinse injection fitting • Mount and install the detergent bulkhead fitting • Probe kit wiring guides • Install rinse and detergent supply and discharge tubes • Install solenoid (if applicable)
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 6 Mechanical Installation Wall Mounting 1. Choose an installation location that is: • Close to the product containers. • At a reasonable height for easy maintenance access and does not interfere with opening of doors. • Away from any direct sources of steam, water spray, and high temperatures. • Close enough to the dish machine electrical control panel to allow dispenser wiring without use of an external junction box (not provided) wherever possible. Wire harness is 11.5 feet. 2. Using mounting bracket as a template, mark holes to drill into mounting surface.
For sheet metal mounting with screws and nuts, drill 1/4” (6 mm) holes. For wall anchors, drill holes as appropriate for anchors used.
3. Attach mounting bracket to mounting surface with hardware provided. 4. Hang unit on bracket. Probe Mounting (Probe Operation and Out of Product Alarm in Probeless Mode only) The probe senses the detergent concentration. Correct probe placement is critical for accurate detergent concentration control. Always use the new probe provided with the dispenser. 1. Choose a mounting location that will allow the probe to be completely immersed in the wash tank solution, in an area that has a good flow of solution.
2. Check for a probe hole. Many dish machines will have knockouts provided for probe installation and/or will have existing probes.
Previously punched probe holes may be suitable, but always confirm that the probe will be immersed in the wash tank solution before installing 3. If no suitable probe hole is present, drill a 3/8” hole in the center of the probe location. Use a Greenlee (or similar) 7/8” hole punch to cut the final hole. 4. Remove the probe retaining nut. 5. From inside the dish machine tank wall, insert probe (with rubber gasket) into hole.
6. From outside the dish machine tank wall, install second rubber gasket, plastic washer and probe retaining nut. Tighten finger-tight only. Using a wrench, snug retaining nut without over tightening. ! WARNING: The Antares dispensing system is intended to be installed by experienced installers in accordance with all applicable electrical and plumbing codes. All dish machine and dispenser power must be disconnected during installation and/or any time the dispenser cabinet is opened. Mounting Bracket Back of Unit Hang unit from this lip on to Mounting Bracket Figure 3-3 Mounting Bracket Figure 3-4 Probe Mounting !
WARNING: Do not over-tighten the retaining nut! Retaining Nut Plastic Washer Dish Machine Tank Wall Lock Washer Nut Ring Terminal Nut Rubber Gasket Rubber Gasket
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 7 Compression Fitting (tube from pump) Threads into rinse plumbing Mechanical Installation Rinse Injection Fitting 1. Choose a location to install the rinse injection fitting at least 6” below the dish machine rinse plumbing vacuum breaker to conform to plumbing codes. The injection fitting threads into 1/8” NPT female threads.
If the dish machine rinse plumbing is thin-wall pipe, use a saddle clamp with a 1/8” NPT threaded hole. If an optional pressure switch will be used, thread the injection fitting into one side of the pressure switch water source fitting pipe tee.
2. Check for a tapped hole to accommodate the fitting. A suitable hole must be at least 6” downstream from the solenoid valve and vacuum breaker. On continuous rack, flight, or conveyor machines, be sure this location is downstream from any rinse by-pass water pipe. 3. If no suitable hole exists, drill an 11/32” hole in the rinse plumbing injection location. 4. Tap the hole with a 1/8” NPT tap. 5. Install the injection fitting. Use thread sealant to ensure a leak-free assembly. Detergent Bulkhead Fitting (Liquid Detergent Only) Correct placement of the detergent bulkhead fitting is critical for accurate detergent concentration control (in probe mode only).
1. Choose a mounting location that ensures the detergent bulkhead fitting is: • Above the water line in the tank. • Close to the probe location (when possible). • Discharging detergent directly into the wash tank and not on top of any shelf areas or other obstacles that could prevent detergent from falling directly into the wash tank.
2. Previously punched holes may be suitable, but always confirm that the fitting is correctly placed. 3. If no suitable hole is available, drill a 3/8” hole in the center of the detergent inlet location. Use a Greenlee (or similar) 7/8” hole punch to cut the final hole. 4. Remove the detergent bulkhead fitting retaining nut. 5. From outside the machine, insert the detergent bulkhead fitting (with rubber gasket) into hole. 6. From inside the machine, install the second rubber gasket, plastic washer and plastic retaining nut. Tighten finger-tight, then snug using wrench.
