060728_Beta_Products_and_Troubleshooting

Report
Beta Products & Troubleshooting
Housekeeping Products
Dishwashing Products
OPL Products
Large Laundry Products
Summit E & XL Troubleshooting
ILS Systems Troubleshooting
Housekeeping: BetaJet
• BetaJet
–
–
–
–
–
–
Proportioner using water & venturi
High flow for sink & bucket fill
Low flow for bottle fill
Indestructible cover
Labels don’t fall off; customized plastic
‘graphics bands’ snap into the cover
Units look good hooked together-no space
in between
Check for
Debris
B E TA S TA TIO N MF06
Patented metering peg makes
clearing chemical clogs a snap!
Large independent water filters B E TA S TA TION MF07
dramatically reduce clogging from debris
in water supply
Dishwashing
•
Tahoe
–
–
•
Single pump with time & speed mode
Inexpensive and simple set up, ideal for distribution
business and small accounts
NS1000E
–
–
–
–
–
Stainless enclosure
2-3 chemicals for high temp & low temp machines
Time or probe mode
Long-life flex rinse tube
Patented VCP software corrects for probe scale:
o Reduces service calls
o Gives better results
•
Sierra
–
–
–
–
–
Plastic water resistant enclosure
2-3 chemicals for high temp & low temp machines
Time or probe mode
Long-life flex rinse tube
Patented VCP software corrects for probe scale:
o Reduces service calls
o Gives better results
Single Washer Laundry Dispensers
Summit E
–
Single washer dispenser with 2-8 chemical pumps.
–
Uses small 100 series and/or medium 600 series
pumps.
–
Auto formula select and other modes
–
Programs instantly using ‘clone’ function
–
Runs a max of 3 pumps simultaneously.
–
Data logging features and network capable via
MNet/DNet.
Summit XL
–
Single-washer dispenser 4-8 chemical pumps.
–
Uses medium 600 Series and/or large 100 RPM 2000
series pumps.
–
Runs a max of 8 pumps simultaneously
–
All programming & electronics other than the power
supply are the same as Summit E
–
Data logging features and network capable via
MNet/DNet.
Summit E & Summit XL Benefits
• Programmer
–
–
–
Does double duty as a formula selector
Holds copies of setups so you can instantly program any
number of dispensers
Allows laundry to select formulas by name rather than having
to refer to a wall chart for a #
• Data PCB
–
–
Allows reports to be generated from a computer showing
chemical use, costs, etc.
Allows unified data for OPL and large laundry ILS dispensers, a
capability most competitors lack
• Reduced servicing costs
–
–
Thick wall pump tubes last longer than conventional tubes,
reducing service calls
Speed control allows you to slow pumps down, increasing dosing
accuracy and tube/motor life with viscous chemicals
Multi-Washer Laundry Dispensers
ILS OPL
–
–
–
–
–
Handles up to 6 washers.
Uses 4-8 medium 600 series pumps
Integral POF (proof of chemical flow)
Optional Proof-of-Delivery feature
Data logging and network programmable via DNet
–
–
–
–
Handles two washers
Uses 4-8 large 2000 series pumps
Integral POF (proof of chemical flow)
Perfect for installs on 3-4 large washers where no
POD is required
ILS
ILS Max
–
–
–
–
–
–
Handles up to 15 washers.
Washer hold ensures chemical goes into the washer
at the right point in the cycle, even when using with
the max number of washers.
Up to 10 large 2000 series chemical pumps
Integral POF (proof of flow)
Optional Proof-of-Delivery feature
Data logging and network programmable via
MNet/DNet
Benefits of the ILS Dispensers
Neater installation
–
–
–
Dispensers can be installed further from the washers.
Less wall space is occupied by dispensers.
Less tubing
Consolidated reporting
–
–
Consolidates chemical use info from all the laundry
dispensers
Competitor systems just offer data for the dispenser,
leaving out any single washer dispensers that are
handling special loads.
Improved cleaning results
–
–
–
Auto-prime prevents missed or short chemical feeds after a chemical drum
is changed.
Low level alarm prevents poor results due to out-of-chemical situations.
Auto-calibration: ILS Max flow meter & ILS OPL float switch constantly
recalibrate the chemical pumps, increasing dosing accuracy.
Troubleshooting
Summit E & XL
No Flow Alarm
• If a no-flow alarm occurs, the pump action is cancelled.
The dispenser will attempt subsequent feeds. A no-flow
alarm occurs when:
– An electrical or mechanical problem prevents a
pump from working.
– Dynamic water pressure goes below the working
range of 15 PSI, or above 60 PSI with the Summit
XL flush manifold (a flow switch wiring short can
also produce this).
– A trigger is active for longer than 5 minutes in
smart relay mode. No more feed commands will be
sent to the pumpbox for that trigger until the
trigger turns off and back on.
– The pumpbox detects that a pump has been
running continuously for 5 minutes, at which point
it turns off.
– You try to prime a pump or run the flush with the
flush manifold attached but no water supply; the
alarm will appear on reverting to run mode from
the programming screens.
System Alarm
•
A system alarm indicates system
components (trigger module,
pumpbox, or programmer), cannot
communicate.
