Ecolab Formula1 Installation & Operation Manual
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Ecolab Formula1 Installation & Operation Manual

Ecolab Formula1 Installation & Operation Manual

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Installation & Operation Manual
Retain this manual for installation, operation,
programming, and servicing information.
This manual is intended for dispenser 9259-1069 (not 9259-1051).
1
Form 36922/0401/0525
Copyright Ecolab Inc. 2006
9259-2201

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  • Page 1 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...
  • Page 2 This page intentionally left blank...

  • Page 3: Table Of Contents

    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.
  • Page 4 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.

  • Page 5: Introduction

    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.

  • Page 6: System Description And Packing List

    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.
  • Page 7 Fig 1.2 Fig 1.3 Item Part Number Description 9259-1075 Washer Interface Module 9259-2226 Communications Cable, 25 ft 9259-2222 Cable, Auxiliary Pump Adapter 9259-2225 Cable, communications, 14 ft 8524-2501 Vacuum Breaker 8539-0079 Pressure Gauge 8501-5026 Tubing, ½ in OD Poly (80 ft) 9482-2186 Water Hoses 15 ft (2 provided) 8501-6046...

  • Page 8: Principle Of Operation

    Miscellaneous Parts 8579-3032 Hose Y w/out shutoff valves (Qty 2) 8730-1032 Hose Clamp 11/16 to 1-1/4 SST 8524-4391 Check valve (Qty 3) 8730-1149 Hose Clamp 7/32” to 5/8” SST (Qty 6) 8561-5565 Union Connector ½ Push in (Qty 3) 9265-3303 32oz Spray Bottle 9259-1075 Washer Interface Module (2 Provided)
  • Page 9 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.

  • Page 10: Specifications

    2. Specifications 2.1. Controller/Dispensing Unit 1/4 turn 1/4 turn fastener fastener Figure 2.1 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 ………………………………………..

  • Page 11: User And Machine Interface Modules

    2.2. User and Machine Interface Modules User Interface Washer Interface Fig 2.2 Washer Interface Module 2.2.1. Dimensions User Interface • Height…………………… 4.5" (114.3 mm) • Width …………………… 3.5" (88.9 mm) • Depth…………………… 2.2" (55.9 mm) • Weight………………… 0.8 lb (0.36 kg) Machine Signal Interface •...

  • Page 12: Installation Requirements

    2.4. Installation Requirements 2.4.1. Water Supply • Both hot and cold, min 15 psig dynamic @ pressure gauge. • 3/4” male garden hose connections. • Hot water temperature – minimum 100°F, maximum 145°F. NOTE: Accounts with hot w ater >145°F, will require a tempering valve kit art # 9259-1043).

  • Page 13: System Installation

    3. System Installation 3.1. Preplanning It is very important to ensure that all necessary equipment is available in order to complete the Formula 1 installation. A few minutes of planning may save a considerable amount of time during the installation. It is necessary to locate a suitable location for the dispenser. Important considerations include: •...

  • Page 14: Accessories & Optional Parts List

    3.2. Accessories & Optional Parts List 14’ Communication Cable ……….……………….. 9259-2225 25’ Communication Cable ……….……………….. 9259-2226 50’ Communication Cable ……….……………….. 9259-2227 (only 2 included with dispenser Washer Interface Module ………….……………… 9259-1075 Optional Auxiliary pump ……………..……………. 9259-1046 (if liquid product is to be used) Tempering Valve Assembly …………….…………...
  • Page 15 HOT WIRE (BROWN) CONNECTION TO BREAKER NEUTRAL WIRE (BLUE) CONNECTION TO BREAKER GROUND WIRE (GREEN/YELLOW) CONNECTION TO CHASSIS GROUND STUD...

