Ecolab Advanced Laundry Dispensing System Installation Manual

Ecolab Advanced Laundry Dispensing System

System Introduction

Preface

This manual has been written and illustrated to present the basic installation, operation and servicing instructions of the Advanced Laundry Control System. This manual applies to current units. Future versions may have additional features; check unit packing for the latest revision. Guidelines will be suggested in reference to the preferred method of installation. However, the variety of equipment and the surrounding environment will dictate the actual installation of the Advanced Laundry Control System.

This heading is used when injuries or accidents could result if operating
procedures, service procedures, etc., are not correctly observed or are
ignored. These installation, operation, and servicing instructions are for use by qualified personnel only. The Advanced Laundry Control System is intended to be installed by an experienced, qualified technician, in accordance with all applicable NEC/CEC (National Electrical Code/Canadian Electrical Code) requirements and with local building, electrical, and plumbing codes. All laundry machines and dispenser power must be disconnected during installation and/or any time the dispenser cabinet is opened.

All safety instructions and important remarks must be followed at all times!

Important Remarks

The remarks WARNING, CAUTION and NOTE have the following meanings in this manual.

WARNING: This heading is used when injuries or accidents could result if operating procedures, service procedures, etc., are not correctly observed or are ignored.

CAUTION: This heading is used when the unit could be damaged if operating procedures, service procedures, etc., are not correctly observed or are ignored.

NOTE: This heading is used when a particular piece of information needs to be highlighted.

System Features

The Advanced Laundry Control System consists of three components. The Machine Interface module accepts the washer signals and converts them to safe low-voltage inputs. The Controller provides a ] menu display system to aid program setup. The Pump Module provides heavy-duty, high-capacity peristaltic pumps for product transfer. An optional Flush Manifold is available for water flush chemical transfer applications.

• Front-mounted keypad for adjusting all functions.
• LCD readout provides clear menus and advice on status.
• Formula programming allows programming/selecting up to 16 different chemical formulas. Product levels – up to three different product levels may be programmed for each product within each formula.
• Product volumes – enter the desired product amounts directly in ounces (or milliliters).
• Chart Stop times may be programmed for any pump and formula.
• Machine Interface automatically adjusts for 24 to 240VAC and 22 to 26VD
• Machine Interface provides a contact closure output for Chart Stop.
• MicroMode feature provides automatic formula control from the washer.
• Automatic recording – the number of times each formula has been used.
• Selectable operating logic allows the unit to be used with all washers.
• Pumps have an approximate output capacity of 10 – 14 ounces/minute (296 – 414 mis/minute) for fast and efficient transfer of the chemical product dosage. The actual delivery rate depends on product viscosity, length of pickup tubing and tees, etc.
• Flush output is available for use with an optional Flush Manifold.

Principle of Operation

The Advanced Laundry Control System “Controller” is connected to the “Machine Interface”.  The
Machine Interface communicates a “supply signal” from the laundry machine to the Controller. Once the signal is received, the Advanced Laundry Control System will pump products based on how you have
programmed it.

The Advanced Laundry Control System is designed for laundry machines having a load capacity of 15 to 600 Ibs. (clean dry weight). Products are pumped by the dispenser from their shipping containers to the laundry machine. Each product injection may be delayed up to 999 seconds and programmed for amounts up to 333.3 ounces (999 milliliters). Up to 16 formulas may be programmed and selected from the Controller.

The “Machine Interface”, installed inside the laundry machine control wiring area receives the laundry machine “supply signals”. It automatically adjusts for supply signal voltages ranging from 24 to 240VAC or 22 to 24VDC. Chart Stop output wiring connections are available at the “Machine Interface”. The “Pump Module” operates on 115 VAC/60HZ, 208VAC/60HZ. It is wired into the appropriate voltage power supply. It also supplies low voltage power to the “Controller” and provides the interface to the optional “Flush Manifold”.

The “Controller” will indicate when pumps are running and which formula is currently selected. The laundry operator can change formulas to match the load unless MicroMode automatic selection has been programmed. Formula Load Counter: Formula load count and formula reset occur from a pump 3 request signal. Even if pump 3 product is not required for the selected formula the signal must occur for the formula to reset and be counted. In this case, set the product 3 amount to 0. The “Optional Flush Manifold” — not shown— provides an alternative means of chemical transfer to the laundry machine. In the flush configuration, the Advanced Laundry Control System is a complete integrated water flush chemical dispensing system — complete with a flow sensor and system alarm.

Controller Description

“NOTE: Paragraph numbers below for numbered items In Figure 1-2.