•
System alarms usually indicate a
wiring problem (such as field splicing)
leading to intermittent
communication, a dirty plug, or a
defective cable.
•
System alarms can be caused by
electrical noise, such as when
communication cables are coiled on
top of the power supply, routed over
100’, or near other high voltage.
Flush Manifold No Flow Errors
Symptom
Problem
Solution
No flow errors
Water
pressure
over 20 PSI
If pressure is over 20 PSI, install a pressure regulator. Note it’s safest to install a
separate pressure regulator per manifold, since there’s some flow drop after the
regulator and in some cases the flow may not be sufficient if the water line is split to
multiple manifolds downstream from the regulator.
No flow errors
Flow
inadequate
No flow errors
stay displayed on
screen
 Main water supply should be ¾”, with ½” to each washer and flush. Our
calculations indicate using under ½” to any washer, such as 3/8”, can result in
adequate flow to the washer but inadequate flow to any flush .
 T after pressure regulator: Splitting the water supply to multiple flush manifolds
after the pressure regulator can result in pressure drop and no flow errors. Only
use a pressure regulator if the pressure is over 60 PSI dynamic (with water on)
after a T, and only use one pressure regulator per manifold if you have to use
them.
 Run separate water supply from the washer water supply, so when the washer
fills the pressure doesn’t drop so far you get no flow errors.
 If flow too low during washer fill, delay pump runtime til after the washer fill is
complete. (For example, if 60 second washer fill time, pout an “06” in front of the
pump # and volume on the bottom line of the formula mode program screen to
delay the pump 60 seconds)
End pump
 Troubleshoot cause per above.
not
 Change end pump to be the last pump that runs for each formula, for example
programmed
the softener pump. If a no flow error occurs, it will be cancelled off the screen
once the end pump action (and any other pump actions programmed for that
trigger) are complete. This way, the error won’t be displayed on the screen
continuously.
 Note that setting the end pump will also allow you to track load counts, and the
number of loads that have alarms, so you have data whether the no flow is a
serious recurring problem, or something that just happens on 1 out of 40 loads.
Troubleshooting ILS Systems
Troubleshooting
General Principals
•
•
•
•
Never be without a key to allow system access.
Use ‘known good component’, ‘suspect component’ swap method.
Most problems are not circuit board related, but are related to air leaks, programming, wiring, and
COM port settings
Keep good spares available for diagnostics and replacement.
First Steps
1.
2.
3.
First step should be to use system events to find errors
Use interrogation mode to check self diagnostic screens.
To enter test mode for manual priming of pumps, turn key to ‘program’, and turn power off,
keeping the button pressed as you restore power:
•
ILS Max: Hold down the menu button
•
ILS OPL: Hold down the blue button on the PCB
Finding air leaks
•
Air leaks can be the source of transport pump errors on ILS OPL & ILS Max
•
Low transport pump flow rates can be caused by air leaks
•
Check manifold for bubble leaks from fitting connections
•
If there are no air leaks replace transport pump
Troubleshooting triggers
•
Checking the trigger records, especially while running a load, can show which triggers aren’t
coming on when you expect them
•
Cycle records shows total number of triggers and drains per load
Alarm Messages: Feed Rejected
Message
Feed Rejected
Pump Box Offline
Feed Rejected
Washer Drain Open
Feed Rejected
Washer Off
Feed Rejected
Washer Not Selected
Feed Rejected
Data Link Erratic
Feed Rejected
Transport Pump Error
Feed Rejected
Transport System Error
Feed Rejected
Unknown Formula
Feed Rejected
Low Water Temperature
Feed Rejected
Water Supply Problem
Meaning
The pump box will not feed chemicals
during a manual chemical pump
calibration.
Drain status has changed.
Action Required
Do not perform a manual calibration while the
wash aisle is active.
Washer status has changed.
Check washer setup machine on polarity.
Network error.
Check pump setup.
Unreliable communication to washer
Check BetaLink cable and washer module
connections.
Check pump motor, PCB, wiring and connections.
Pump did not run, or current is too high.
Check washer setup drain polarity.
Transport system flow rate is below limits Check the transport tube for blockage or air leaks.
prior to a chemical feed.
A chemical request has been received in Check washer setup. May be caused by operator
PDCI formula mode, but the dispenser
error or power outage.
doesn’t know what type of cycle is running.
The water supply is too cold for the
Check the hot water supply temperature valve
selected chemical.
setting and temperature probe at POF.
Transport water flow failed or the break
Check the break tank, water supply pressure, float
tank is empty during a chemical feed.
switches, inlet valve, filter, transport pump, motors
and chemical pumps.
Alarm Messages: Feed Aborted
Message
Feed Aborted
Water Supply Problem
Meaning
Action Required
Transport water flow failed or
Check the break tank, water supply pressure, float
the break tank is empty during a switches, inlet valve and filter.
chemical feed.
Feed Aborted
Transport system flow rate
Check transport tube for blockage or air leaks.
Transport System Error below limits during chemical
Check manifold filter and transport pump.
feed.