  • Page 16: Installation Plumbing

    3.4. Installation Plumbing Formula 1 installation requires plumbing the overflow connection, attaching the vacuum breaker bracket, connecting water sources (both cold and hot), and connecting the product delivery tubes. TANK DRAIN PRESSURE GAUGE AND VACUUM RESERVED FOR FUTURE BREAKER APPLICATIONS WATER INLET FROM TO USER INTERFACE VALVE...
  • Page 17 3.4.1. Plumbing the Overflow Connection An overflow outlet for the dispenser’s tank is provided to direct the solution to a drain should the tank level sensors or water solenoid fail. The overflow outlet (blue hose barb) is located on the back of dispenser. A length of 5/8” tubing (as provided with dispenser) must be connected to the outlet and routed to a floor drain.
  • Page 18 3.4.2. Attaching the Vacuum Breaker Attach the vacuum breaker bracket to the electrical enclosure, using the two supplied #8-32 screws (factory-installed at the mounting location). (See Figures 3.3, 3.4, and 3.5.) Figure 3.3 Figure 3.4 Figure 3.5 Insert the inlet tube (originating from the base of the dispenser) into the inlet (lower) fitting on the vacuum breaker.
  • Page 19 3.4.3. Connecting Water Supplies The dispenser automatically alternates between hot and cold water during the fill cycle. Hot water >145°F can cause separation of the detergent use-solution and can adversely affect the enzymes contained in some Formula 1 products. For installations with hot water in excess of 145°F, a tempering valve kit (P/N 9259-1043) must be ordered.
  • Page 20 3.4.4. Connecting the Product-Delivery Tubes A 1/2” OD (3/8” ID) polyethylene tube (P/N 8501-5139) is used to deliver the detergent to each laundry machine. It is important that the outlet tubing DOES NOT exceed 50’ (15 meters) under normal installation. Locate the three 1/2”...

  • Page 21: User And Machine Interface Module Installation

    3.5. User and Machine Interface Module Installation 3.5.1. Washer Interface Components Dispenser Communications Ports Reserved for Future Use Figure 3.11 Figure 3.12 Notes: Each Washer Interface Module has two communications ports (6 pin). They are identical and completely interchangeable. You may connect the communication cables to either port. The dispenser is supplied with two communications cables (one 14 ft.
  • Page 22 Note: Make certain that you follow all local electrical codes and requirements during your installation Mount the washer interface box to the laundry machine controller box, using the conduit elbow. Route the black (for detergent), red (for liquid product) and white/black and white/red (for common) to the inside of the laundry machine controller.
  • Page 23 3.5.3. Communications Cable Communication cable and ports must not get wet. The communications cable is used to link the Washer Interface Module with the dispenser. Two cables (14’ and 25’) come in the installation kit. 25’ is the recommended maximum cable length.
  • Page 24 Referring to fig 3.16, route the cable (Figure 3.14) from the Washer Interface Module to the back of the dispenser and connect to the port labeled Machine #1 (Figure 3.15). Insert cable gently into the communications port of the washer interface module until it locks.
  • Page 25 Fig 3.17 User Interface Power up Displays If a number (0 – 99) is displayed, then the address has already been set. Follow the procedure below to correct/re-set the Washer Interface Module address: • Referring to section 5.2.1 Log into the programming mode of the F1 controller.

  • Page 26: Power Up

    Start Up 3.6. Power Up (See section 3.3.1 for hard wiring requirements and procedures) 3.6.1. Referring to Fig 3.2 for component locations 1. Plug the dispenser power cord into a convenient, suitable outlet 2. Turn on the Main Power Switch/Circuit Breaker 3.

  • Page 27: Calibrate Dispenser

    After Docking Formula 1 Capsule and tank is FULL, prime product lines to washer. There are two priming options with the Formula 1 System. (See Section 4.8 and fig 4.9). 3.9. Calibrate Dispenser Refer to the Time Calibration instructions (see Section 4.9 and fig 4.10). 3.10.

