Metos WD-90GR FLEX Service Manual

Metos WD-90GR FLEX Service Manual

Potwasher with granulate
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POTWASHER WITH GRANULATE
WD-90GR FLEX & WD-90GR HC
(translation of the original documentation)
Service manual
S/N:
Valid from: 15. 05. 2011
Rev.: 2.0
4246124, 4246125

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Summary of Contents for Metos WD-90GR FLEX

  • Page 1 POTWASHER WITH GRANULATE WD-90GR FLEX & WD-90GR HC (translation of the original documentation) Service manual S/N: Valid from: 15. 05. 2011 Rev.: 2.0 4246124, 4246125...
  • Page 3: Table Of Contents

    WD-90GR Rev. 1. Safety instructions ................1 1.1 General information ..................1 1.2 Transport ......................1 1.3 Installation ......................2 1.4 Detergent and drying agent ................2 1.5 Operation ......................2 1.5.1 Hot water ....................2 1.5.2 Crushing risk ..................... 2 1.5.3 Risk of slipping ..................
  • Page 4 WD-90GR Rev. 3. Adjustment instructions ..............14 3.1 Diagnostics function ..................14 3.2 Activating and using the diagnostics function ..........15 3.2.1 REFERENCE VALUES ................16 3.2.2 Other information from the diagnostics system ........18 3.2.3 DIAGNOSIS .................... 18 3.2.4 RELAY TEST ..................18 3.2.5 STATISTICS ...................
  • Page 5: Safety Instructions

    WD-90GR Rev. 2.0 (20110515) Safety instructions 1. Safety instructions 1.1 General information The machine is CE marked, which means that it complies with the requirements of the EU machinery directive with regard to product safety. Product safety means that the design of the machine will prevent personal injury or damage to property. Modifying the equipment without the approval of the manufacturer invalidates the manufacturer’s product liability.
  • Page 6: Installation

    WD-90GR Rev. 2.0 (20110515) Safety instructions 1.3 Installation This symbol on a component is a warning of electrical equipment. The machine is sensitive to electrostatic discharge (ESD), which is why a static electricity wrist- band must be used when handling the electronics. Water and steam pipes must only be connected by authorised personnel.
  • Page 7: Cleaning

    WD-90GR Rev. 2.0 (20110515) Safety instructions 1.6 Cleaning The temperature of the water in the tank is approx. 58°C and contains detergent. Be careful when draining and cleaning the tank. Use protective gloves. 1.6.1 Pressure washing The machine must not be cleaned with a pressure washer. If pressurised water is directed at the electrical cabinet, the water may penetrate the cabinet and dam- age the electrical equipment, which may affect the safety of the machine.
  • Page 8: Repairing And Servicing The Dishwasher

    WD-90GR Rev. 2.0 (20110515) Safety instructions 1.7 Repairing and servicing the dishwasher Disconnect the power supply before opening the electrical cabinet. Avoid touch- ing hot pipes and the booster heater. 1.7.1 Safety instructions if the machine is not functioning Check the following: •...
  • Page 9: Operational Description

    Operational description 2. Operational description 2.1 General information The WD-90GR FLEX / WD-90GR HC is a potwasher with granulate primarily in- tended for washing heavily soiled items which are used for preparing and storing food. The machine comes as standard with electric heating but is also available with steam heating.
  • Page 10: Design

    WD-90GR Rev. 2.0 (20110515) Operational description 2.2 Design The machine is manufactured entirely from non-corrosive materials. The bottom frame has adjustable feet and attachments for pumps. The electrical cabinet is at the top edge of the machine and the incoming compo- nents are clearly labelled.
  • Page 11 WD-90GR Rev. 2.0 (20110515) Operational description Hot water Cold water Cold water nozzle for steam reduction Drive motor Ventilation duct Washer arms Circular table Granulate valve Granulate wash pump Wash pump Wash tank Wash tank with granulate Drive arm Rinse pipe for final rinse Booster heater The lower part of the machine contains the pumps and tanks.
  • Page 12: Control Panel

