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OPERATING & MAINTENANCE MANUAL EX-15 and EX-25 Emerald Series 438 9030-01/02 97.02 WARNING: ALL OPERATING AND MAINTENANCE PROCEDURES SHOWN ON THE NEXT PAGE OF THIS MANUAL MUST BE FOLLOWED DAILY FOR PROPER OPERATION OF YOUR WASCOMAT MACHINE. PLEASE ENTER THE FOLLOWING INFORMATION AS IT APPEARS ON THE MACHINE(S) DATA PLATE(S).
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NOTICE TO: OWNERS, OPERATORS AND DEALERS OF WASCOMAT MACHINES IMPROPER INSTALLATION AND INADEQUATE MAINTENANCE, POOR HOUSEKEEPING AND WILLFUL NEGLECT OR BYPASSING OF SAFETY DEVICES MAY RESULT IN SERIOUS ACCIDENTS OR INJURY. TO ASSURE THE SAFETY OF CUSTOMERS AND/OR OPERATORS OF YOUR MACHINE, THE FOLLO- WING MAINTENANCE CHECKS MUST BE PERFORMED ON A DAILY BASIS.
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SAFETY AND WARNINGS SIGNS Replace If Missing Or Illegible One or more of these signs must be affixed on each machine as indica- ted, when not included as part of the front instruction panel. LOCATED ON THE OPERATING INSTRUCTION SIGN OF THE MACHINE: PRECAUCION CAUTION 1.
Introduction Introduction The washer-extractors described in this manual are high-speed extract machines Fig. with built-in wash programs. They are designed for use in applications such as apartment-house laundries, hotels, commercial laundries, in industry, hospitals, small institutions, and by other users who require a machine with a high level of reliability, good performance and easy maintenance.
Technical data Technical data EX-15 ES Dry load capacity up to 15 lbs Overall dimensions Width 720 mm 28 11/32 in Depth 660 mm 26 in Height 1100 mm 43 5/16 in Net weight 169 kg 373 lbs 1.6 ± 0.7 kN 390 ±...
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Technical data Technical data EX-25 ES Dry load capacity up to 25 lbs Overall dimensions Width 720 mm 28 11/32 in Depth 820 mm 32 9/32 in Height 1100 mm 43 5/16 in Net weight 255 kg 562 lbs 2.5 ± 0.95 kN 598 ±...
1" at the rear and sides, since most service operations are carried out from the front or top of the machine. Floor The floor must be able to withstand the following loads: EX-15 ES EX-25 ES static 390 lbs 598 lbs dynamic...
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Installation Mechanical installation Each machine is delivered with the drum locked in place by four security bolts fitted between the frame and the drum. In order to remove these and install the machine, proceed as follows: • Unpack the machine. •...
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Installation Water supply NOTE! All plumbing must conform to national and local plumbing codes. Fig. The water supply to the machine should be fitted with manual shut-off valves to facilitate installa- tion and servicing. Water inlets are labelled for hot and cold water Fig.
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Installation Steam connections (optional steam heating) The steam inlet pipe must be fitted with a manual cut-off valve in order to facilitate installation and service operations. Fig. Fit the filter supplied to the manual cut off valve. The connection hose must be of an approved type. Connection size at filter: DN 15 (1/2").
Installation Electrical installation Electrical installation must be carried out by an authorized electrician, and must follow national and local regulations. Make sure that the ground wire is properly connected. • Install a 1-phase circuit breaker for the machine’s electrical supply. •...
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Installation Start-up and safety checklist Before initial start-up of a Wascomat washer- extractor, the following safety checks must be performed: • Make sure that all electrical and plumbing Fig. connections have been made in accordance with applicable local codes. • Use only flexible water fill and drain hoses of the proper length to avoid sags and kinks.
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Installation Function control check-out list In the machine cylinder, you will find the warranty registration card, a copy of the warranty policy and other pertinent material. The warranty card should be completed and sent to Wascomat. All other items should be placed in a safe place for future reference.