Feed Aborted
Pump did not run, or current is Check pump motor, PC board, wiring and
Chemical Pump Error too high.
connections.
Alarm Messages: Other
Message
Proof of Flow Failure
Proof of Delivery Failed
Meaning
Action Required
Chemical not detected at pump Check supply drums for chemical level. Check
box
suction tube, uptake hose and pump tube for air
leaks and blockage.
Chemical not detected at
Check transport tube for leaks or breaks. Check
washer. Applies only to ILS
POD cell for air. Clean POD cell.
Max emulation systems.
Too much chemical requested. Check washer control and washer setup.
Relay Mode Trigger Time Limited
Exceeded
Feed Rejected High Water TemperatureWater temperature is > 150F
or 70C.
Delivery: Transport System Error
Transport system flow rate
below limits after a chemical
feed.
Delivery: Water Supply Problem
Transport water flow failed or
the break tank is empty after a
chemical feed.
Worn Chemical Pump Tube
Washer Network Link Lost
Tube needs to be replaced
soon.
Unable to communicate with
washer.
Check cold water supply and temperature valve
setting.
Check transport tube for air leaks and blockage.
Check the manifold filter and transport pump.
Check break tank, water supply pressure, float
switches, inlet valve and filter.
Replace pinch tube and reset date changed.
Check BetaLink wires, remote modules,
connections, network and setup.
Errors from hydrogen peroxide
•Peroxide has low
conductivity so the POF
and POD cells won’t
see it, unless a
conductive material is
added during
manufacture to it. If
you are getting POF
and POD errors, turn
off POD and POF in the
chemical setups
screen. System events
will show "POD
assumed.”
•If you don’t turn it off
and it’s not conductive,
errors, including “out of
product” will result as
the system won’t see
the change in
conductivity.
The System Events screen will show all events and errors, but not all trigger logs,
as shown above for the Beta ILS. “POF Failure” is usually due to lack of
conductivity as with peroxide or air leaks.
DNet
Symptom
Cause
No communication with
computer
–
1. Wiring
2. Network address
–
3. DNet COM
setting
–
Loads logged too long
with wrong chemicals
with AFS
Machine on signal
not connected
Solution
Verify wires connected correctly to protocol converter (if reversed, there will
be no communication)
Turn key to enter program mode, Press <> arrows 3x to reach “Network
ID”, and change it to 00.
If DNet can’t locate washers, the issue is probably that the COM port
number is set incorrectly in DNet. To check which computer port number
should be used in Windows, click on start, settings, control panel, and
system. A window will show up; click on the hardware tab on the device
manager button. In the device manager menu, scroll down to ports and
click on the + to open it up; it will show you the correct port number to use
in DNet. Do not change the setting in the computer’s device manager;
change it in DNet only.
Connect machine on signal, or ignore cycle records data. Correct chemical
amounts will be dosed for the various formulas activated by the AFS signal,
however all amounts will be logged under the formula number active when the
dispenser power was toggled off and on
Load pump volume too
large
1. Call rate setting
2. No machine on
signal
1. If the relay mode call rate setting is accidentally set to be too large, you’ll
get more chemical than you expect
2. If the machine on signal doesn’t turn off in between cycles, the system will
count the total volume pumped as being during one cycle, even if it’s the
total volume until the washer is powered down, such as a whole day
DNet: Unidentified Loads
Causes
–
–
Drain signal counts incorrect, or signal flickers
Trigger counts programmed incorrectly, or signal flickers
Solutions
–
–
–
If a microprocessor machine, you can use a trigger for AFS, or automatic formula selection, to
log triggers
If a chart based machine, program Load Classification Setups
If Load Classification Setups are programmed, troubleshoot them using cycle records
Flowmeter Issues
Some damaged flowmeters only read ½ the pulses
–
This can make all dose sizes double size intended
–
May trigger replace tube alarm early (assuming flowmeter originally read all pulses and later
only read half)
–
May trigger transport pump error (given flow reading of half may result in reading dropping
below minimum, once chemical pump turns on)
Solution
–
Enter pump setup screen and manually turn on transport pump for one minute, collecting
output in bucket
–
Check output vs. calibration on screen, change screen setting, likely to half previous setting
–
Replace flowmeter at earliest available opportunity
Transport pump
•
If a transport pump fails to run:
–
Verify it’s correctly addressed
–
Verify drive wires are hooked up correctly
•
If either 1.5 GPM or 3 GPM have a flowrate of under 60%, they should be inspected for air leaks. If
no air leaks are found, it could be the pump is nearing the end of its life and needs to be replaced.
•
If pumps are failing too soon:
•
–
Ensure continuous water supply
–
Verify no air leaks
–
Verify water temperature in specifications, check for debris in the valves (valve kit available)
and add a 20 mesh filter prior to transport pumps.
When to change? Change out the transport pump when it’s weeping or the flowrate falls by about
40%, to 1.8 GPM (from 3 GPM) or 0.9 GPM on older 1.5 GPM transport pumps.
Beta Products & Troubleshooting
Housekeeping Products
Dishwashing Products
OPL Products
Large Laundry Products
Summit E & XL Troubleshooting
ILS Systems Troubleshooting

similar documents