1. LED light: The lights indicate the following.
   • ‘Groen light Controller has power.
   • ‘Yollow gh — Controle s returning to default settings.
   • Red light – not currently used.
2. Infrared Communication Port: For future use.
3. Koy pad: These keys provide a means for selecting and reviewing programming:
   1. MiddIe/NEXT key:
      • Run Mode: password and prime prompt.
      • Program Mode: menu advance.
   2. Up arrow key:
      • Run Mode: scroll/select the formula
      • Program Mode: sro options, increment displayed value, and activate (tu on) selection.
   3. ‘Down arrow key:
      • Run Mode: scroll/select formula
      • Program Mods: scroll options, decrement displayed value, and deactivate (turn off) selection.
   4. Left arrow key:
      • Run Mode: view/scroll load counts.
      • Program Mods: step back with program menus.
   5. Right arrow Key:
      • Run Mode: view/scroll load counts
      • Program Mode: step forward within program menus and select options/enter.
4. LCD Display:
   • Run made: Current formula number/name display, pump run status, load counts, and user prime.
   • Program mode: Data entry request/menu/settings display.
5. Communications port: For future use.
6. “Pump Module” (DB-9 male) connector: This provides the communication Ink between the ‘Controller and the Pump Module and supplies power 0 the Controller. Attach the female end of the 20 cable hore. NOTE: You may also use an optional 50′ cable if necessary.
7. Gnet connector: For future use.
8. System expansion port: For future use
9. “Machine Interface” (DB female) connector: This provides the communication link between the Controller and the Machine interface. Attach the 10’cable here.

Specifications

Pump Module Assembly

Note: Specifications are subject to change without notice.

Pump module Assembly

Service Access

Access to the Pump Cabinet Printed Circuit Board (PCB), On/Off Toggle Switch, communication cable Plug, and Optional Pump Wiring Harnesses are all located in the left portion of the Pump Cabinet (pumps 1 and 2, or 1, 2, and 3). The front of each Cabinet is secured with four (or six) screws located behind the Pump Front Plates. Remove the Pump Front Plate to access to squeeze tube and roller.

Controller

Machine Interface

Utilities

Electrical Supply

• A constant 115VAC/60 Hz or 208VAC/60 Hz (check serial number label for voltage, wall outlet power supply is required. A 7-foot power cord is provided with the 115VAC unit.
• The power must be on whenever the laundry machine is operating.
• Maximum amperage draw for each pump running during operation is:
  • 115VAC (+/-10%), 60 HZ ………….2.4 amps;
  • 208VAC (+/-10%), 60 HZ ………….1.3 amps;
• A 10 amp circuit breaker is fitted to the 115VAC Pump Module.
• A 6 amp circuit breaker is fitted to 208 VAC/60 Hz Pump Module.

Communication Cables

• Two cables are supplied with male and female DB-9 connectors.
• The internal connections — of the cables — are identical.
• The matching connectors are reversed to eliminate cross-connection.
• The 10′ (3.05 meter) cable is intended for the Machine Interface to Controller connection.
• The 20′ (6.10 meter) cable is intended for the Pump Module to Controller connection.
• An optional 50′ (15.24 meter) cable is also available.

General and Environmental Specifications

Installation

Preplanning the Installation

There is no substitute for planning the installation prior to beginning the work. Several minutes in planning may save an hour or more during the installation. The following is a list of the factors to consider:

• Location of the Pump Module must be within 50″ of the laundry machine.
• Locate the Pump Module at a convenient height for pump tube servicing.
• Allow room underneath the Pump Module for the optional Flush Manifold when planning flush installations.
• The Pump Module must be mounted to a solid surface, e.g., drywall, masonry, wood, cement, cinder block, etc. Use appropriate hardware for each mounting surface, e.g. metal anchors in cement or cinder block.
• Verify access to the appropriate power source for the unit. A separate power supply is desirable, but you may have to use the laundry washer power. If an external switch or circuit breaker is used, it should be located as close as possible to the Pump Module.
• The outlet supply tubing run should not exceed 50′ (15.24 meters). The total input and output tubing runs should be kept to less than 60’ (18.3 meters) or tubing durability will be affected.
• The Controller must be mounted securely to the laundry washer or other convenient location so that the operator can easily see the screen and operate the buttons. Allow space on the right side and bottom of the controller for cable connections and future cable access.

Materials Ordered Separately

• Product pickup and output supply tubing, and probes.
• For long Controller to Pump Module distances, a 50′ (15.24 meter) cable may be ordered.
• Optional Flush Manifold.
• Optional controller swivel mount bracket.

Pump Module Installation

Review the pre-planning information before installation.