    WD-90GR Rev. 2.0 (20110515) Operational description The hot water, which is connected to (1), is used for filling the tank and for rinsing the items during the final rinse stage. The final rinse water is heated to rinsing temperature in the booster heater. The cold water is connected to (2) and is used to cool the rear panel of the ma- chine after the wash cycle, to reduce the amount of steam released when the door is opened.
  • Page 13 WD-90GR Rev. 2.0 (20110515) Operational description The control panel has a display (1) which shows a variety of text messages. You can see, for example, a description of the sequence of events when the machine is started up, alarm messages, diagnostic messages, temperatures, reference values and the current wash programme etc.
  • Page 14: Operating Principle

    WD-90GR Rev. 2.0 (20110515) Operational description 2.4 Operating principle 2.4.1 Starting the machine • Press button (6). • The printed circuit board is live. • The booster heater starts to heat up (E41=1) and remains on until a tem- perature of 80°C has been reached. •...
  • Page 15 WD-90GR Rev. 2.0 (20110515) Operational description Intermediate spin cycle • Once the chemical pump stops, the intermediate spin cycle starts and runs for a preset time. Final rinse • When the intermediate spin cycle is finished, valve Y02 opens and the final rinse starts.
  • Page 16: Wash Cycle For Programmes P1, P2 And P3

    WD-90GR Rev. 2.0 (20110515) Operational description 2.4.5 Wash cycle for programmes P1, P2 and P3 • The granulate pumps and the rotating table start. The granulate valve is in the position for washing with granulate. • When the granulate pump stops, the granulate valve switches to the posi- tion for washing without granulate.
  • Page 17: Controlling The Washing Process

    WD-90GR Rev. 2.0 (20110515) Operational description 2.5 Controlling the washing process WD9_18 Circuit board Buttons for changing reference values The various machine functions are controlled by a microcomputer. The circuit board (1) is located in the electrical cabinet. The machine has three different authorisation levels. •...
  • Page 18: Adjustment Instructions

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions 3. Adjustment instructions The machine is equipped with WEB Tool, which allows you to connect to the ma- chine's website. This is described in a separate manual. This symbol on a machine component is a warning of electrical equipment. The component may only be removed by a qualified electrician.
  • Page 19: Activating And Using The Diagnostics Function

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions Display for messages. LED which lights when the diagnostics function is activated. Button for activating the diagnostics function. Button for switching between diagnostic messages. On/Off LED which lights when the power is switched on. I/O board Contact for Ethernet connection Plus and minus buttons for changing values.
  • Page 20: Reference Values

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions 3.2.1 REFERENCE VALUES The table shows the normal factory settings. Reference values. Authorisation levels S1 and S2 Text in display (1) Reference Comment value (1) TEMPERATURE TANK 58°C (2) GRANULE WASHTIME P1 3.2 minutes (3) GRANULE WASHTIME P2 6.2 minutes (4) GRANULE WASHTIME P3...
  • Page 21 WD-90GR Rev. 2.0 (20110515) Adjustment instructions A computer must be connected to the machine for people with authorisation level S2 to be able to change the following reference values. You connect to the ma- chine's website and log in with a password to use WEB Tool to change the values. Reference values.
  • Page 22: Other Information From The Diagnostics System

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions 3.2.2 Other information from the diagnostics system In addition to the setting options for reference values, the diagnostics system can display other information. It is also possible to check the operation of the various components of the machine.
  • Page 23: Language

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions 3.2.7 LANGUAGE • When the diagnostics function has been activated with button (3), select the LANGUAGE group by pressing the same button. • Press button (4) to display the language options. • Choose the language by pressing the plus and minus buttons (9) on the cir- cuit board.
  • Page 24: Setting Up The Frequency Converter

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions 3.3 Setting up the frequency converter Enter 90_16 Frequency converter Display Memory module Button for switching between codes and adjusting values Button for switching between codes and adjusting values Enter button...
  • Page 25: Checking And Setting The Reference Values