Safety Rules Safety rules • This machine is designed for water washing only. • Machines must not be used by children. • All installation operations are to be carried out by qualified personnel. Licensed personnel are necessary for all electric power wiring. •...
Operating instructions The Emerald Series program unit controls the various functions of the machine in a certain time sequence with the aid of seven built-in standard programs. The standard programs can also be modified by selecting various options. By selecting options, the user has access to programs for all types of wash loads and degrees of soiling.
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Operating Instructions Washing Fig. • Press the button for the desired program. Perm Press • Now the LEDs alongside the program symbols Fig. will show what the selected program consists of. Warm Quick-Wash • Press the button(s) for any options required. Fig.
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Operating Instructions Fig. • Now the display will show the clock symbol and two digits. The two digits are the time left before the wash will be finished. The two digits indicating time left will not appear when the machine is first installed. Each program needs to have been used at least once before the time left will be displayed.
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Operating Instructions For coin-operated machines Select a wash program, then insert the number Fig. of coins corresponding to the figure shown on the display. As each coin is added the machine counts backwards towards 00 on the display. The machine will not start until the display shows 00. Fig.
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Operating Instructions Rapid advance Whole steps in programs can be skipped using rapid advance. START • Press and hold the START button until Fig. the program indicator LEDs have mo- ved past the program steps you wish to skip. Program end After final extraction, the LED by the Fig.
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Operating Instructions Maintenance This machine has been carefully designed to minimize preventive maintenance. However, the following routine operations should be performed at regular intervals (depending on how much the machine is used). Daily • Clean detergent residue from the door seal and check that the door does not leak.
Programming Coin-operated machines In coin-operated machines the prices for the various programs have to be programmed in. Values from the coin mechanism (the accumulated value) can be read out with the aid of the service program. If a machine is fitted with a coin mechanism after its original installation the relevant electronic circuitry will have to be activated before the prices can be programmed in.
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Programming Codes 91 and 92 are used to store the values for coin slots 1 and 2. For mechanisms with only one slot, only code 91 is used. The values to be stored are the ratio of one coin to the other. For example: if the coin slots are for a 10 cent coin and a 50 cent coin.
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Programming Price programming: • Press the relevant wash program selector button. When programming the price of a wash program plus options, press both the relevant program selector button and the option button. Fig. • Keep the price-programming button activated. Now the display shows 00 plus the coin sym- bol.
Wash Cycles Wash Cycles In the figure below and on the following page is an overview of the seven Fig. wash cycles. On the pages following you will find a more detailed description of the cycles. WARM COLD PERM PRESS Time Temp.
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Wash Cycles Prewash After the machine has started and the door Fig. automatically locked, the drain valve will close and the hot and cold water valves will open to fill the machine with mixed hot and cold water to the Time Temp.
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Wash Cycles Warm On starting the machine, the door will automatic- Fig. ally be locked, and the pre-wash carried out as previously described, whereafter the main wash is started. As the main wash is started, the drain valve WARM closes, detergent is admitted and mixed hot and cold water is filled to the level determined by the Time Temp.
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Wash Cycles Cold On starting the machine, the door will automatic- Fig. ally be locked, the drain valve closed, the cold water valve opened and the pre-wash carried out as previously described, whereafter the main wash is started. COLD As the main wash is started, the drain valve Time Temp.
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Wash Cycles Permanent Press On starting the machine, the door will automatic- Fig. ally be locked, the drain valve closed, the hot and cold water valves opened and the pre-wash will be carried out as previously described, where- after the main wash is started. PERM PRESS As the main wash is started, the drain valve Time Temp.
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Wash Cycles Delicate On starting the machine, the door will automatic- Fig. ally be locked. As the main wash is started, the drain valve closes, detergent is admitted and mixed hot and cold water is filled to the level determined by the level control.
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Wash Cycles Quick-Wash On starting the machine, the door will automatic- Fig. ally be locked, the drain valve closed. As the main wash is started, the drain valve closes, detergent is admitted and warm water is QUICK-WASH filled to the level determined by the level control. On reaching this level, hot water is closed.
