Ecolab Formula1 Manual de usuario

Installation & Operation Manual

Retain this manual for installation, operation,

programming, and servicing information.

This manual is intended for dispenser 9259-1069 (not 9259-1051).

Form 36922/0401/0525 Copyright Ecolab Inc. 2006 9259-2201

This page intentionally left blank

Table of Content

1. Introduction................................................................................................................... 5

1.1. Preface............................................................................................................... 5

1.2. System Features................................................................................................ 5

1.3. System Description and Packing List............................................................... 6

1.4. Principle of Operation....................................................................................... 8

2. Specifications.............................................................................................................. 10

2.1. Controller/Dispensing Unit............................................................................. 10

2.2. User and Machine Interface Modules............................................................. 11

2.3. Auxiliary Pump Cabinet – Optional ............................................................... 11

2.4. Installation Requirements ............................................................................... 12

3. System Installation...................................................................................................... 13

3.1. Preplanning..................................................................................................... 13

3.2. Accessories & Optional Parts List.................................................................. 14

3.3. Dispenser/Controller Installation.................................................................... 14

3.4. Installation Plumbing...................................................................................... 16

3.5. User and Machine Interface Module Installation............................................ 21

3.6. Power Up ........................................................................................................ 26

3.7. Dock Product Capsule..................................................................................... 26

3.8. Prime Product Delivery Tubes........................................................................ 26

3.9. Calibrate Dispenser......................................................................................... 27

3.10. Program Formula Amounts............................................................................. 27

3.11. Verify Delivery Amounts ............................................................................... 27

4. Programming............................................................................................................... 28

4.1. General Information........................................................................................ 28

4.2. Program Mode ................................................................................................ 30

4.3. QUICKSTART (See Figure 4.4) .................................................................... 33

4.4. ACCT SETUP (See Figure 4.5)...................................................................... 35

4.5. WASHER SETUP (See Figure 4.6)................................................................ 37

4.6. FORMULA PROG (See Figure 4.7) .............................................................. 40

4.7. RECORDS (See Figure 4.8)........................................................................... 42

4.8. PRIME MODE (See Figure 4.9)..................................................................... 44

4.9. TIME CALIB (See Figure 4.10)..................................................................... 47

4.10. DIAGNOSTIC (See Figure 4.11)................................................................... 50

4.11. Exit Programming........................................................................................... 51

5. Account Features ........................................................................................................ 52

5.1. Replacing Product Capsule............................................................................. 52

5.2. Selecting Formula........................................................................................... 52

5.3. Controller Access............................................................................................ 52

6. Set-Up and Operation ................................................................................................. 54

6.1. Product/Wash Signal Check ........................................................................... 54

6.2. Dispensed Quantity Check.............................................................................. 54

7. Troubleshooting.......................................................................................................... 55

8. Replacement Parts....................................................................................................... 60

8.1. Pump Tray....................................................................................................... 61

8.2. Water Valve.................................................................................................... 61

8.3. Electrical Parts................................................................................................ 62

8.4. Electrical Part Numbers.................................................................................. 63

8.5. Other Dispenser Components......................................................................... 63

8.6. Auxiliary Pump Components.......................................................................... 65

9. Maintenance................................................................................................................ 66

10. Appendix..................................................................................................................... 67

10.1. Pump Access................................................................................................... 67

10.2. Plumbing Schematic ....................................................................................... 67

10.3. Formula 1 Dispenser – Internal Construction................................................. 68

10.4. Labels and Overlays........................................................................................ 69

10.5. Programming Flow Chart ............................................................................... 70

1. Introduction

1.1. Preface

Formula 1 is the single-step laundry solution for on-premise laundry customers. The Formula 1 system comes

equipped with one main pump and three delivery valves to service up to three washers. The system

automatically makes a use-solution from a concentrated Formula 1 product. This use-solution is then delivered

to the washers automatically as requested. Formula 1 is an all-in-one formula; however, the system has an

optional pump cabinet for delivering a liquid product or sanitizer if desired.

The Formula 1 dispenser is for use with Formula 1 products ONLY!

Other chemicals must be added via an auxiliary pump.

