Wascomat EX-30 S and EX-50 S Operating & Maintenance Manual
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Wascomat EX-30 S and EX-50 S Operating & Maintenance Manual

Wascomat EX-30 S and EX-50 S Operating & Maintenance Manual

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OPERATING & MAINTENANCE MANUAL
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).
MACHINE TYPE OR MODEL
MACHINE SERIAL NUMBER(S)
ELECTRICAL CHARACTERISTICS: ________ VOLTS, _______ PHASE, _______ HZ.
MAKE CERTAIN TO KEEP THIS MANUAL IN A SECURE PLACE FOR FUTURE
REFERENCE.
EX-30 S and EX-50 S
438 9030-13/01
99.20

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  • Page 1 OPERATING & MAINTENANCE MANUAL EX-30 S and EX-50 S 438 9030-13/01 99.20 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).
  • Page 2 Be sure to keep the machine(s) in proper working order: Follow all maintenance and safety procedures. Further information regarding machine safety, service and parts can be obtained from your dealer or from Wascomat through its Teletech Service Telephone - 516/ 371-0700.
  • Page 3 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.

  • Page 5: Table Of Contents

    EX-30 S, EX-50 S Contents Introduction ..................7 Technical data ................8 Installation ..................11 Safety rules .................. 21 Operating instructions ..............22 Programming ................27 Wash programs ................30 Mechanical and electrical design ..........33 Serviceprogram ................70 Trouble shooting ................73 The manufacturer reservs the right to make changes to design and material specifications.

  • Page 7: Introduction

    When ordering spare parts or contacting Wascomat for any purpose always give the machine serial number, model, voltage and other electrical characteris- tics appearing on the nameplate at the rear of the machine.

  • Page 8: Technical Data

    Technical data EX 30 S Dry load capacity up to 30 lbs Overall dimensions Width 870 mm 34 1/4'’ Depth 790 mm Height 1325 mm Net weight 290 kg 639 lbs 3.3 ± 1.1 kN 790 ± 264 lbs force Floor load Crated dimensions Volume...
  • Page 9 Technical data EX 50 S Dry load capacity up to 50 lbs Overall dimensions Width 1000 mm 39 3/8'’ Depth 900 mm Height 1435 mm Net weight 553 kg 1218 lbs 6.0 ± 2.0 kN 1440 ± 480 lbs force Floor load Crated Dimensions Volume...
  • Page 10 Technical data Outline and dimensions 4699 1. Opening for electrical cable connection EX 30 S EX 50 S 2. Steam connection (optional) 3. Cold water 1000 4. Hot water 1325 1435 5. Hot water (only EX 50) 1100 6. Drain outlet 7.

  • Page 11: Installation

    Installation Installation The machine is delivered with expansion bolts and other items packed inside the drum. Shipping securities The machine is shipped with four large metal Fig. brackets bolted to the four suspension legs as well as a support between the pulley and the back plate.
  • Page 12 Installation Mechanical installation • Mark and drill two holes 3/8'' in (8 mm) in Fig. EX 30 S diameter and approximately 3 1/2'' in. (90 mm) deep according to the dimensions in figure 5. • Place the machine in position. Never lift the machine by the door or handle.
  • Page 13 Installation Connection for liquid supply (option) Electrical installation must be carried out by an authorized personnel! 1 2 3 4 Installed appliances must be EMC approved according to EN 50081-1 and EN 50082-2. 1 2 3 4 X146-1 471 75 98 01 The connections A (1-5) are signals for the liquid Fig.
  • Page 14 Installation Water connections All intake connections to the machine are to be fitted with manual shut-off valves and filters, to facilitate installation and servicing. In certain Cold EX 30 S cases non-return valves will need to be fitted before the machine to comply with local plumbing regulations.
  • Page 15 Installation Drain connection Connect a 3'’ (75 mm) flexible hose to the drain Fig. outlet of the machine. The drain must not have any sharp bends and must slope downward from the machine to assure proper drainage. The outlet must open freely to the main drain.
  • Page 16 Installation CABLE FROM MACHINE STEAM HOSE APPROVED FOR min. 0,1 MPa max. 0,8 MPa SEAL WITH TEFLON OR SIMILAR CONNECTION STEAM INJECTOR IN MACHINE For rebuilding look at the wiring diagram of the machine. 1719...
  • Page 17 Installation Steam connections (optional steam heating) Steam pressure required: • minimum 7 PSI • maximum: 110 PSI • recommended: 40-85 PSI A steam valve for this machine type is fitted separately in a bracket on the upper rear cover plate. The steam valve, hose and filter are sup- plied with the machine.
  • Page 18 Installation Electrical installation Electrical installation must be carried out by an authorized personnel! Mount a multi-pole switch prior to the machine to facilitate installation and service operations. The connecting cable should hang in a gentle curve. Fuse size can be found on next page. Single-phase connection: Connect the earth and other two wires as shown Fig.
  • Page 19 Therefore we recommend that the rear panel be removed and a visual inspection made on a bimonthly basis. When the oil reaches a low level, the cannister must be replaced with a new one available from Wascomat as Part No. 827601. Date Last Replaced Date Last Replaced...
  • Page 20 OUT OF ORDER and the door interlock system must be repaired or replaced. Disconnect electrical power from 4945 the machine until the necessay repairs are made. Door safety interlock must be checked daily in accordance with above procedure. Before servicing Wascomat equipment, disconnect electrical power.