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Wash Cycles Heavy Soil On starting the machine, the door will automatic- Fig. ally be locked, the drain valve closed, the hot and cold water valves opened and the two pre-wash- es will be carried out as previously described, whereafter the main wash is started. HEAVY SOIL As the main wash is started, the drain valve Time Temp.
Mechanical and electrical design General This machine has a suspended drum, which means that the outer drum and motor rest on a ”cradle” with four counterweights and a broad retaining strap. The cradle rests on four coil springs and has four (EX 15) or five EX 25 shock absorbers which, together with the counterweights, are highly effective in counteracting any imbalance which may arise from the load.
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Mechanical and electrical design Water inlet valves Control valve, drain Motor control unit Automatic control Detergent unit dispenser Transformer Program unit circuit board Control Heating relay panel (optional) Motor Door and Retaining door lock strap Outer drum Cradle/counter- weights Spring Shock absorber Drain valve...
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Mechanical and electrical design Machine construction Panels The machines are equipped with a top panel made of stainless steel. The front panel is available in different colors or in stainless steel. The colored panels are made of phosphatized steel plate. For servicing purposes, the panels can easily be removed.
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Mechanical and electrical design Back gable and bearing The back gable and the bearing trunnion housing are constructed of Fig. a webbed heavy casting for extra rigidity. There are three neopreene seals to protect from filtration of water. The sleeve bearings are water protected.
Mechanical and electrical design Door Lock handle Description The door is mounted on the outer drum of the Fig. machine. The door glass is held inside the door by three retainers and is easy to replace. The door seal is retained by a flange on the outer drum and creates a seal directly against the door glass.
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Mechanical and electrical design Function When the door is closed, the door status switch closes a circuit and sends a signal to the program control unit to indicate that the machine is ready to start. When a program has been selected and the start button has been pressed, the door lock will be activated and will lock the door, at the same as the switch in the door status switch closes.
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Mechanical and electrical design Instructions for repair To replace the door lock To be carried out by authorised personnel only. • Remove the front panel. • Release the door lock by unscrewing the two Fig. screws. • Pull out the lock mechanism. Transfer the electrical connections one by one from the old lock to the new.
Mechanical and electrical design Electrical components F12 F22 F11 F21 C1 3335 Fig. Electronic, microprocessor-controlled program control unit. Controls the sequences of the various programs as set out in program tables. Motor control unit, microprocessor-controlled. Controls the direction of rotation and speed.
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Mechanical and electrical design Electronic program control unit Description The program control unit is electronic and consists of a circuit board with Fig. components. On one half are the microprocessor, program memory (EPROM), power supply circuits, temperature and level control devices and so on.
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Mechanical and electrical design Operating time, accumulated coin value, EPROM no. The machine’s built-in service program can be used to check the machine’s accumulated operating time, the accumulated coin value (for coin-operated machines), and the program EPROM part number. Accumulated operating time To check during normal operation Fig.
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Mechanical and electrical design To check in service mode Fig. Enter code 43. The first two digits of a four-digit number will now be displayed, e.g. 13. Code 43 Enter code 44. The last two digits of a four-digit number will now be displayed, e.g. 47. This means that the machine’s accumulated operating time is 1,347 hours.
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Mechanical and electrical design To check in service mode Fig. Enter code 41. The first two digits of a four-digit number will now be displayed, e.g. 06. Code 41 Enter code 42. The last two digits of a four-digit number will now be displayed, e.g. 58. This means an accumulated coin value of 658 currency units or 658 tokens.
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Mechanical and electrical design Program EPROM part no. (check in service mode) Enter code 51. The letter A and two digits will be Fig. displayed, e.g. A47. ”A” denotes part no. (article no.). Code 51 Enter code 52. The display will show (e.g.) 195. Enter code 53.
Mechanical and electrical design Level control Description Servicebutton The "level control", which is located on the circuit board, is a pressure switch which monitors the different water levels in the drum by sensing the air pressure in a tube which is connected to the bottom of the drum.