  • Page 28: Programming

    4. Programming 4.1. General Information The information provided here will take you step-by-step through the programming of the Advanced Laundry Control System Controller. Refer to figures 4.3 through 4.11 to help you access the various screens. 4.1.1. Definitions and Conventions •...
  • Page 29 Controller Component Descriptions 4.1.2.1. The following numbered items refer to Figure 4.2 KEY PAD: These keys provide a means for selecting/reviewing/programming: Center/NEXT key: Normal operation: access password screen. Program Mode: menu advance. Up arrow key: Normal operation: no function. Program Mode: scroll options, increment displayed value, and activate (turn on) selection.

  • Page 30: Program Mode

    4.2. Program Mode 4.2.1. Enter Program Mode To enter program mode, press the NEXT key once. The display changes to “ENTR PASSWRD.” Then press the UP arrow key, LEFT arrow key, RIGHT arrow key, and DOWN arrow key. “NEXT” “UP” “LEFT”...
  • Page 31 MAIN MENU Figure 4.3 ENTER PASSWRD QUICKSTART ACCT SETUP WASHER SETUP FORMULAPROG RECORDS PRIME MODE TIME CALIB DIAGNOSTIC EXITING 5...
  • Page 32 QUICKSTART MENU Figure 4.4 QUICKSTART to scroll number of washers WASHERS 2 (1-3 available) Auxiliary Pump? AUX PUMP? N to toggle (YES or NO) Chart Stop – Washer 1 CHARTSTOP? N to toggle (YES or NO) Chart Stop – Washer 2 CHARTSTOP? N to toggle (YES or NO)

  • Page 33: Quickstart (See Figure 4.4)

    Figure 4.4 Continued to toggle (YES or NO) CALIB? TIME CALIB CALIB? Returns to Top of menu ACCT SETUP CALIB? To advance to ACCT SETUP 4.3. QUICKSTART (See Figure 4.4) menu at any time A wrench icon (located at the top left of the screen) is displayed on all QUICKSTART screens. The QUICKSTART programming includes selecting the number of washers, electing optional product pumps, electing chart stop, and selecting machine capacities.
  • Page 34 ACCT SETUP MENU Figure 4.5 ACCT SETUP to scroll acct #s 10000000 to move the (up to 999999999) flashing cursor Note: A flashing line beneath a number indicates the digit that will be changed. Use the LEFT and RIGHT arrow keys to move the position of the flashing cursor. Note: If you press the RIGHT arrow key when the right-most number is flashing, you will advance to the next screen.

  • Page 35: Acct Setup (See Figure 4.5)

    4.4. ACCT SETUP (See Figure 4.5) A wrench icon is displayed at the top left of the screen on all ACCT SETUP screens. Account Setup programming includes establishing account number, unit of measure (UOM), and date/time. Once ACCT SETUP is displayed, you can press the RIGHT arrow key to step through the available screens.
  • Page 36 WASHER SETUP MENU Figure 4.6 WASHER SETUP SET WASHER 1 to scroll formula mapping for 1 MAP TO 01 Formula / Washer ( 0-99 ) Repeat steps for Formulas 2-4 / Washer 1 to scroll formula mapping for 5 MAP TO 05 Formula / Washer ( 0-99 )

  • Page 37: Washer Setup (See Figure 4.6)

    4.5. WASHER SETUP (See Figure 4.6) A wash machine icon (located at the top of the screen) indicates that you are in a WASHER SETUP screen. WASHER SETUP is where you set the User Interface Formula numbers to match the Washer formula numbers that the account is using. The user interface is preprogrammed with 2-digit formula numbers.
  • Page 38 FORMULA PROGRAMMING MENU Figure 4.7 FORMULA PROG Delay Time Delay Formula # (Seconds) to select product delay 1DLY Formula /Washer (Formula 1 product) (000 – 999 sec) Formula 1 Washer # product Press BOTH to select 1AMT product amount Amount (000 –...
  • Page 39 FORMULA PROG Menu (Continued from previous page) to select chart stop runtime 1TMR (MN) Formula /Washer (00 – 99 MINUTES) Repeat previous steps for each formula (2-5). COPY entries to Washer COPY TO W2? N to toggle (YES or NO) If NO, repeat previous steps for Washer 2.

