Jackson Gas Heated Door-Type Dishmachines Tempstar TGP, Technical Manual

Page 1: ... FOR DOMESTIC UNITS FOR JACKSON MODEL TEMPSTAR TGP Jackson MSC Inc P O BOX 1060 HWY 25E BARBOURVILLE KY 40906 FAX 606 523 9196 PHONE 606 523 9795 www jacksonmsc com An Company DUAL TEMPERATURE GAS HEATED DOOR TYPE DISHMACHINES June 24 2004 P N 7610 001 98 99 Revision C ...

Page 2: ...ING THERMISTORS 10 CONTROL BOARD LED LIGHT INDICATIONS 11 TROUBLESHOOTING 12 DIMENSIONS 19 TABLE DIMENSIONS 20 PHOTOGRAPHS Main Assembly 21 Control Box Assembly Front View 22 Control Box Assembly Top View 23 Hood Assembly 24 Cantilever Arm Assembly 25 Tub Assembly 26 Back of Tub Drain Assembly 27 Lower Assembly Right Side 28 Incoming Plumbing Assembly 29 Gas Pack Assembly 31 Upper Wash Rinse Arm A...

Page 3: ...6 7 WATER REQUIREMENTS INLET TEMPERATURE 70 140 F INLET TEMPERATURE 21 11 60 C GALLONS PER HOUR 52 0 LITERS PER HOUR 196 84 WATER LINE SIZE I P S Minimum 3 4 WATER LINE SIZE I P S Minimum 1 9 CM DRAIN LINE SIZE I P S Minimum 1 1 2 DRAIN LINE SIZE I P S Minimum 3 81 CM FLOW PRESSURE P S I Optimum 20 GAS REQUIREMENTS BTU INPUT RATE 55 000 INLET LINE PRESSURE TOWN GAS 4 6 wci MANIFOLD PRESSURE MINIMU...

Page 4: ...hine line strainer using copper pipe It is recom mended that a water shut off valve be installed in the water line between the main supply and the machine to allow access for ser vice The water supply line is to be capable of 20 PSI flow pres sure at the recommended temperature indicated on the data plate In areas where the water pressure fluctuates or is greater than the recommended pressure it i...

Page 5: ...o the gas train When making the connection to the booster unit take care to start the gas line fitting by hand and tighten by hand to avoid cross thread ing Tighten fitting with a wrench taking care not to damage any internal components of the unit After making a final connection of gas with power to the unit turned off check all gas line fittings for leaks using a liquid test solution GAS CONNECT...

Page 6: ...human beings In order to do this ware must be properly prepared prior to being placed in the machine DAILY MACHINE PREPARATION Refer to the section entitled PREPARATION at the top of this page and follow the instructions there Afterwards check that all of the chemical levels are correct and or that there is plenty of detergent available for the expected workload WARM UP CYCLES For a typical daily ...

Page 7: ...ain control box supplies 12vdc to the electronics control drawer location in the lower section of the unit The electronics control board ECB is the brain of the system The ECB receives various inputs and determines the amount of heating required When energized the ECB receives input from the T mid thermistor indicating a low water temperature in the recirculating sys tem The ECB will power the ign...

Page 8: ...ture above the required temperature The stabilization temperature may be adjusted by means of a potentiometer located on the ECB This is referred to as the T set normally 4 25vdc The recirculating pump draws water from the rinse booster tank and circulates it through the wash tank coils where it will heat the water residing in the wash tank The water then returns to the heat exchanger where it is ...

Page 9: ...Clockwise CW until flashing Green LED on control board turns off The recirculating pump will also turn off 6 To ensure that the trim screw has not been turned too far CW turn CCW very slowly until Green LED turns on and once again turn CW very slowly until Green LED goes out 7 Start normal operation and monitor wash tank temperature 8 If readjustment is needed repeat steps 5 7 until wash tank temp...