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Mechanical and electrical design Motor General notes Belt tensioning device The motor is mounted on a motor mounting plate Fig. above the outer drum. It drives the inner drum via a drive belt. There is a belt-tensioning device on the motor mounting plate.
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Mechanical and electrical design Motor control unit The motor control unit communicates with the program control unit board Fig. via a serial (input/output) interface. With the aid of the motor control unit the program control unit can control not only the speed of the motor at any Fig.
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Mechanical and electrical design Fault/error indication If a fault or error occurs in the motor or motor control unit, the latter will Fig. indicate this to the program control unit board. Information on these errors, besides appearing as an error code on the display, is also provided by a Fig.
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Mechanical and electrical design Extraction For extraction the motor operates in an extraction pattern which is always Fig. the same with regard to motor speed. The pattern is as follows: 1. A brief, fast extraction, which removes most of the water from the wash load.
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Mechanical and electrical design Belt tension The tension of the drive belt is preset at the factory. Fig. F = 30 N (EX-15) F = 40 N (EX-25) When checking belt tension, or after replacing components which affect belt tension, follow the 7 mm instructions contained in the figure.
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Mechanical and electrical design Inlet valves Construction Each valve has a single-inlet with either one, two Fig. or three outlets, each with its own solenoid coil. The body is made of heat-resistant polyamid plastic and the solenoids encased in water-tight plastic.
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Mechanical and electrical design Repair instructions Limescale can block the holes in the valve diaphragm and interfere with the function of the valve. It is therefore advisable to dismantle and clean Fig. the valve at certain regular intervals. The frequency depends on operating conditions and the level of contamination in the water.
Mechanical and electrical design Drain valve Description The water pressure of the cold water intake is Fig. used for closing the drain valve. There is a hose (1) connected between the water intake and the control valve (2). When the control valve is activated it opens and lets water into the supply line (3) which is connected to the drain valve.
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Mechanical and electrical design Drain pump (optional) Description The pump is located under the drum and consists of a pump and pump motor, plus a Fig. container with cover between the drain valve and the pump. Because the hose diameter at the pump is less than the outlet of the drain valve there is the risk that solid matter and lint will lodge between valve and pump.
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Mechanical and electrical design Soap supply box The three-compartment soap supply box is located at the top of the Fig. machine. Viewed from the front, the compartments marked with figures 1, 2 and 3 are used as follows: Compartment 1 This compartment is used for adding detergent to the wash at the start of the Prewash cycle.
Service program Built-in service program Service button The machine has a built-in service program to facilitate function checking and fault-finding. This program may only be used by train- ed and authorized service personnel. To switch on service mode • Remove the machine top and the cover for the program unit circuit board.
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Service program Simulation of functions Some machine functions can be simulated by entering a numerical code via the keys. This function can then be switched on and off with the ON/ OFF key. Number Code Function Detergent signal 1, liquid detergent. Detergent compartment 2, cold water /Detergent signal 2, liquid detergent.
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Service program Number Code Function LED test 41-42 Coin mechanism (see Page 39, Program control unit). 43-44 Counter (hours) for accumulated operating time (see Page 39, Program control unit). Last error code flagged. 51-54 Program EPROM part number (see Page 39, Program control unit).
Trouble shooting Trouble shooting If the power supply to the machine should be cut while it is operating, the program unit has a memory which stores the program selected for about 3 to 5 minutes. Within this period the machine will restart automatically once the power supply is restored.
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Trouble shooting Error codes Given below is a brief summary of all the error codes and their causes. Starting on page 5 of this section there are fault-finding charts for all error codes. At the end of the chapter there are also charts for faults which do not generate error codes. Error code Cause Water level not reached within set time.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Check that the manual water valves (taps) are open. Acknowledgement signal for water level not received within Taps turned on. Taps turned off. time allowed. Open taps.
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Trouble shooting Error code/symptoms Fault-finding Cause/Action Open door. Close door and try to restart the machine. Door status switch open Error code returns No error code during program operation. Transient fault in door lock or program PCB. Set program control unit to service mode (see ”To switch on service mode”).