  • Page 40: Formula Prog (See Figure 4.7)

    4.6. FORMULA PROG (See Figure 4.7) A chemical flask icon (located at the top center of the display) indicates that you are in a FORMULA PROG screen. Formula Program options include programming delays, volumes, and chart stop for up to 5 Formulas, 3 washers, and 2 products (Formula 1 and auxiliary product). Other screen indicators include the following: Formula Identifier –...
  • Page 41 RECORDS MENU Figure 4.8 RECORS SOFTW 2. X The last capsule change is displayed to review 00 0000 0000 history of capsule changes Clear Capsule History? CLEAR LOG? N to toggle (Yes or No) Clear ALL load counts? CLEAR CNT? N to toggle (Yes or No) Displays pump run times...

  • Page 42: Records (See Figure 4.8)

    4.7. RECORDS (See Figure 4.8) A file cabinet icon (located in the top right of the display) indicates that you are in a RECORDS screen. The RECORDS programming menu includes software revision information, capsule change history, Formula 1 pump run time, filter cleaning run time, and clearing options (i.e. capsule history, load counts, pump run time, and filter change run time).
  • Page 43 PRIME MODE MENU Figure 4.9 PRIME MODE PRIME Detergent for Washer PRIME DET to turn on prime to turn off prime PRIME Detergent for Washer PRIME DET to activate prime to deactivate prime PRIME Detergent for Washer PRIME DET to activate prime to deactivate prime PRIME Auxiliary Pump for Washer...

  • Page 44: Prime Mode (See Figure 4.9)

    4.8. PRIME MODE (See Figure 4.9) An icon of a hand pressing a button (located at the top of the screen) indicates that you are in PRIME MODE. Other screen indicators include: Capsule icon – located in the bottom left of the screen – indicates that you are priming the Formula 1 product.
  • Page 45 TIME CALIB MENU Figure 4.10 TIME CALIB CALIBRATE detergent pump to Washer CALIB OZ 16.0 to calibrate Pump ( 5 sec on ) ENTER OUNCES ENTER OZ 16.0 to select volume dispensed (6.0 – 26.0 ounces) CALIBRATE detergent pump to Washer CALIB OZ 16.0 to calibrate Pump ( 5 sec on )
  • Page 46 TIME CALIB Menu (Continued From Previous Page) CALIBRATE AUX PUMP? to calibrate CALIB OZ 3.4 Pump / Washer ( 20 sec on ) ENTER OUNCES ENTER OZ 3.4 to select volume dispensed ( 1.0-6.0 ounces ) CALIBRATE AUX PUMP? to calibrate CALIB OZ 3.4 Pump / Washer ( 20 sec on )

  • Page 47: Time Calib (See Figure 4.10)

    Calibrating From User Interface While in TIME CALIB MODE, you can also calibrate at the User Interface: Select TIME CALIB (at the dispenser). Select the product (Formula1 or auxiliary) and washer (1, 2, or 3) that you want to calibrate. Note: At the User Interface, the display shows “animated”...
  • Page 48 DIAGNOSTIC MENU Figure 4.11 DIAGNOSTIC to turn “ON” to turn “OFF” GRN LED green LED light green LED light to turn “ON” to turn “OFF” YEL LED yellow LED light yellow LED light to turn “ON” to turn “OFF” RED LED red LED light red LED light again for...
  • Page 49 DIAGNOSTIC Menu (Continued from previous page) to retract to extend (latch) LID LATCH LID LATCH LID LATCH to activate to deactivate COLD H2O Cold water valve Cold water valve to activate to deactivate HOT H2O Hot water valve Hot water valve to activate the to deactivate the RECIRC VLV...