Figure 3-4 Rinse Injection Fitting ! WARNING: Follow the instructions provided with your solid, powder, or slurry feed system for solenoid equipped units instead of using the following section.
Figure 3-5 Detergent Bulkhead Fitting ! WARNING: Do not over-tighten the retaining nut! The installation instructions for the detergent bulkhead fitting are for liquid detergent feed systems only. Follow the instructions provided with your solid, powder, or slurry feed system for solenoid equipped units.
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 8 Mechanical Installation Rinse Probe Kit Wiring Guide Disconnect all power to the unit before opening the front cover. Connect the other end of the cable to the 10096829 rinse probe assembly using the crimp-on spade connectors. Attach the two smaller connectors to the rinse probe wires, and the two larger connectors to the 2-conductor cable. (Polarity is not important). T/C Probe Kit Wiring Guide Connect the end of the cable to the 10096824 rinse probe assembly using the crimp-on spade connectors and ring terminals included in the kit.
Attach the two smaller spade connectors to the white thermistor wires, and the two larger connectors to the green & white wires of the 4-conductor cable. (Polarity is not important).
Crimp the ring terminals to the black & red wires of the 4-conductor cable and attach the ring terminals to the threaded studs of the 10096824 probe, using the nuts and lock washers provided. (Polarity is not important) Figure 3-6 Rinse Probe Kit Figure 3-7 T/C Probe Kit
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 9 Mechanical Installation Rinse and Detergent Supply and Discharge Tubes 1. Route the pump supply tubes from supply containers to the inlet (left) sides of each pump. Slip the tube fully through the compression nut into fitting and tighten.
2. Route the pump discharge tubes to the outlet (right) sides of each pump. Slip the tube fully through compression nut into fitting and tighten. 3. Route other end of the rinse pump discharge tube to the rinse injection. Slip the tube fully through compression nut into the fitting and tighten.
4. Route the other end of the detergent pump discharge tube to the detergent bulkhead fitting. Slip tube fully through compression nut into fitting and tighten. NOTE: Supply and discharge tubes are not included with the standard unit. DM-6221 DM-6220 Figure 3-8 Product Pickup and Discharge tubing Connections Connection Solenoid Water Feed (Solenoid Equipped Units Only) If you are using a solid, powder or slurry feed system, you will need a water source for the dispenser solenoid valve. This water supply may be hot or cold but, for safety reasons, should not come from the boosted temperature rinse water line on high temperature dish machines.
The dispenser solenoid valve fittings are 1/4” (6mm) compression. Typically, a saddle clamp is used for the solenoid valve water source. If the plumbing is steel or brass, drill an 11/32” hole and tap for 1/8” NPT threads.
1. Install petcock valve to water source plumbing. Connect 1/4” copper or plastic tube to the valve. 2. Route tube to dispenser solenoid valve. Slide tube into water inlet side compression fitting and tighten. 3. Connect another 1/4” tube to the outlet side of the dispenser solenoid valve and route to the water inlet connection for the feed system. 4. Confirm that all compression fittings are tight. 5. Be sure to turn on water source valve prior to adjusting dispenser settings. ! WARNING: If the water source is hot, use only copper tubing. DO NOT use poly tubing.
from water source pump discharge tube connection pump supply tube connection to detergent feed bowl
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 10 Electrical Installation Overview This chapter describes the electrical connections of the Antares. In this chapter, you will connect: • Probe wiring • Electrical connections • Main power wiring • Detergent signal wiring (probe and probeless modes) • Rinse Signal Wiring NOTE: All electrical connections (except the probe) must be in either the dish machine control circuit panel or an external junction box. Power cable (Type Y) is not field replaceable.
The dispenser is pre-wired with a multi-conductor electrical cable that must be run through a conduit to the location where hard-wired connections are made on the dish machine.
Use a 1/2” (13 mm) ID water tight conduit meeting all local and national codes. A threaded fitting is present on the bottom of the dispenser where the power cable exits to connect a 1/2” conduit fitting. The probe wire is also pre-wired and should be routed to the probe location and cut to length if a probe is used.