Page 10: ...ation 6 With your multi meter set on DC volts attach to the molex plug going to the modulating valve NOTE Do not disconnect molex plug Insert probes in the rear of one side so the contact is made with the metal pins inside of the plug see figure 2 7 Turn dishmachine ON Burner will ignite and run through a series of steps Watch the readings of your multi meter They will run approximately 11 9 VDC 2...

Page 11: ...m perature To test the setting or to reset the temperature of the rinse water make sure the unit is on and the green LED on the board is flashing steadily Insert the NEGATIVE Black Common probe of a multi meter set on DC volts in the BLACK test point see above Insert the POSITIVE Red probe of the multi meter in the BLUE test point The reading will indicate the set point temperature The fac tory se...

Page 12: ...temperature at the T in Thermistor There is a BLACK test point along the top edge of the control board on the right side of center This is where the NEGATIVE Common Black probe of a multi meter is inserted There is an ORANGE test point along the top edge of the control board on the left side of center This is where the POSITIVE Red probe of a multi meter is inserted A DC voltage reading is then ta...

Page 13: ... power to the ECB C ECB may have never recieved an AUTO CALIBRATION D ECB may be damaged due to high voltage E Control chip in ECB may be misaligned not fully inserted or damaged 2 Green LED is a illuminated and steady A ECB has been damaged in some form 3 Green LED is illuminated and flashing A This is the normal operating condition whether the LED flashes rapidly or at a slower rate 4 Red LED is...

Page 14: ...ected correctly If so replace door switch Misadjusted or faulty cycle reset cam microswitch Replace microswitch No water supply to machine Check to ensure that all water valves are open and that water is being supplied to the machine at 20 PSI Incoming water supply solenoid not operating Check to ensure that valve is wired correctly If so replace valve Incoming water supply solenoid not operating ...

Page 15: ...uid level control board or probe Check voltage going to each component and ensure they are wired correctly If satisfactory replace the defective part Door switch shorted out wired incorrectly Check the wiring of the door switch if correct replace the door switch Faulty wash relay wash relay welded closed Turn machine off if wash relay doesn t release replace contactor Faulty control relay Measure ...

Page 16: ...y are tight Compression fitting over compressed Replace compression fitting NPT fitting cross threaded Replace the fitting Loose fitting Using an approved leak detector determine which fitting is loose and either tighten or replace Bad thread sealer on fitting Remove fitting and apply an AGA approved thread sealer Defective part has crack hole or break in it Replace the part Excessive water flow i...

Page 17: ...Check for kinks in flexible gas supply line Improper circulation through system Check recirculating pump operation Check for obstructions T set needs adjustment Ensure set point is approximately 4 25 VDC Defective T mid thermistor Red LED light may be flashing Check Ohms reading is between 950 and 1150 Ohms when probe is at room temperature Check for frayed wiring Ensure connection to control boar...

Page 18: ...THE CIRCUIT BOARDS Circuit chip microprocessor pins not fully inserted into its sockets Check for bent pins Ensure chip fully inserted by gently pressing with thumb T mid thermistor reading incorrectly May be sensing non existing high temperature Check T mid voltage reading at test points on control board Ignition relay on control board inoperative Place finger on ignition relay and turn power on ...

Page 19: ...alve and the modulating valve This tapping helps to free the piston Ignition wire loose or broken Check wire for continuity Check connection to both the DSI and spark probe Improper gap on spark probe Check height of probe above burner should be 1 8 318 CM Check gap between probe ends 1 8 318 CM Ensure probe is not touching burner Defective DSI Disconnect ignition wire from DSI spade connector Dur...

Page 20: ... type of gas being used Remove burner manifold and check correct nozzle orifice size Gas leak may be present Check for localized large yellow flame or a flame located above the burner Obstruction in heat exchanger vent or air intake Check for obstructions Flame proofing not occurring Check ignition wire Check that lights above connection point to DSI are dimly lit proofing signal is present Failur...