  • Page 50: Diagnostic (See Figure 4.11)

    4.10. DIAGNOSTIC (See Figure 4.11) A cross icon (located at the top of the display) indicates that you are in a DIAGNOSTIC screen. GRN LED / YEL LED / RED LED – these screens are to confirm that the LED lights are functioning.

  • Page 51: Exit Programming

    Chart Stop for the displayed washer and the DOWN arrow key to deactivate Chart Stop. Press the RIGHT arrow key to advance to the next screen. 14. TANK LOW, MID, or HIGH – this screen indicates product level in the tank. When there is a mismatch of levels (i.e.

  • Page 52: Account Features

    5. Account Features 5.1. Replacing Product Capsule Replace capsule only when dispenser calls for new capsule (amber light, alarm, and controller message). Lift dock lid. Remove empty capsule and discard. Remove and discard cap from new product capsule. DO NOT REMOVE THE FOIL SEAL! Dock new capsule.
  • Page 53 5.3.1. Total Load Counts From the idle screen, the Load Counts can be reviewed. Use the LEFT and RIGHT arrow keys to review load counts for up to 5 formulas for each of the three washers and total load count. The display indicators include the following: Laundry cart icon- indicates that the displayed number refers to load counts.

  • Page 54: Set-Up And Operation

    6. Set-Up and Operation The following procedures are designed to check out the system to ensure that everything is operating correctly. It is assumed that the following steps have been completed. The laundry machine supply signals have been wired to the Washer Interface Module. The communications cables have been plugged in.

  • Page 55: Troubleshooting

    7. Troubleshooting Symptom Possible Cause Action a. Press Enter. Screen Display Incorrect Key Sequence should read ENTR PASSWRD. Now 7.1 Unable to enter password enter password sequence. when attempting to access In-active Keys programming menu. b. Use “Next” “Up” sequence prior to Tank at Low Level entering password (required at low level)
  • Page 56 Symptom Possible Cause Action a. Check main power switch on back of dispenser. b. Verify that main power cord is plugged in. c. Verify that main circuit breaker and 1. No power supplied to the wall circuit breaker are turned on. dispenser.
  • Page 57 7.6 Poor Results in one 2. Product Valve product valve coil. Washer c. Check/clean product valve strainer. d. Replace Product Valve. a. Call Ecolab Technical 3. Formula Service for recommendation. 4. Missing signals from that Verify Wiring washer a. Verify that pump is operational and dispensing correct amount.
  • Page 58 Symptom Possible Cause Action a. Verify that there are product 1. Product amounts amounts entered into the dispenser. a. Ensure that the auxiliary pump is plugged in. b. Check the connections between 7.8 Auxiliary pump does dispenser and the auxiliary pump not run.
  • Page 59 Symptom Possible Cause Action 7.13 Unable to save date/time 1. Faulty battery in controller Replace controller changes. 7.14 Red LED on Controller is 1. Controller Fault Call Tech Service illuminated 1. Lid not closed a. Close lid 2. Lid magnet is missing a.

  • Page 60: Replacement Parts

    8. Replacement Parts Water Valve Front Panel Pump Tray Components Fig 8.1...

  • Page 61: Pump Tray

    8 TUBING Fig 8.2 6 ELBOW 5 COUPLING 7 PUMP 1 DISTRIBUTION VALVE 3 MALE QUICK 4 FEMALE QUICK 2 ELBOW COUPLING COUPLING 8.1. Pump Tray PART NO. DESCRIPTION REF. 9259-2013 FORMULA 1 PRODUCT VALVE ASSEMBLY 8605-9006 ELBOW, 90 DEG, 3/4FNPT PP 8490-0015 MALE QUICK COUPLING, ¾...