1.2. System Features

•Serves 3 washers from 25 – 990 lbs rating each

Up to 5 Independent and programmable formulas per washer•

•Formula numbers can be matched to washer formula numbers for ease of training and use

•

y product

tion)

r proper capsule replacement

tart and stop length – No add on equipment

•Maximum Formula 1 Dose = 999 fl oz

•Maximum Auxiliary Product Dose = 33.3 fl oz

•Slide Out Pump Tray for Easy Service Access

•High Mount Product Drain Plug

•Load counter & capsule log

•Low voltage washer connections

•Pump and filter run time counters

Visual & audible low product alarm

•Concentrated product (Formula 1 product)

Plus optional product with Auxiliary Pump

•Programmable delays for Formula 1 and Auxiliar

•Universal washer signal input with indicator lights

•Automatic solution mixing (recircula

•Icon-based display for ease of training and use

•Digital user interface for ease of program selection

•Wheels for easy roll in installation

•Automatic Lid Latch to prompt users fo

•Chart Stop Integral with programmable delay s

required

•Dose Scaling for Washer Size – Automatic

Notes:

The dispenser is supplied with two communications

cables (one 14 ft. and one 25 ft.).

Only two Washer Interface Modules are supplied with the Formula 1 dispenser. If you plan to hook

up to three washers, you will need to order an additional Washer Interface Module AND an additional

communication cable (See Section 1.4 for Part Numbers)

1.3. System Description and Packing List

The Formula 1 System consists of several individual components designed to work

together to provide a safe, simple and reliable dispensing solution for On Premises

Laundry applications. The packaged system includes and is shipped with (See fig 1.1

through 1.4 for illustrations and details):

1. Formula One Dispenser

2. Two (2) Washer Interface Modules – Include Formula number and name labels

3. 14’ and 25’ communications cables

4. Auxiliary Pump Adapter cable

5. 80’ of 1/2 “ OD poly tubing for product delivery

6. 5’ of hose for the overflow to drain connection

7. Two (2) 15’ water hoses for Hot and Cold Water Connections

8. Vacuum Breaker assembly with pressure gauge

9259-1069 Formula 1 Dispenser Boxed and Un-Boxed

Fig 1.1

Item Part Number Description

1 9259-1075 Washer Interface Module

2 9259-2226 Communications Cable, 25 ft

3 9259-2222 Cable, Auxiliary Pump Adapter

4 9259-2225 Cable, communications, 14 ft

5 8524-2501 Vacuum Breaker

6 8539-0079 Pressure Gauge

7 8501-5026 Tubing, ½ in OD Poly (80 ft)

8 9482-2186 Water Hoses 15 ft (2 provided)

9 8501-6046 Drain Hose 5 ft

5 6

Fig 1.3

Fig 1.4

Fig 1.2

10 Miscellaneous Parts

N/S 8579-3032 Hose Y w/out shutoff valves (Qty 2)

N/S 8730-1032 Hose Clamp 11/16 to 1-1/4 SST

N/S 8524-4391 Check valve (Qty 3)

N/S 8730-1149 Hose Clamp 7/32” to 5/8” SST (Qty 6)

N/S 8561-5565 Union Connector ½ Push in (Qty 3)

N/S 9265-3303 32oz Spray Bottle

11 9259-1075 Washer Interface Module (2 Provided)

12 9259-2220 Formula Number Labels

13 9259-2221 Bi-Lingual Formula Name Labels

14 8999-2201 Dual Lock Tape

Fig 1.4 Continued

1.4. Principle of Operation

1. Overview

The Formula 1 System includes a combination controller/dispensing unit that is capable of feeding

up to three washers. The system uses a washer interface and user interface combination (together

referred to as a Washer Interface Module) at each washer and offers an optional auxiliary pump

cabinet for one liquid product. The “Controller” in the dispenser, is connected to the “Washer

Interface Module” at the Washer via “Communications Cables”. The Washer Interface Module

automatically adjusts for supply signal voltages ranging from 24 to 240VAC or 22 to 24VDC and

communicates the “supply signal” from the washer to the dispenser. Once a signal is received, the

Formula 1 System will pump products based on formula selection (at the User Interface portion

of the Washer Interface Module) and the associated dispenser programming.

The Formula 1 product is packed in a safe, convenient “capsule”. Upon removing the cap from the

capsule, placing it in the dock and initiating an evacuation sequence (see section 3.6 for details

of the procedure), the entire contents are sprayed out of the capsule and the dispenser reservoir

is filled with a use solution.