Page 21: ...IONS LEGEND LETTER A B C D E F G H I J DIM IN 2 1 2 2 1 2 25 1 4 28 32 8 75 60 3 4 17 34 DIM CM 6 35 6 35 64 14 71 12 81 28 20 32 190 5 154 31 43 18 86 36 LETTER K L M N O P Q R S T DIM IN 6 9 11 1 2 16 60 3 4 11 1 2 3 3 4 5 1 2 9 16 1 2 DIM CM 15 24 22 86 29 21 40 64 154 31 29 21 9 53 13 97 22 86 41 91 A B C B D C E A E A D C S T R Q P D E O N M L G H I J F K ...

Page 22: ...IONS CONNECTION TO DISHMACHINE TABLE DIMENSIONS STRAIGHT THROUGH INSTALLATION C OPENING D E A B A C OPENING D C G F ROLL A B D C OPENING 25 1 4 64 14 CM LETTER DIM IN DIM CM A 4 MIN 10 16 MIN B 2 1 2 6 35 C 20 1 2 52 07 D 25 1 4 64 14 E 2 1 4 5 72 F 1 1 2 3 81 G 3 4 1 91 ...

Page 23: ...8 75 06 1 Front Panel 5700 002 19 44 07 1 Left Side Panel 5700 031 89 63 08 1 Incoming Plumbing Assembly 208v 5700 002 21 09 09 1 Right Door Assembly 5700 002 21 33 10 1 Cantilever Arm Assembly 5700 002 21 34 11 1 Right Side Panel 5700 002 16 32 12 1 Vent Flue Assembly 5700 002 19 45 13 1 Vent Flue Adapter NOT SHOWN 5700 002 22 70 14 4 Bullet Feet 5340 108 02 06 02 03 05 06 08 09 10 11 12 01 14 13...

Page 24: ...32 X 3 8 Phillips Truss Head 5305 173 12 00 05 1 Delime Manual Wash Switch 5930 301 21 18 06 1 On Off Power Switch 5930 011 49 55 07 1 Delime Normal Decal 9905 011 34 96 08 1 Timer 220v 50 8 cam 5945 001 99 08 09 1 Cycle Light Green 5945 504 08 18 10 1 Timer Mounting Bracket 5700 021 34 54 11 8 Micro Switch 5945 111 68 49 12 1 Wash Thermometer 96 Lead 6685 111 68 49 01 02 04 05 06 07 08 10 12 03 0...

Page 25: ... Temperature 5945 109 03 69 07 1 Timer 220v 50hz 8 Cam 5945 001 99 08 08 1 Fuse Holder 5920 401 03 14 09 1 Relay Control 240v 50 60hz Top Mount 5945 111 47 51 10 1 Liquid Level Control 220v 6680 200 08 21 11 1 Inner Control Panel Assembly TGP 208 50 1 5700 002 21 06 12 4 Transformer Mounting Bracket 5700 002 18 95 13 1 Transformer 100 240vac to 24vdc 5950 002 19 88 14 1 Transformer 100 240vac to 1...

Page 26: ...oor Guide Right Front 5700 021 33 19 03 28 Screw 1 4 20 x 1 2 5305 274 02 00 03 28 Washer s s 1 4 ID 5311 174 01 00 03 28 Locknut 1 4 20 s s Hex w Nylon Insert 5310 374 01 00 04 1 Door Guide Left Rear 5700 021 84 71 05 1 Hood Weldment 5700 002 18 76 06 1 Door Guide Right Rear 5700 021 84 70 02 03 05 01 04 06 ...

Page 27: ...21 33 04 2 Plug Cantilever 5340 011 35 00 05 2 Cantilever Arm Connector 5700 011 90 99 06 1 Cantilever Arm 5700 031 50 67 07 4 Washer s s 1 4 ID 5311 174 01 00 07 4 Locknut 1 4 20 s s Hex w Nylon Insert 5310 374 01 00 08 6 Wear Button 1 2 Dia UHMW 5700 001 98 69 09 2 Spring Rod 5700 001 28 18 10 2 Cantilever Arm Support Bracket 5700 031 88 00 11 2 Yoke Assembly 5700 000 75 78 12 1 Hood Assembly 57...