NOTE: The AC Mains are disconnected from the dispenser when the ON/OFF is in the OFF position. This is a Type 1.A application. Probe Wiring 1. Route the probe wire to the probe location. If you need to extend the probe wire, use high quality corrosion resistant (waterproof is best) butt splices with a good quality crimping tool. 2. Strip wire ends and crimp on the ring lugs provided. 3. Connect the ring lugs to the probe with nuts and star washers provided. Be sure that connections are tight and secure.
4. For optional rinse temperature probe, connect Black and Red wires from probe to internal interface terminals Sensor 2, channel 1.
5. Connect Black and Red wires from probe to internal interface terminals Sensor 1, channel 1. 6. For optional tank temperature probe, connect Green and White wires from probe to internal interface terminals Sensor 1, channel 2. Figure 4-1 Probe Wiring Sequence Retaining Nut Plastic Washer Dish Machine Tank Wall Lock Washer Nut Ring Terminal Nut Rubber Gasket Rubber Gasket
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 11 Electrical Installation Electrical Connections Table 4-1 Wire Colors Circuit Voltage Function Internal Connector Blue 100-250 VAC 50/60 Hz Main AC Power Brown 100-250 VAC 50/60 Hz Main AC Power Green/Yellow --- Earth Ground Yellow +24-VDC or 24-250 VAC, 50/60 Hz Detergent Signal Trigger 1+ Yellow/White 24 VDC Negative or 24-250 VAC, 50/60 Hz Detergent Signal Trigger 1- Purple +24-VDC or 24-250 VAC, 50/60 Hz Rinse Signal Trigger 2+ Purple/White 24 VDC Negative or 24-250 VAC, 50/60 Hz Rinse Signal Trigger 2- Main Power Wiring Connect the blue wire to one side of the voltage source.
Connect the brown wire to the other line of the voltage source. Detergent Signal Wiring The detergent signal input is an optically isolated signal input, include in table internal terminal locations that draws no more than 20 mA. It is a universal voltage input that accepts any voltage listed in Table 4-1. Detergent Signal Wiring – Probe Mode Typical wiring locations are dispenser detergent power supply (DPS1 & DPS2) or the wash motor contacts in the dish machine control panel. This power source is on when the dishwasher is running the wash pump. • Connect Yellow (+DC or AC) and Yellow/White (-DC or AC) colored wires to detergent power supply.
Detergent Signal Wiring – Probeless Mode On conveyor type dishwashers, the detergent signal must occur only once per dish machine fill/drain occurrence–beginning when the dish machine fills. Typical wiring locations are an “on light,” an on/off switch if present, or an electrical tank heat circuit between the tank heater switch and the thermostat. Each time this power source comes on and stays on for 10 seconds, the dispenser will feed the detergent initial charge amount. On door-type dishwashers, connect this signal input to the dispenser detergent power supply or the wash motor contacts in the dish machine control panel.
This power source is on when the dishwasher is running the wash pump.
To facilitate Automatic Initial Charge on alternate machines or machines that do not provide a rinse signal during the fill, connect the detergent signal wires to a power source that occurs only once per fill/drain occurrence beginning when the dish machine fills. Typical wiring locations are a main ON/OFF switch or an on light. • Connect Yellow (+DC or AC) and Yellow/White (-DCor AC) colored wires to initial charge power source. Line Brown Main Power Blue Line Figure 4-2 Main Power Connections Detergent Signal 24-240 VAC~50/60Hz or 24 VDC Line (+)Yellow (-) White/Yellow Figure 4-3 Detergent Signal Wiring Diagram—Probe or Probeless Mode
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 12 Electrical Installation Rinse Signal Wiring The rinse signal input is an optically isolated signal input that draws no more than 20 mA. It is a universal voltage input that accepts any voltage listed in Table 4-1. Typical wiring locations are dispenser rinse power supply (RPS1 & RPS2) or the rinse solenoid valve circuit in the dish machine control panel. This power source is live whenever the dishwasher is rinsing. When no suitable rinse signal connection is available, an optional pressure switch may be used with a constant power source instead.
• Connect Purple (+DC or AC) and Purple/White (-DC or AC) colored wires to rinse power supply (or constant power for pressure switch installations).