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Open door. Close door and try to restart the machine. The lock has not locked the door within the set time. Error code returns No error code Transient fault in door lock or program PCB.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Temperature sensing device Start a program. indicates temperature below - Error code returns No error code 5°C (continuity fault).
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Start a program. Temperature sensing indicates temperature above Error code returns No error code 98°C (short-circuit). Transient fault.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Are there water in the drum? Water level signal above parameter set, on program start-up. Disconnect the level tube from the program PCB. Turn the machine’s wall switch off and on again.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on. Start a program. Water level signal above Error code 06 No error code parameter set for safety, during program.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Start a program. Increase in water temperature is below parameter set. Error code returns No error code (Heated machines only).
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Is water visible in the drum? The water level is above the safety level set for after drain. Remove the water drain valve from the drum. Is there water at the bottom of the drum? Disconnect the level tube...
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Start a program. The program control unit Error code returns No error code cannot read the program EPROM.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Start a program. Program control unit receiving Error code returns No error code no response from the motor control unit.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action When START is pressed wash programs will Level system not tempera- run, but the water level will not be optimally ture-calibrated adjusted. Turn the machine’s wall switch off and on again. Start a program.
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Trouble shooting Error codes which may arise on the control panel display Cause/Action Error code/symptoms Fault-finding Turn the machine’s wall switch off and on again. Start a program. Door status switch open, even though the door lock is Error code returns No error code locked.
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Trouble shooting Error codes which may arise on the control panel display Cause/Action Error code/symptoms Fault-finding Turn the machine’s wall switch off and on again. Start a program. Interlock signal absent at motor control unit during Error code returns No error code program operation.
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Trouble shooting Error codes which may arise on the control panel display Cause/Action Error code/symptoms Fault-finding This error code can occur if the ambient temperature has been extremely high. If so, Temperature of motor control lower the temperature, e.g. by opening a unit heat sink too high.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn off the machine’s wall switch. Check that the drum and motor rotate smoothly. Thermal protection for motor has cut out. Drum/motor OK Drum/motor not rotating smoothly Bearing failure in drum or motor or objects between...
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Trouble shooting Error codes which may arise on the control panel display Cause/Action Error code/symptoms Fault-finding Turn the machine’s wall switch off and on again. Start a program. Motor control unit receiving start command from program Error code returns No error code control unit without first receiving lock acknowled- Transient fault.
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Trouble shooting Error codes which may arise on the control panel display Cause/Action Error code/symptoms Fault-finding Turn the machine’s wall switch off and on again. Motor control unit indicating Start a program. short-circuit between outputs Error code returns No error code for motor windings.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Start a program. Motor control unit indicates fault in receiving circuitry for Error code returns No error code lock acknowledgement signal.
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Trouble shooting Error codes which may arise on the control panel display Cause/Action Error code/symptoms Fault-finding Turn the machine’s wall switch off and on again. Start a program. Motor control unit indicating DC voltage level too low. Error code returns No error code Transient fault.
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Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Start a program. Motor control unit indicating DC voltage level too high. Error code returns No error code Transient fault.
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Trouble shooting Error code/symptoms Fault-finding Cause/Action Turn the machine’s wall switch off and on again. Machine completely ”dead”. Display blank. Fault persists. Machine working Transient fault. No action required. Check fuses F11, F12, F21 and F22. Fuses sound Fuse fault Change fuse(s) and check functioning.
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Trouble shooting Error code/symptoms Fault-finding Cause/Action Display blank, but machine is Turn the machine’s wall switch off and on again. working otherwise. Fault persists. Machine working Transient fault. No action required. F2, F3 Check glass-tube fuses F2 and F3 on program Display control unit PCB.
Maintenance Maintenance Preventive maintenance has been reduced to a minimum by the careful design of reliable compo- nents and material. However, the following measures should be taken at regular intervals and in proportion to the hours of service. Daily • Check the door lock and interlock before starting operations.
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