Page 28: ... 77 05 1 Thermostat Wash Temperature Over Limit 78 Deg 5930 121 67 72 06 3 Clamp 5 8 Nylon 4730 011 39 01 07 2 Elbow 90Deg 1 2 Street Brass 4730 206 08 00 08 1 Thermometer Wash 96 Lead 6685 111 68 49 09 1 Probe High Water 6680 200 02 68 10 1 Hose Assembly Wash Pump Discharge 1 1 4 ID 5700 002 18 85 11 2 Clamp Reg Range 1 5 16 2 1 4 4730 719 01 37 12 1 Tub Weldment 5700 002 18 77 13 1 Wash Pump Mot...

Page 29: ... 1 Plumbing Drain Assembly 5700 002 21 29 06 1 Bracket Drain Support 5700 002 20 58 07 1 Hose 3 4 Recirculating Pump Suction 5700 002 17 79 08 2 Elbow 90 Deg 1 2 Street Brass 4730 206 08 00 09 2 Bolt Cantilever Hanger Eye 3 8 16 5306 956 05 00 10 2 Plug Bulk Head 4730 609 05 00 11 1 Hose 1 2 Recirculating Pump Discharge 5700 002 17 71 12 2 Spring 5340 109 02 00 13 2 Rod Spring 5700 001 28 18 14 1 ...

Page 30: ...50 05 1 Air Shield 5700 002 18 27 06 6 Locknut 10 24 s s Hex w Nylon Insert 5310 373 01 00 07 1 Bracket Pump Support Assembly 5700 002 18 81 08 1 Wash Pump Motor Assembly 240v 50hz 1ph 6105 002 19 87 09 1 Clamp 5 5 8 to 6 4730 011 34 90 10 1 Bracket Drain Support 5700 002 20 58 11 2 Washer 5700 001 17 87 12 1 Hose Flex Gas s s Assembly 5700 011 93 95 13 1 Plumbing Drain Assembly 5700 002 21 29 14 ...

Page 31: ...INCOMING PLUMBING ASSEMBLY 29 11 12 13 15 16 10 09 08 07 17 18 19 20 06 05 04 03 02 01 26 25 24 23 22 21 14 ...

Page 32: ... 5700 002 17 99 12 1 Panel Upper Back Cover 5700 002 17 98 13 5 Locknut 10 24 s s Hex w Nylon Insert 5310 373 01 00 14 1 Clamp Nylon 1 1 4 4730 011 51 16 15 1 Conduit 3 4 X 37 1 2 5700 002 19 08 16 1 Plumbing Assembly Outlet From Rinse Tank 5700 002 18 90 17 1 Clamp Double Pipe 5700 002 23 89 18 1 Washer 1 4 ID s s 5311 174 01 00 18 1 Locknut 1 4 20 s s Hex w Nylon Insert 5310 374 01 00 19 2 Gaske...

Page 33: ...Glass 5700 002 18 62 02b 1 Electronics Control Drawer Assembly 5700 002 21 10 03 1 T Mid Thermister Assembly 5700 002 12 22 04 1 Valve Solenoid Combination Cut Off 4810 002 20 11 05 1 T In Thermister Assembly 5700 002 12 23 06 1 Valve Modulating 24v 4810 002 20 12 07 1 Spark Probe Igniter 6680 002 12 24 08 1 Heat Exchanger copper 5700 002 20 50 02 04 08 01 03 05 06 07 ...