• Interface board Output Wiring (internal Solenoid + options) 24V DC Red = +DC, Black = -DC • 6211 Output 1 - Int Solenoid, Output 2 - Ext Sol, Output 3 - Ext Alarm • 6220 Output 1 - unused, Output 2 - Ext Sol, Output 3 - Ext Alarm • 6321 Output 1 - Int Solenoid, Output 2 - Ext Sol 1, Output 3 - Ext Alarm, Output 4 - Ext Sol 2 • 6330 Output 1 - Ext Sol 1, Output 2 - Ext Sol 2, Output 3 - Ext Alarm, Output 4 -unused Overview The Antares allows detergent control using two different modes: 1. Probe Mode—This mode requires a conductivity probe be mounted in the wash tank to measure detergent concentration.
Detergent is dispensed automatically when measured concentration levels fall below the programmed set point.
2. Probeless Mode—No probe is required. An initial charge of detergent is dispensed when the machine is filled and upon a specified signal from the dishwasher. Detergent dose is dispensed for a fixed programmed time each time. Rinse control and Rack counts are handled differently for each mode as described below. Detergent Control In Probe Operating Mode, the controller begins monitoring the conductivity probe to determine detergent concentration. The detergent feed is activated as soon as the concentration calculated from the conductivity signal has gone below the programmed set point and there is a detergent signal present.
When the set point is reached the detergent feed is de-activated.
The detergent signal from the washer should remain on while the wash tank motor is on, otherwise the detergent feed will not activate. The detergent signal is typically wired to a power source that is on when wash pump is running. Low Detergent Alarm If the conductivity is below the set point and has not increased by 10% within a programmed number of racks, a visible and audible alarm will be activated. The alarm will sound at the end of each rack until the conductivity rises by 10%. If the conductivity has not increased by 10% for twice the preset number of racks, an alarm will be activated and the detergent feed will stop.
Operator intervention is required to restart the detergent feed.
(-) White/Violet (+) Violet Rinse Signal 24-240 VAC~50/60Hz or 24 VDC Line Figure 4-4 Rinse Signal Wiring Diagram Operating Modes Operating Modes: Probe Operation Mode NOTE: If an external optional device will be used, you must supply your own wire.
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 13 Rinse Control In Probe Operating Mode, rinse signal input controls the rinse output. When the rinse signal is present, the rinse pump will run at the programmed speed until the rinse signal goes off. This varies depending on the selected rinse feed option for door machines.
Conveyor Machines Rack Counts For conveyor machines, conveyor time is defined as the time it takes to move one rack length. A programmed conveyor time setting is used to count the number of racks on a conveyor machine. A rack is counted when the rinse on time equals the programmed conveyor time.
Tank Change Interval To signal an alarm when it is time to change the tank water, a tank change interval can be used in conjunction with number of racks run since the initial charge. (In Probe Mode, this will require a separate initial fill signal to determine the initial charge.) Rinse Pump Rinse Saver is not a feature of conveyor machines. Instead, the rinse pump will run continuously as long as the rinse signal is active. However, the rinse pump will only operate if a detergent signal has occurred within the previous 90 seconds.
Door Machines Rack Counts For door machines, a rack count will be registered each time the rinse signal toggles from Off to On.
Tank Change Interval To signal an alarm when it is time to change the tank water, a tank change interval can be used in conjunction with number of racks run since the initial fill. Rinse Delay Time A rinse delay of 0-19 seconds can be programmed for door machines. The rinse delay will occur at the beginning of each rinse signal input. Rinse Saver The pump will only be allowed to operate continuously for a maximum of 20 seconds. After 20 seconds, the rinse signal input must toggle Off and back On again. Please note, this will also cause the rack count to be incremented The Rinse Pump will only operate if a detergent signal has occurred within the previous 90 seconds.
Rinse Feed Option There are two options for the Rinse Pump to activate. Option 1 (Rinse on Rinse) will run the Rinse Pump each time the Rinse Signal activates (for the duration of time the signal is present). Option 2 (Rinse on Det) will run the rinse pump for a fixed time of 12 seconds each time the Detergent Signal activates. Please note, the Detergent Signal must be toggled On/Off for the rinse pump to run again. With each toggle, the rack count will be incremented.
Pulse Feed Pulse Feed is used only with capsule-type detergent in Probe Operating Mode. If the conductivity reading is within the set point by a user-specified percentage, the detergent feed will be cycled On and Off (pulsed) at a user-selected frequency. Otherwise, the detergent feed will be on continuously. This allows the controller to gradually reach the set point without overshooting. If it is turned on, the user must choose between one of seven different fixed options for frequency and percentage with the set point. (For example, if the reading is within 80% of the set point, the default option is 2 seconds on, 6 seconds off.