1. Locate the pump module close to your product containers and close to AC power. A vertical wall behind the washer at a 4 to 5-foot (1.22 to 1.52 meter) height is usually suitable.
2. Install the Pump Module wall mount bracket with the hardware provided.
3. Hang the pump module on the wall mount bracket, pressing downwards until the Pump Module locks in place.
4. Connect the power cable to an appropriate wall outlet or hard wire to the laundry machine. For permanently connected equipment, the power cable should be run through a conduit (flexible preferred). Electrical connections must be made to screw terminals.
5. Cut the tie-wrap to remove the Flush Jumper Plug. Remove the Flush Jumper Plug from the flush connector on the underside of the Pump Module. IMPORTANT: Retain the Flush Jumper Plug for future use.
6. Connect the Flush Manifold cable to a flush connector on the Pump Module.

Controller Installation

Mounting on Vertical Surfaces (Preferred)

1. Find a suitable location for the Controller either on or close to the washer. The keypad should be
   readily accessible and the display easily visible to the user.
2. Connect communication cables, Pump Module connector, and Machine Signal Interface connector, to Controller bottom. Secure cables at the Controller with tie wraps.
3. Clean the surface of the vertical mounting location with alcohol or similar to provide the best adhesion of the Dual Lock ™ strips.
4. Cut two 3″ x 1” Dual Lock ™ strips. Remove the adhesive backing paper and affix both strips vertically on the back of the controller enclosure.
5. Cut two additional 3” x 1” Dual Lock ™ strips and fasten to the strips located on the back of the controller. Remove the adhesive backing paper and affix the Controller to the desired mounting surface location.
6. Connect communication cables, Pump Module connector, and Machine Signal Interface connector, to the Controller’s bottom. Secure cables at the Controller with tie wraps.

Mounting on Horizontal Surfaces

1. Find a suitable location for the Controller either on or close to the washer. The keypad should be
   readily accessible and the display easily visible to the user.
2. Use the optional mounting bracket for installation on horizontal surfaces.
3. Attach the stainless steel mounting plate on the back of the controller with provided screws.
4. Line up the holes of the stand with the holes on the side of the plate.
5. Tighten the provided thumbscrews through washers and stand to the controller plate.
6. Screw stand to the washer or another horizontal surface.
7. Connect communication cables, Pump Module connector, and Machine Signal Interface connector, to Controller’s bottom. Secure cables at the Controller with tie wraps.

Mounting to Machine Wall

1. Find a suitable location for the Controller on either side of the washer. The keypad should be readily accessible and the display easily visible to the user.
2. Complete steps 2-5 in section 3.4.2 — Mounting on Horizontal Surfaces.
3. Mount the “L” bracket using the four provided mounting screws.
4. Attach the base of the optional mounting bracket to the “L” bracket using the two provided nut/bolt ‘assemblies.
5. Connect communication cables, Pump Module connector, and Machine Signal Interface connector,
   to the Controller’s bottom. Secure cables at the Controller with tie wraps.

Machine Interface Installation

WARNING: Make sure to disconnect all power to the washing machine before proceeding.

Mounting Machine Interface

1. Fasten the machine interface to the washer chassis within the wiring area. Keep the machine interface and ‘communication cable away from high-voltage wires and relays. Never parallel the cable with high-voltage lines.
2. Electrical connections between the MI and the washing machine must be made with screw terminals.
3. Route the 10’ communication cable into the washer signal wiring area through a rear knock-out.
4. Plug the 10° communication cable into the Machine Interface Module.
5. Bundle excess cable outside the washer rear. The other end of this cable will be plugged into the
   “Machine Interface” connector on the Controller.

Signal Voltage

“The Machine Interface will work with any signal voltage between 24 — 240 VAC or 22 – 24VDC. With DC signals, polarity must be observed. Common is negative. The signals should be positive voltages

Supply Trigger Wiring

1. Identify the washer supply signals. Check with technical service or with the washer manufacturer if you are not sure of the connections.
2. Electrical connections between the MI and signal wires must be made with screw terminals. Use the following color codes for both “Timer” and “Relay” modes ~ see section 4.1.1 for mode explanations:

Wiring Notes:

• Individually wire-nut unused wires. If the washer has a single common, wire-nut all of the ‘commons together.
• If one or more pump signals are not used they do not need to be connected.
• If you are triggering more than one pump from a single signal then connect all of the Machine Interface pump signal wires for those pumps to that signal.
• Each of the 6 LEDs on the Machine Interface will light when a valid signal is received at the respective input.

Chart Stop Wiring

Two grey wires are present for Chart Stop connections. These wires provide a normally-closed contact closure that opens when the Controller calls for Chart Stop. This provides an interruption of the washer timer motor for the programmed Chart Stop time.