2. Capsule Evacuation (Refer to fig 11.2 Plumbing Schematic)

At the beginning of the capsule evacuation “spray out “cycle, the dispenser controller turns on the

hot water valve allowing hot water, from the facility, to pass through the dispenser’s water valve,

through the integrated flow control, (to control the amount of water delivered through the system)

through the atmospheric vacuum breaker and pressure gauge and on through the nozzle located

in the bottom of the dock.

After two minutes of hot water spray, the controller turns the hot water off and turns on the cold

water from the facility and routes the water through the same valve and flow control system

through to the nozzle. The cold water spray is for one minute.

Note: The ratio of hot water to cold water on time is selectable through the

programming menus. See Section 4.10 and fig. 4.11 for details.

The hot spray followed by a cold spray sequence is repeated for four cycles by the controller. As

the reservoir is filling a float switch mounted on the rear reservoir wall (low float) will close and

signal the controller to start recirculating the solution through the delivery pump and distribution

valve manifold and routed through a tank mix eductor to thoroughly mix the solution into a

homogonous mixture. Each time a new capsule is docked, the tank will recirculate for thirty

minutes. At every hour, on the hour, the controller will initiate the same recirculation sequence for

five minutes to keep the solution mixed.

After the four hot water/cold water cycles, the controller then continues to fill the reservoir with cold

water sprayed through the nozzle until the solution level closes a second float switch (high float)

mounted on the back wall of the reservoir. The cold water flow continues for four more minutes

after the high float switch closes.

Each capsule produces a use solution of approximately 9.5 gallons. If there is demand for the

Formula 1 product from the washers via the Washer Interface Module, the controller will deliver

the programmed volume of product to the required washer. Until the next capsule is docked and

evacuated, every hour, on the hour, the tank will be recirculated to keep the solution mixed.

The controller continuously monitors the float switches for product level. It is possible through the

programming menus to check the product level. If the product is at or above the high float, the

level will be reported as “HIGH”, if the level is at or below the below the low float, the level will be

reported as “LOW”. If the level is anywhere between “LOW” and “HIGH” the level will be reported

as “MID”. If the low float is open and the high float is closed the controller will display “????” for

level as an indication of an error.

As the dispenser responds to demand from any of the washers, the reservoir level will drop until

the low float switch opens. When the low float switch opens, the controller will turn on the “TANK

EMPTY” light and the audible alarm. The lid latch will unlock the lid and the lid will spring open.

All of these actions indicate that he capsule should be replaced and the capsule evacuation

sequence initiated. If product dosing continues for 90 seconds of cumulative pump run time

beyond low level, without capsule replacement, the dispenser will be in Lock Out mode. At this

point, the dispenser will ignore washer signals for product until a new capsule is docked and spray

out initiated. In the diagnostic menu, tank level will display “LOCK.”

The Formula 1 product can be programmed for amounts up to 999 ounces (29544 milliliters).

Liquid products (added via the auxiliary pump) are pumped directly from their shipping containers

to the washers. Each product injection may be delayed up to 999 seconds. Liquid products can be

programmed for amounts up to 33.3 ounces (985 milliliters). Up to 5 formulas may be programmed

for each washer. Chart Stop output wiring connections are available at the Washer Interface.

2. Specifications

2.1. Controller/Dispensing Unit

Figure 2.1

1/4 turn

fastener 1/4 turn

fastener

2.1.1. Dimensions

Height …………………………………………. 36.5 inches (927.1 mm)

Width ………………………………………….. 19.9 inches (505.5 mm)

Depth ………………………………………….. 24.1 inches (612.1 mm)

Weight …………………………………………. 76.0 lbs. (34.5 Kg)

Power ………………………………………….. 120 VAC, 60HZ, 3A

(GFI circuit recommended)

Washers ……………………………………….. 3 Maximum

Communications Cable …………………….… One 14’ and One 25’ cables supplied

Pump

Lift & Run …………………………………… 10’ lift max; 50’ run max

Pump Flow Rate …………………………… 1 GPM (approximately)

2.1.2. Service Access

The dispenser unit includes a controller and pump housing. The controller electronics are

accessible through a keyed-access plate to the right of the controller face plate. The

plumbing and water supply can be accessed on the back of the unit. The pump and product

diverter valve assembly are accessible by rotating the two 1/4 turn fasteners on the face of

the pump tray and pulling out the pump tray (see Figure 2.1).

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