Operating Modes: Probe Operation Mode
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 14 Initial Charge Door Machines Whenever the dispenser receives a rinse signal that was not preceded by a detergent signal within 90 seconds prior (as in an initial fill), an automatic initial charge occurs. The automatic initial charge consists of disabling the rinse feed and feeding detergent for the preset amount of time programmed for detergent initial charge. Normal rinse signal activations within 90 seconds after a detergent signal will not trigger an initial charge.
A five minute lockout timer begins at the start of the initial charge to prevent additional triggering if multiple rinse signals are detected during fill.
Alternate Door Machines An Automatic Initial Charge in a Alternate Door machine occurs each time the dispenser receives a detergent signal input (with 2 second qualification). The detergent feeds for the programmed time for initial charge. Conveyor Machines Each time the dispenser in a conveyor machine receives a detergent signal input (with 3 second qualification) that remains on for 10 seconds continuously, an automatic initial charge occurs. The detergent feeds for the programmed time for detergent initial charge.
The rinse pump is locked out during the detergent initial charge if the rinse signal was previously on. When the initial charge is complete, the rinse pump will not turn back on until the rinse signal is toggled Off to On. Because the initial charge will occur each time a detergent signal occurs, the source of the detergent signal must remain on for the duration of time the tank is full, or must not occur more than one time per machine fill. If the detergent signal is toggled and qualified for 3 seconds, then continuously on for 10 seconds, the dispenser will receive another signal. If this happens before the initial charge completes, it will run the detergent for another initial charge cycle.
The initial charge will run the full charge time regardless if the detergent signal is turned off prior to completion. On a conveyor machine, the detergent signal is typically wired to an “on light” or an electrical tank heat on/off switch. Each time the power source comes on, the dispenser feeds the detergent initial charge amount. If Manual Initial Charge is selected, there is no automatic initial charge. Detergent Dose Door Machines When the detergent signal on a door machine is activated with (3 second qualification) a detergent dose of a programmed time will occur once per programmed detergent dose rack interval.
The rinse signal must then activate to run the rinse pump before detergent can run again.
Door Machines with No Rinse Signal on Fill (Alternate Door machines) If a door machine has no rinse signal upon fill, select this option. In an Alternate Door Type dishwasher Detergent is dispensed when the Rinse Signal is activated based on the detergent dose interval and detergent dose time. Conveyor Machines On a conveyor machine, a detergent dose of a programmed time will occur when the accumulated Rinse On signal time reaches the conveyor rack time multiplied by a programmed detergent dose interval (1, 2, or 3 racks). The rinse signal does not need to be toggled off and on for another dose to occur.
Operating Modes: Probeless Operation Mode
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 15 Low Detergent Alarm Threshold A low detergent alarm is available for Probeless Operating Mode if a conductivity probe is installed in the same manner as for Probe Operating Mode. When the probe is connected, it senses detergent conductivity at 20 different preset threshold values (0-19). Each setting is equivalent to a calibrated conductivity value divided by 10 (i.e., the default setting of 5 is equal to a conductivity setting of 50). If the conductivity goes below the setting and remains there without rising at least 10% for a programmed number of racks, a visible and audible alarm will be activated.
The alarms will remain on until the conductivity rises above the threshold point. If the conductivity has not increased for twice the preset number of racks, an Overfeed Alarm will be activated and the detergent feed will stop. Operator intervention is required to restart detergent feed. Rinse Control In Probeless Operating Mode, rinse signal input controls the rinse output. When the rinse signal is present, the rinse pump will run at the programmed speed until the rinse signal goes off. This varies depending on the selected rinse feed option for door machines.
Rack Counts Door Machines For door machines, a rack count will be registered each time the rinse signal toggles from Off to On. Door machines include a rinse feed option which, when set to Rinse on Det, increases the rack count when the detergent signal toggles from Off to On. Alternate Door Machines a rack count will be registered each time the rinse signals toggles from Off to On. Conveyor Machines For conveyor machines, conveyor time is defined as the time it takes to move one rack length. A programmed conveyor time setting is used to count the number of racks on a conveyor machine. A rack is counted when the rinse on time equals the programmed conveyor time.