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions 3.3.1 Checking and setting the reference values • When checking and setting the reference values for the frequency convert- er, the FU/M circuit breakers for the operating voltage and FU16 for the drive motor must be switched on. •...
  • Page 26: Alarm Codes Frequency Converter

    WD-90GR Rev. 2.0 (20110515) Adjustment instructions 3.3.2 Alarm codes frequency converter Alarm Cause Action cF / CF / GF Memory failure in frequency converter. Reset the frequency converter (C02=2).Re- move the short-circuit between 20 and 28 on the freq. Converter. The ext "OFF" must be dis- played.Note ! All values must be restored after resetting the freq.
  • Page 27: Service

    WD-90GR Rev. 2.0 (20110515) Service 4. Service The machine must be serviced after around 15,000 washes or once per year. Read the SAFETY INSTRUCTIONS chapter carefully before starting work. 4.1 Repairs and machine maintenance Switch off the power supply at the mains switch before working on the machine. The electrical cabinet may only be opened by a qualified electrician or trained per- sonnel.
  • Page 28: Drive Motor

    WD-90GR Rev. 2.0 (20110515) Service 4.2 Drive motor 4.2.1 Assembly The machine has a worm gear to drive the circular table. Fitting When fitting the worm gear, it is important that no stresses are applied to the gear housing when it is bolted in position. Therefore you must ensure that the base of the gear is level and stable.
  • Page 29: Troubleshooting

    WD-90GR Rev. 2.0 (20110515) Troubleshooting 5. Troubleshooting 5.1 General information The electrical cabinet may only be opened by a qualified electrician or trained per- sonnel. NOTE: Read the SAFETY INSTRUCTIONS before attempting any form of trou- bleshooting and repair work. All work involving the dismantling of equipment must be carried out by authorised service personnel.
  • Page 30: Troubleshooting

    WD-90GR Rev. 2.0 (20110515) Troubleshooting 5.2 Troubleshooting STARTING THE MACHINE PROBLEM CAUSE ACTION No indication on the control pan- No power supply to the machine. Check the fuses and the incom- el display when the control but- ing power cable. ton is pressed.
  • Page 31 WD-90GR Rev. 2.0 (20110515) Troubleshooting TEMPERATURES PROBLEM CAUSE ACTION The tank temperature is too low. The heating element in the tank Replace the element. is defective. (Electrically-heated machine). The relay is not working. (Electri- Check and, if necessary, replace cally-heated machine). the relay.
  • Page 32 WD-90GR Rev. 2.0 (20110515) Troubleshooting STARTING THE WASH PROGRAMME, WASHING PROBLEM CAUSE ACTION The machine does not start The doors are not closed. Close the doors. washing. One of the doors’ solenoid Check and, if necessary, replace switches is not working. the solenoid switch.
  • Page 33 WD-90GR Rev. 2.0 (20110515) Troubleshooting WASHING RESULTS PROBLEM CAUSE ACTION The machine is not cleaning The rinsing and washing nozzles Check and clean the nozzles. properly. are clogged with dirt. There is too little detergent. Check that there is sufficient de- tergent and that the detergent dosage is correctly set.
  • Page 34: Error Messages

    WD-90GR Rev. 2.0 (20110515) Troubleshooting 5.3 Error messages Machine faults and user faults are indicated with messages on the display (1). In addition to the alarms described in the INSTRUCTIONS FOR USE, there are also the following alarms: ALARM TEXT CAUSE ACTION (63) POWER SUPPLY...
  • Page 35 WD-90GR Rev. 2.0 (20110515) Troubleshooting ALARM TEXT CAUSE ACTION (31) TEMPERATURE The temperature sensor has Replace the sensor. SENSOR ERROR registered either a failure or a TANK B21 short-circuit in the sensor. CALL SERVICE (32) TEMPERATURE The temperature sensor has Replace the sensor.

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