1. Disconnect one wire from the machine timer motor and connect it to a screw terminal.
2. Add a supplemental wire (18g., 300V rated) from the timer motor, where the wire was removed in step 1. Connect the other end of this supplemental wire to the screw terminal.
3. Connect the two grey wires from the Machine Interface to the screw terminals in positions corresponding to the motor timer wires.
4. Program the Controller for desired Chart Stop times for each pump and formula.

Event Mode Wiring

In event mode, the dispenser sequences itself to the laundry machine cycle. It may be programmed to add products to certain “events” or fills of the machine. Regular supply signals are not needed. Electrical connections between the washer and signal wires must be made with screw terminals. Event mode wiring connections are below:

Program Mode

Enter Program Mode

To enter program mode, press the NEXT key once, and you will be prompted to enter the password. Then press the UP arrow key, LEFT arrow key, RIGHT arrow key, and DOWN arrow key.

The password sequence allows the user to access Quickstart, Account Setup, Washer Setup, Formula Programming, Records, Prime Mode, Time Calibration, and Diagnostic menus.

Program Mode Navigation

• Refer to Figure 4 —1 for an overview of programming menus.
• Program Mode menus are linked to display icons.
• Program modes may be accessed incrementally, by pressing the NEXT key.
• Press and hold keys to use the “auto key repeat” feature for faster scrolling.

QUICKSTART – See Figure 4-2

A wrench icon (located at the top left of the screen) is displayed on all QUICKSTART screens. The QUICKSTART programming allows for a quick initial setup. The programming is basic. However, itis sufficient to setup an account and can be refined at a later date. Once QUICKSTART is displayed, you can press the RIGHT arrow key to step through the available screens.

1. WASHER ID – Use the UP/DOWN arrow keys to select the washer ID number (numbers 1-16 are
   available). Press the RIGHT arrow key to save the displayed ID number.
2. UOM – Use the UP/DOWN arrow keys to toggle between OZ/LB and ML/KG. Press the RIGHT arrow key to save the displayed unit of measure (UOM)
3. MODE – Use the UP/DOWN arrow keys to select the appropriate mode (Relay mode, Event mode, or Timer mode). See section 4.1.1 for additional information on modes. Press the RIGHT arrow key to save the displayed mode
4. MICROMODE? – Use the UP/DOWN arrow keys to toggle between YES and NO. If you select YES, you will be asked to indicate which signal is dedicated to MicroMode. Use the UP/DOWN arrow keys to scroll signal numbers (4-6 available). Press the RIGHT arrow key to save the displayed response.
5. SIZE – Use the UPIDOWN arrow keys to select the appropriate washer size (15 — 600 LB dry linen weight). Press the RIGHT arrow key to save the displayed machine capacity
6. PRODUCTS – Use the UP/DOWN arrow keys to select the appropriate number of products (3 – 6 products available). Press the RIGHT arrow key to save the displayed product number
7. CALIB? – Use the UP/DOWN arrow keys to toggle between YES and NO. In the QUICKSTART menu, Calibration defaults to “Yes” because the calibration of pumps is recommended.
   • If you select YES and press the RIGHT arrow key, you will automatically enter TIME CALIB programming (see Section 4.9 for information on calibrating pumps).
   • If you select NO and press the RIGHT arrow key, you will move to the WASHER ID screen.

Account Features

“The Controller display will provide account management and employees with the following screen displays and user options.

• Idle Screen Formula Selection;
• Total Load Counts.
• Pump Running Status;
• User Prime menu selection, when enabled.

Set-Up and Operation

The following procedures are designed to check out the system to ensure that everything is operating correctly. It is assumed tha these steps have been completed.

1. The pump module has been wired to the appropriate power supply.
2. The laundry machine supply signals have been wired to the Machine Interface.
3. The communications cables have been plugged in
4. Chemical formulas have been programmed into the Controller
5. All pumps in use have been primed and calibrated.

Product/Wash Signal Check

1. Select a formula and run the laundry machine through a complete cycle.
2. The pumps should run as programmed. The screen will display when a pump is running.
3. If pumps do not run as programmed check the signal LEDS on the Machine Interface. If they do not light then re-check the rigger wiring.

Dispensed Quantity Check

1. Enter program mode, select the FORMULA PROG menu, and using the right arrow key move to the pump and quantity that you want to check.
2. While viewing the pump and quantity on the screen, press both the NEXT key and the UP arrow key.
3. The pump will run as if triggered by the machine and will dispense the programmed amount.
4. Collect the output in a measuring cup to verify accuracy.

Troubleshooting

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Ecolab Advanced Laundry Dispensing System-FAQs