Rinse Delay Time (Door Machines Only) A rinse delay of 0-19 seconds can be programmed for door machines. The rinse delay will occur at the beginning of each rinse signal input. Rinse Saver (Door Machines Only) The pump will only be allowed to operate continuously for a maximum of 20 seconds. After 20 seconds, the rinse signal input must toggle Off and back On again. Please note, this will also cause the rack count to be incremented The Rinse Pump will only operate if a detergent signal has occurred within the previous 90 seconds. Rinse Feed Option (Door Machines Only) There are two options for when the Rinse Pump will activate.
Option 1 (Rinse on Rinse) will run the Rinse Pump each time the Rinse Signal activates (for the duration of time the signal is present). Option 2 (Rinse on Rinse) will run the rinse pump for a fixed time of 12 seconds each time the Detergent Signal activates. Please note, the Detergent Signal must be toggled On/Off for the rinse pump to run again. With each toggle, the rack count will be incremented.
Tank Change Interval To signal an alarm when it is time to change the tank water, a preset tank change interval can be used in conjunction with accumulated racks since the initial fill. Operating Modes: Probeless Operation Mode
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 16 Start-up Splash Screen At start-up, the controller displays a splash animation consisting of a short series of bitmap images that identify the manufacturer and device. Upon the initial start-up, this screen defaults to allow selection for language of operation.
Additional language choices can be selected if a USB Language Key is available and selectable from the menu at power up. Pressing any key during boot-up skips the splash screen and takes the user to the date and time input screen.
Language Selection The language selection screen follows the splash screen at the first power-up or when a USB drive is in place at power-up. After that, the splash screen leads to the Date and Time Set screen. The language selection screen provides a selectable menu for the languages that are available on the device (or on a language key if one is installed prior to power-up). The screens will always include English and one additional language as default selections. In North America, the additional default language option is Spanish. In Europe, it is German. Language files have an .LNG extension.
Additional languages may be downloaded from a USB Language Key.
To load, power must be turned off. Connect the Language Key and start up. Select a language from the list and load onto the controller. Once a language has been selected, it replaces the second default language choice and becomes the selected language for this controller. English will always remain one of the available default languages. The USB Language Key can be removed as soon as the Date and Time Set screen appears. Date and Time Set The start-up continues with the Date and Time Set screen. The date follows the ISO 8601 standard format with four digits for the year followed by two digits for the month and two digits for the day.
(e.g. 2013/02/15). The time also follows an ISO 8601 standard, but is limited to hours and minutes on a 24-hour clock (for example, instead of 8:00pm, you would enter 20:00).
If a date is entered that is not valid, an error message will appear. Select Enter or Back to return to the Date and Time Set screen. Programming Menus, Screens, and Setup Default No USB Key Installed With USB Key Installed Date and Time Error LANGUAGE ENGLISH SPANISH LANGUAGE ENGLISH SPANISH FRANCAIS DEUTSCH SVENSKA PORTUGUESE DATE & TIME < 2013-02-15 > YYY-MM-DD HH:MM ERROR INVALID DATE/TIME ▼ ▼
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 17 Home Screen The home screen displays information during periods of activity, including company name, rack count, operating mode, tank conductivity and temperature, rinse temperature, pump activity, and signal activity.
Two distinct options for additional features can be accessed by the press of a button. The display is in ready state when a pump is enabled in the configuration and the pump name is shown. The display is in active state when a pump is running and the pump name is inversely displayed. Pump names show the first three characters of the pump’s name. (Keep this in mind when naming pumps.) If a pump is not enabled, the three character pump name will be blank. If enabled in the installer setup menu, signal states are displayed as either 0 or 1.
Most recent alarms will be displayed in the alarm status line, when there is an active alarm. If there is no active alarm, this area is blank. (See the section on Alarms for a list of all possible alarms.) The rack count is displayed in five digits. If enabled at system setup, conductivity, wash tank temperature, and rinse temperature are all options for display. Keypad, Menus, and Symbols The keypad is designed for easy operation. Directional keys (Up, Down, Left, Right) let you navigate through menus. The Enter key allows you to enter commands and choices as well as start or stop actions, and the Back key takes you to your previous screen.