Page 34: ...sh Manifold Tube 5700 131 15 07 04 1 Wash Arm 5700 021 35 93 05 2 Nut 3 8 16 Hex 5310 276 01 00 06 2 Bolt 3 8 16 X 1 1 4 Long Hex 5305 276 10 00 07 1 Upper Wash Casting 5700 031 34 82 08 1 Rinse Arm 5700 031 50 63 09 8 Locknut 1 4 20 s s Hex w Nylon Insert 5310 374 01 00 10 2 Rinse Arm End Plug 4730 609 04 00 11 1 Hood Assembly 5700 041 90 56 12 2 Bracket Door Connecting 5700 021 33 39 ...

Page 35: ...ug 4730 609 05 00 04 1 Strainer Weld Assembly 5700 031 50 07 05 1 Rinse Arm 5700 031 50 63 06 1 Rinse Manifold Assembly 5700 021 47 61 07 1 Lower Wash Casting 5700 031 46 01 08 2 Bolt 3 8 X 11 4 Long 5305 276 10 00 09 1 Wash Arm 5700 021 35 93 10 1 Rack Guide Weldment 5700 002 01 01 11 1 Lower Wash Manifold 5700 002 05 18 01 02 03 04 05 06 07 08 09 10 11 ...

Page 36: ...STEAM COIL ASSEMBLY 34 01 02 03 05 06 07 08 10 11 12 13 14 15 16 04 09 17 18 ...

Page 37: ...Support 5700 002 08 52 07 1 Bulk Head Plug 4730 609 05 00 08 1 Steam Coil Weldment 5700 021 41 38 09 4 Gasket Steam Coil 5700 001 17 86 10 1 Stand A Steam Coil Support 5700 002 08 50 11 2 Locknut 1 4 20 s s Hex w Nylon Insert 5310 374 01 00 12 1 Suction Strainer Weldment 5700 001 22 23 13 1 Bracket Suction Strainer 5700 001 22 24 14 1 Stand B Steam Coil Support 5700 002 08 51 15 1 Wash Thermometer...

Page 38: ...coming Plumbing Assy 4730 212 05 00 02 2 Nipple 3 4 X 2 4730 207 46 00 03 1 Valve 3 4 NPT Female Check High 4820 002 01 76 04 3 Nipple 3 4 NPT X 1 3 8 Close Brass 4730 207 34 00 05 2 Elbow 3 4 Street Brass 4730 206 04 34 06 1 Rinse Tank Weldment 5700 002 17 81 07 1 Elbow 90 Deg 1 2 Street Brass 4730 206 08 00 08 1 Valve 3 4 NPT Female Check 4820 011 94 20 09 1 Circulating Return Tube NOT SHOWN 570...

Page 39: ...Harness Thermistor Cable 5700 002 12 34 03 1 Electronic Control Board ECB 6680 002 12 26 04 1 Wiring Harness DSI Cable 5700 002 12 36 05 1 Wiring Harness Power Supply Cable 5700 002 12 35 06 1 Wiring Harness Modulating Valve TGP 5700 002 37 03 07 1 Direct Spark Ignition Board DSI 6680 002 12 25 08 1 Ignition Cable 5700 002 12 37 09 1 Circuit Breaker 3 amp 5925 022 36 94 ...

Page 40: ...9344 km h AREA IMPERIAL METRIC 1 SQUARE INCH in2 6 4516 cm2 1 SQUARE FOOT ft2 0 0929 m2 1 SQUARE YARD yd2 0 8361 m2 1 SQUARE MILE 2 59 km2 VOLUME IMPERIAL METRIC 1 CUBIC INCH in3 16 3871 cm3 1 CUBIC FOOT ft3 0 02831 m3 1 CUBIC YARD yd2 0 7645549 m3 FLOW IMPERIAL METRIC 1 GALLON MINUTE 0 0038 m3 min 1 GALLON HOUR 1 0515 mL s TEMPERATURE CONVERSION F C x 1 8 32 Example F 32 C x 1 8 32 89 6 F C F 32 ...

Page 41: ...Tempstar TGP ELECTRICAL DIAGRAM 208 240 VOLT 50 HERTZ 1 PHASE 39 ...