  • Page 21: Safety Rules

    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. •...

  • Page 22: Operating Instructions

    Operating instructions 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.
  • Page 23 Operating instructions Washing Fig. • Press the button for the desired program. Perm Press • Now the LEDs alongside the program sym- Fig. bols will show what the selected program Warm Quick-Wash consists of. • Press the button(s) for any options required. Heavy Soil Cold Fig.
  • Page 24 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 dis- played.
  • Page 25 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.

  • Page 26: Door Unlocked

    Operating Instructions Rapid advance Whole steps in programs can be skipped using rapid advance. START • Press and hold the START button until the Fig. program indicator LEDs have moved past the program steps you wish to skip. Program end After final extraction, the LED by the "doorlock Fig.

  • Page 27: Programming

    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.
  • Page 28 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.

  • Page 29: Wash Programs

    Programming Price programming: • Press the relevant wash program selector button. When programming the price of a wash program Fig. plus options, press both the relevant program selector button and the option button. • Keep the price-programming button activated. Now the display shows 00 plus the coin sym- bol.

  • Page 30: Wash Programs

    Wash programs Hospitality wash formulas For hotels/motels, restaurants, retirement communities, schools and universities, commercial and institutional laundries. 1A White towels 1 White uniforms 1B White table 1AB White table (medium soil sheets & pillow- linen (bleach, linen (bleach short program) cases (light no starch) and starch)
  • Page 31 Wash programs Healthcare wash formulas For nursing homes, hospitales and medical center. 1A Diapers/pads 1B Colored uni- 1 White uniforms 1AB White cotton medium soil forms, sheets sheets & pillow- or blend & pillowcases cases (very table linen (light soil) light soil) 2 White uniforms 2A Diapers/pads...
  • Page 32 Wash programs Shirt laundry formulas 1A Short formula 1 Shirts 1B Delicates 1AB White or colored shirts (starch, cold blend (no starch) rinses) table linen (may use with (with bleach, 5 or 6) no starch) 2 Shirts 2A Heavy soil 2B Mops 2AB White or colored (starch, warm...