Within the display, the selection box highlights your current menu selection. You can change this by using the directional keys on the keypad. Additionally, there are two types of arrows that you may see on the display-- Edit Value and Scroll arrows. When the display shows the Edit Value arrows, use the directional keys to adjust the given value shown. When the Scroll arrow is present, you can use the directional keys to view additional items or options. Flashing black bars indicate when the pump is running.
Programming Menus, Screens, and Setup NOVA CONTROLS Racks: 00000 PROBE Cond: 000 WTemp:000 Setpt: 000 RTemp:000 Signl: 1 0 Pump: DET RIN SAN Alarm: ** LOWDET ** Keypad Buttons BACK ENTER UP/DOWN LEFT/RIGHT Selection Box Edit Value Arrows Scroll Arrows Flashing Bars
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 18 Navigation to User/Program Menus Press Back to immediately access the user menu. If no selection is made within 15 seconds, the home screen will return. Press any navigation key to access the program menu. Additional menus provide access to features available to the installer and manager. If no selection is made within 15 seconds, the home screen will return. Power Saver The power saver feature activates after fifteen minutes of inactivity. In Power Saver Mode, the backlight turns off but the display and green power-on LED remain active.
Pressing any button returns the controller to normal operation.
User Menus User menus are available to the operator/user in the kitchen facility and do not require a password. They allow menu selection as well as inputs. They will typically be in the format of a double-height header with information or menu selections in single lines below. When the user menu option is selected from the home screen, the user menu screen is displayed. Each line in this screen (aside from the heading) is a menu item and can be selected. User Prime Pumps This screen allows the user to prime one or more pumps (not simultaneously) from a selection. This screen is only available if it has been enabled from the programming menu.
The number of pumps in the list will be determined by the total number of pumps available within the system. The list will consist of a pump number and name (if a name has been input). The pump name will display in the language of input. Once you have selected the appropriate pump, press Enter to start priming. Press Enter again to stop. Press Back to exit.
When priming a pump, an animation will appear on the pump line and will stop once priming is finished. Prime speed for peristaltic pumps is 110 RPM (full speed). If the user prime has not been enabled, a message screen will appear noting that it has been disabled. Enter or Back will return you to the previous menu. NOTE: The pump name will not appear unless input by the installer or as part of a setup upload and will appear in the language in whgich created. Flash animation (moving black bars) will indicate pump running.
Programming Menus, Screens, and Setup USER MENU USER PRIME PUMPS DE-LIME CYCLE MAX DETERGENT TIME MANUAL INITIAL CHRG PROGRAM MENU MANAGER REPORTS INSTALLER MENU Keypad Buttons BACK ENTER UP/DOWN LEFT/RIGHT SET PRIME PUMP P1 DETERGENT P2 RINSE P3 SANITIZER PRIME P1 DETERGENT SET PRIME PUMP DISABLED
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 19 De-Lime Cycle You can de-lime from the De-Lime Cycle screen by selecting Enter to begin. The de-lime cycle is ten minutes. During this time all dispenser operation stops. Select Back to return to user settings. After starting the cycle, the screen will change as shown and begin counting down the ten-minute interval. To cancel early, select Exit. Otherwise, the screen will return to the home screen and restore normal operation of the dispenser upon completion. Max Detergent Time In Probe Operating Mode, the Max Detergent Time screen displays the longest time in minutes and seconds that the detergent feed has had to run to satisfy the set point.
Press Enter to reset the value to “0”, or select Exit to return to the user settings menu.
Manual Initial Charge Manual initial charge is available in Probeless Mode only. Set the dispensing time for detergent from the program menu. All dispenser operation is stopped. Select Enter to start the charge or Back to return to user settings. Once the cycle begins, the screen will change as shown and begin counting down the charge time interval. To cancel the cycle early and return to the user mode menu, select Exit. When the cycle is complete, the display will return to the home screen and restore normal operation of the dispenser.
Programming Menus, Screens, and Setup START DE-LIME THIS WILL STOP ALL OPERATION CONTINUE? DE-LIME CYCLE TIME REMAINING: 09:59
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 20 Programming menus are password protected. The default passwords (0123 - Manager, 01234 - Installer) are shipped with the device and works until a new password is selected by the installer or technician. Manager Reports The kitchen manager can download a summary report to a USB key using the 4-digit password set at installation. This password can be changed in the installer menus. Download Productivity Report This screen prompts the manager to install a USB key. Once the report has been downloaded, the screen reverts to the user settings menu.