  • Page 62: Electrical Parts

    8.3. Electrical Parts 2 Low Tank Light 4 Controller, Programmed, Complete with I/O 5 Fuse 3 Power Supply...

  • Page 63: Electrical Part Numbers

    Electrical Part Numbers REF. PART NO. DESCRIPTION 9259-1075 Washer Interface Module 8363-0541 Low Tank Light 8349-0001 Power Supply 9259-2200 Controller, Programmed, Complete 8390-0357 Fuse ¼ x1-1/4 3A 250V 9259-2225 Cable Communications (14 ft) 9259-2226 Cable Communications (25 ft) 9259-2227 Cable Communications (50 ft) 8305-3001 Liquid level Float Switch 8.4.
  • Page 64 Piercing Device 9259-2109 Reed Switch Spray Nozzle 8305-1136 8531-2502 Dock Lid Switch 8305-1102 & 9259-2111 Fig 8.5 Vacuum Breaker 8524-2501 Pressure Gauge 8539-0079 Fig 8.6 Strainer Outlet 8530-0502 Line Strainer 60 Mesh SST Recirculation Inlet Tube...

  • Page 65: Auxiliary Pump Components

    8.5. Auxiliary Pump Components REF. NO. PART NO. DESCRIPTION 9259-1046 OPTIONAL AUXILIARY PUMP 9261-0047 FORMULA 1 EPDM SQUEEZE TUBE (used with aux. pump) 9259-3425 FORMULA 1 VITON SQUEEZE TUBE (used with aux. pump) (VITON SQUEEZE TUBE IS FOR USE WITH SANITIZER, SOUR, OR SOLVENTS) 9259-3144 FORMULA 1 REPL AUX PUMP MOTOR...

  • Page 66: Maintenance

    Maintenance • TM should check the calibration of the Formula 1 pump 30 days after installation and every six months thereafter (see section 4.9). • Filter must be cleaned every 600 hours of cumulative run time (see section 4.7). NOTE: IF YOU ARE IN AN ENVIRONMENT WITH E XCESS LINT, CHECK THE STRAINER MONTHLY!

  • Page 67: Appendix

    9. Appendix 9.1. Pump Access Fig. 10.1 Fig 10.2 9.2. Plumbing Schematic Fig 10.3 Formula 1 Dispenser Hydraulic Schematic...

  • Page 68: Formula 1 Dispenser - Internal Construction

    9.3. Formula 1 Dispenser – Internal Construction Capsule Float Piercing Switches Device Spray Nozzle Tank Mix Eductor Manifold Incoming Water Tank Line Outlet Strainer Pump Distribution Valve Fig 10.4...

  • Page 69: Labels And Overlays

    9.4. Labels and Overlays 9259-2221 Formula 9259-2219 User Name Labels Interface Nameplate 9259-2220 Formula Number Labels...

  • Page 70: Programming Flow Chart

    9.5. Programming Flow Chart See Addendum for Programming Flow Chart...
  • Page 71 Formula 1 Programming Guide – Addendum to 9259-2201 for Dispenser 9259-1069 Not 9259-1051 FORMULA 1 02COUNT 0001 03COUNT 0001 05COUNT 0001 TOTAL 00005 01COUNT 0001 04COUNT 0001 ENTR PASSWRD NOTE: AT LOW LEVEL (EMPTY), PRESS ? AND ^ TO ACCESS PASSWORD SCREEN DEFAULT PASSWORD - (UP/LEFT/RIGHT/DOWN) QUICKSTART...
  • Page 72 WASHER INTERFACE USER INTERFACE TO TABLET PC (ETHERNET ONLY) FIELD WIRING 10-FT PUSH BUTTON CABLE LIQUID PROD YEL(SIGNAL 3=AUX) WHT/RED GRY=COMMON ORG(SIGNAL 2) WHT/VIO=N.OPEN BRN(SIGNAL 1=DET) TABLET BLEACH WHT/BRN WHT/GRY=N.CLOSED GRN(CHART STOP) CHARTSTOP BLK(DC GND) WHT/BLK FORMULA 1 PROD CONNECTIONS RED(+ 5VDC) WASHER #1 TO TABLET PC (ETHERNET ONLY)

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