  • Page 33: Mechanical And Electrical Design

    Mechanical and electrical design 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.
  • Page 34 Mechanical and electrical design Machines with permanent programs Steam valve Motor control unit Inlet valves, (obscured) water Automatic Detergent control unit dispenser Inward power supply terminals board Control panel Heating relay Door lock Transformer Imbalance switch Machine Outer drum door Motor Elements Spring...
  • Page 35 Mechanical and electrical design The washing machines are controlled by a microprocessor program unit. This provides several major advantages: • The control of times, levels and temperatures takes place with considerable precision and flexibility • The large character display provides detailed information in clear text about the different wash programs, the machine's different activities, relevant wash times and temperatures.
  • Page 36 Mechanical and electrical design Frame Description The frame is constructed on the free-swinging principle, i.e. the washing Fig. drum is freely and resiliently suspended in the fixed frame. The entire frame is constructed of U-shaped iron beams forming a stable and torsionally rigid structure.
  • Page 37 Mechanical and electrical design Drum with bearings Description The inner drum is journalled to the outer drum by two robust bearings in a bea- Fig. ring housing which is bolted to the rear plate. The bearing unit supports the drum without any support being needed at the front.
  • Page 38 Mechanical and electrical design Description The machine door lock consists of the following: Fig. • The locking unit, located behind the front panel below the detergent dispenser. The unit consists of a solenoid which locks the door, and two microswitches. Switch S4A indicates that the door is locked and switch S3 indicates that the door is closed.
  • Page 39 Mechanical and electrical design Door lock control unit The sole function of this control unit is to oversee the correct functioning of Fig. the door lock. The CPU board receives information from the motor control unit about motor rotation, and has its own level-monitoring device. The control unit also detects water level and motor speed through separate level measurement devices and the rotation guard (speed-monitoring device).
  • Page 40 Mechanical and electrical design Error indication patterns If the door lock is working correctly, this is indicated by the red LED, by a Fig. pattern of flashes which indicates “OK”. The error indication patterns revea- led by the LED flash at various frequencies for the various errors or faults. All error indication patterns have a frequency cycle of 50%, i.e.
  • Page 41 Mechanical and electrical design Program control unit Control system transformer T10 The control system transformer is used to provide the voltage feed for the Fig. circuit boards. The transformer supplies 12 V on its secondary side, and can be adapted to suit any of four different primary voltages by moving a strap.
  • Page 42 Mechanical and electrical design Imbalance switch Description The imbalance switch is a safety feature which protects the machine from Fig. damage during extraction caused by uneven distribution of the wash load. The imbalance switch consists of a microswitch and a switch arm, mounted on the left-hand front pillar of the frame.
  • Page 43 Mechanical and electrical design Motor Description The motor is mounted inside a motor mounting unit beneath the outer Fig. drum. It drives the inner drum via a drive belt. The drive belt tension is adjusted with the aid of two retaining screws on the side of the motor mounting unit.
  • Page 44 Mechanical and electrical design Motor control unit E10 X312 X301 X302 X304 X308 X311 4744 Suppression filter Fig. Connectors X301 Serial communication with PCU X302 Input, lock sequence X304 Relay output X308 Imbalance input X311 Main input X312 Connection, motor and thermal protection device (Klixon)
  • Page 45 Mechanical and electrical design Motor control unit The motor control unit communicates with the PCU board via a serial Fig. duplex interface. With the aid of the MCU, the PCU board can not only control the speed the motor is to have at any given moment, but also control Fig.
  • Page 46 Mechanical and electrical design For the 220 l machine there is a cooling fan on the MCU, on account of its higher wattage. The fan starts up automatically when the heat sink reaches a temperature of approx. 65°C, which can arise during extraction if the load is unfavourable or if the ambient temperature is high.
  • Page 47 Mechanical and electrical design X308: Imbalance input The function of the imbalance input is to stop the motor if the drum’s movement is too great. (The imbalance switch is normally open.) When the imbalance switch is activated (closes) a voltage of 96 - 276 V AC is supplied to the MCU.
  • Page 48 Mechanical and electrical design Error indication patterns If a fault or error occurs in the motor or motor control unit, the MCU sends Fig. an error signal to the PCU board. In addition to an error code showing on the display, errors/faults are revealed by the flashing of a yellow LED on the Fig.
  • Page 49 Mechanical and electrical design Fault-finding There are fault-finding charts for all error codes. X312 X313 X301 X302 X311 X308 X304 Yellow LED Green LED 4708 Error indication patterns, green LED The green LED on the MCU board is normally lit except for a brief pause Fig.
  • Page 50 Mechanical and electrical design Extraction During extraction, the motor speeds follow an extraction sequence which is Fig. always the same. This extraction sequence is used for all WE/MP machines and for standard programs 991-999 for CLARUS machines. The table shows the extraction speeds during the various phases of the sequence, for various drum volumes.
  • Page 51 Mechanical and electrical design Imbalance measurement At the start of every extraction sequence the system monitors variations in the motor torque while the drum is operating at distribution speed. If these variations are too great, it indicates that the load is unevenly distributed in the drum.
  • Page 52 Mechanical and electrical design Belt tension The tension of the drive belt is preset at the factory. Fig. When checking belt tension, or after replacing Fig. components which affect belt tension, follow the instructions contained in the illustrations. Max. 9 mm Correct belt tension is important.