The report is based on formula run data stored in the controller’s memory. Once the files have finished writing, the user is returned to the main menu. The last file name entered will be shown upon entering the report name screen (unless the controller is reset to factory defaults). The data generated in the reports is based on a date range. The default date range is from the last entered from date to the current date. The installer may change the default range if desired. Once the date range and name have been entered, all reports are written to the drive. If an invalid date/time has been entered, the error screen will appear.
The only report that the manager is allowed to download is the Productivity Report. See the installer menu for additional reports available.
Installer Password The installer uses this screen to input the appropriate 5-digit password for operation. This password is either the default password shipped with the device, or a password programmed in a previous operation. Once the password is entered, the installer main menu screen appears. From here, the installer will adjust settings, input values, or perform data functions. NOTE: To input a password, use the Up/Down keypad buttons to change character (shown on screen display with “Edit Value Arrows”) and Left/Right keypad buttons to change digit.
WARNING: The password must be remembered or the controller must be shipped back to the factory to be reset.
Programming Menus, Screens, and Setup Mnnager Password Report Date (From) Report Date (To) Report Name Installer Password Installer Main Menu PROGRAM MENU MANAGER REPORTS INSTALLER MENU MGR PASSWORD REPORT DATE FROM: REPORT DATE TO: REPORT NAME INSTL PASSWORD INSTALLER MENU CONFIG SETTINGS PROGRAM SETTINGS ALARM SETTINGS INSTALLER SERVICE INITIAL SYSTEM SETUP DATA TRANSFER !
P/N 10096880 REV A © Hydro Systems Company, Inc. 2014 HydroSystemsCo.com Toll Free: 1.800.543.7184 21 Configuration Settings The configuration settings allow the installer to provide service operations or view details of the system. When programming the dispenser for a new installation always set the configuration settings first. Conveyor rack time appears only for conveyor machines and alternate door machines. Initial charge appears only in Probeless Mode. Pulse feed only appears for capsule detergent types. Detergent Control The detergent control menu is where the installer sets the operating mode (Probe Mode or Probeless Mode).
Whichever mode is selected determines which settings are available under the program menu. Use the Up and Down arrow buttons to select the mode and select Enter to accept the setting. Select Back to return to the previous menu. Machine Type The machine type menu is where you select the machine type (Door, Conveyor or Alternate Door). Alternate Door refers to those door machines that do not provide a rinse signal during the fill. Whichever mode you select determines which settings are available under the program menu.
Use the Up and Down arrow buttons to select the mode and select Enter to accept the setting. Select Back to return to the previous menu. Detergent Type The machine type menu is where you specify which type of detergent you will use (liquid or capsule). Whichever detergent type you select determines which settings are available under the program menu. Use the Up and Down arrow buttons to select the mode and select Enter to accept the setting or Back to return to the previous menu. Pulse Feed Settings When the detergent type selected is capsule, you can set the pulse feed to adjust the length of time the detergent feeds (that is, the pulse) and the interval between each pulse.
These settings will vary depending upon the strength of your detergent and the distance between the product container and the machine. (The default setting is 2-ON, 6-OFF, 80% Setpoint.) Select Off to turn the pulse feed option off.
Use the Up and Down arrow buttons to select the and select Enter to accept the setting or Back to return to the previous menu. Programming Menus, Screens, and Setup Configuration Settings Detergent Control Machine Type Detergent Type Pulse Feed Settings CONFIG SETTINGS DETERGENT CNTRL MACHINE TYPE DETERGENT TYPE ALARM OPTION UNITS OF MEASURE DISP LIVE COND DISP RINSE TEMP USER PRIME PUMPS INITIAL CHARGE DETERGENT CNTRL PROBE PROBELESS MACHINE TYPE DOOR CONVEYOR ALTERNATE DOOR DETERGENT TYPE LIQUID CAPSULE PULSE FEED OFF -NO PULSE FEED 1-ON 9-OFF 50% SPT 1-ON 9-OFF 70% SPT 2-ON 6-OFF 50% SPT 2-ON 6-OFF 80% SPT (DEFAULT) 4-ON 4-OFF 70% SPT 6-ON 4-OFF 80% SPT 6-ON 1-OFF 90% SPT