  • Page 53: Drain Valve

    Mechanical and electrical design Drain valve Description The drain valve is a motor-operated diaphragm Fig. valve which allows rapid emptying thanks to its large cross-section. This is a self-clearing design, Fig. so there is no need for a lint filter. Main parts of the valve: •...
  • Page 54 Mechanical and electrical design When the motor is activated and begins to rotate, the piston rod is turned upwards via the gear, the diaphragm is pressed upwards with the piston and presses against the valve seat: the valve closes. The connection for overfilling is connected to the upper part of the wash drum, water and foam are diverted straight to the drain if the intake valves or level control should malfunction.
  • Page 55 Mechanical and electrical design Tensioning of return spring With the valve housing removed: - Turn the return spring so that the “tongue” of the spring is resting against the stop screw. - Position the valve housing over the return spring so that the pin on the spring will fit into the recess on the piston rod.
  • Page 56 Mechanical and electrical design Heating Description Fig. The machine elements are in the lower part of the outer drum, accessible from the machine front. They are switched in by heating relays, Fig. controlled by the program control unit. For input voltage 400-440 V one heating relay is used (K21), and for 208-240 V, two are used (K21 and K22).
  • Page 57 Mechanical and electrical design To replace an element • Switch off the power supply to the machine at the main switch/wall switch and check that the machine is isolated from the power supply. Remove the front panel. • Note exactly how the elements electrical connections are arranged, then disconnect them.
  • Page 58 Mechanical and electrical design Weighing equipment Scale unit Description The weighing equipment comprises the following Fig. units: • A scale unit located inside the machine’s right side panel • Four load cells, one in each corner of the frame • Wiring The weight of the wash load is registered by the four load cells, which send analogue signals to the scale unit.
  • Page 59 Mechanical and electrical design Inlet valve, detergent Construction The 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.
  • Page 60 Mechanical and electrical design Maintenance instructions Lime scale can block the hole in the valve diaph- ragm and interfere with the function of the valve. It is therefore advisable to disassemble and clean Fig. the valve at certain regular intervals. The fre- quency depends on operating conditions and the level of contamination in the water.

  • Page 61: Inlet Valve

    Mechanical and electrical design Inlet valve The water inlets have brass bodies with larger Fig. cross section of the outlet in order to achieve a shorter filling time for the machine. Construction Fig. The valve housing is made of pressed brass. The spring-loaded plunger is made of stainless steel and located at its lower end.
  • Page 62 Mechanical and electrical design Soap supply box The three-compartment soap supply box is located at the top of the machine. Fig. 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 at the beginning of the Prewash cycle.
  • Page 63 Mechanical and electrical design Drain valve Description The drain valve consists of a bracket (1), on Fig. which are mounted the motor and gear (2) and diaphragm (3). The rubber diaphragm is resistant to a water temperature up to 100°C (212°F). The installation of a lint trap is not necessary.
  • Page 64 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.
  • Page 65 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 opera- ting time, the accumulated coin value (for coin- operated machines), and the program EPROM part number. Accumulated operating time To check during normal operation The machine needs to be actually operating...
  • Page 66 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.
  • Page 67 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.
  • Page 68 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.

  • Page 69: Level Control

    Mechanical and electrical design Level control Description 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 Service switch air pressure in a tube which is connected to the bottom of the drum.

  • Page 70: Serviceprogram

    Service program Built-in service program The machine has a built-in service program to facilitate function checking and fault-finding. Service switch 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.
  • Page 71 Service program Error codes Given below is a brief summary of all the error codes and their causes. Error Code Cause Detergent signal 1, liquid detergent. Detergent compartment 2, cold water /Detergent signal 2, liquid detergent. Detergent compartment 3, cold water /Detergent signal 3, liquid detergent.
  • Page 72 Service program Error Code Cause 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).

  • Page 73: Trouble Shooting

    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.
  • Page 74 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.
  • Page 75 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.
  • Page 76 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”).
  • Page 77 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.
  • Page 78 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.
  • Page 79 Trouble shooting Error codes which may arise on the control panel display Error code/symptoms Cause/Action Fault-finding 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.
  • Page 80 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...
  • Page 81 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.
  • Page 82 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.
  • Page 83 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.
  • Page 84 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.
  • Page 85 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.
  • Page 86 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.

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Ex-50 s

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