WL Max Technical Manual
WL Max Technical Manual WL Max Technical Manual - Version 1 - May 2013 Index Machine Overview Flow Diagram Pre Delivery Inspection Procedures (PDI) Installation Procedures Installation Kit Operating Instructions Maintenance and Servicing Sanitizing Fault Finding Technical Specifications and Warranties End of Life ROHS BioCote® Electrical Wiring Diagram 230V Wetted Parts Illustration Main Parts List Illustration 4 8 11 12 14 15 16 18 20 22 24 24 24 26 28 32 WL Max Technical Manual - Version 1 - May 2013 2 3 Machine Overview WL Max ICE BANK TECHNOLOGY The WL Max is available in the following options: a) Cold Only Single Faucet (High Capacity) b) Cold Only Double Faucet (High Capacity) The ice bank technology system is manufactured from 304 Stainless Steel which is non-corrosive and inert. The cold water temperature is preset at the factory at approximately 5 degrees C, this being the ideal temperature for a cold drink. The ice bank technology system, unlike other reservoir systems, reduces the amount of water stored in the machine. The capacity of the coil system is 18cl. FILTERS The filtration system on the WL Max is designed to reduce dirt and sediment particles from the water. Furthermore, the Activated Carbon process will remove a whole range of contaminants e.g. chlorine and pesticides. It is important for the UV sterilization system to be supplied with clean water in order to achieve maximum efficiency. There are many kinds of different filter combinations available from Waterlogic to suit local water conditions. FIREWALL CHAMBER The Firewall chamber incorporates the in-Faucet UV and is made of aluminium and is highly reflective. The Chamber houses the UV lamp and quarts spiral as well as the faucet. IN FAUCET UV The Unique design allows the faucet area to be sterilized before, during and after every dispense. There are two types of sensors available, the CDS UV sensor that detects if the UV lamp is working and the UV sensor that monitors the UVC intensity from the UV lamp. WL Max Technical Manual - Version 1 - May 2013 WL Max Technical Manual - Version 1 - May 2013 4 5 UV LAMP The UV light is a 13 watt germicidal lamp at a wavelength of 253.7 NM, which is very efficient at destroying bacteria in water. The UV lamp is situated in the Firewall Chamber surrounded by a quartz spiral that attains NSF standard 55 purification of water. The UV lamp must be replaced at 6 months intervals or when indicated by the warning lights, and the quartz spiral may need to be cleaned by using an ultrasonic bath. PCB The PCB (Printed Circuit Board) is the control unit for the WL Max; it is responsible for the functions of all the mechanical and electrical parts (24V DC) including the solenoid valves. COMPRESSOR The compressor operates at 220-240V at 50Hz or 120V at 60Hz. It uses 165g of R134a non-Ozone depleting refrigerant gas. WATER PIPES AND FITTINGS The inlet and the internal water circuit pipe size is 1/4”. The entire internal water circuit and all the components which come in contact with water are food grade NSF approved. WATER VALVES Dispensing of water to the customer is achieved by means of a 24V DC electrical solenoid valve. The valves are energized every time the customer activates the dispense button for a drink. DC voltage is used to give a positive and quieter action of the solenoid valve. DRAIN The WL Max drip tray has a drain feature which requires a connection to a container/ waste. WL Max Technical Manual - Version 1 - May 2013 6 7 Flow Diagram Flow Diagram Single Faucet Double Faucet IN (Water) IN (Water) SOLENOID VALVE FILTER FILTER SOLENOID VALVE COLD WATER OUT COLD WATER OUT SOLENOID VALVE COLD SENSOR COLD SENSOR ICE BANK ICE BANK CONDENSER CONDENSER FILTER DRYER FILTER DRYER COMPRESSOR COMPRESSOR DRAIN VALVE DRAIN VALVE WL Max Technical Manual - Version 1 - May 2013 8 9 Pre Delivery Inspection Procedures (PDI) CAUTION: Only competent trained technicians should work on Waterlogic products. Waterlogic units may weigh over 25KG. We recommend caution when lifting. Packing materials could present a trip hazard. Keep them off the floor. Take care not to allow the power lead to get wet. If the lead gets wet it must not be used. 1. Remove packing straps and unpack unit and visually inspect for any damage. (Report any defects to Waterlogic as soon as possible). 2. Place the unit on a suitable flat surface. 3. Open the top and bottom covers by removing the screws that fix them in place. 4. Visually inspect all electrical connections and power lead. 5. Visually inspect all water connections. 6. Remove the top cover from the Firewall Housing and inspect the quartz spiral for damage. If all is ok then re-assemble. 7. Connect to a potable drinking water supply via a 1/4” John Guest tube, the supply must be limited to 3bar. 8. Connect the power cord to an appropriate power supply and the machine. 9. Replace all the panels and re-fit the screws. 10. Select the cold dispense button until water flows clearly from the faucet. 11. When the ice bank reservoir has been filled, turn on the compressor switch. Allow up to two hours for the unit to heat and chill. Test water temperatures and ensure the water tastes acceptable. 12. Check all functions of the WL Max. 13. Turn off the power and water. 14. Turn the unit around and drain from rear drain valves if fitted. 15. Clean and repack ready for dispatch. 16. Waterlogic recommend that all units are fully electrically (PAT) tested on site by the commissioning engineer as damage may have occurred during transit to the unit’s final destination. WL Max Technical Manual - Version 1 - May 2013 10 11 Installation Procedures 1. Mount the WL Max on a firm, level surface so the machine cannot topple or fall over. A 50mm air gap is required the whole way around the machine to allow for sufficient ventilation. The WL Max must not be installed in direct sunlight, adjacent to a heat source, or in an ambient room where the temperature is above 30°C or below 5°C. 2. Level the machine using the adjustable feet if needed. 3. It is advisable to have the power and water supply within a 2 metre range of the machine, the isolation for the water and electricity should be easily accessible. The supply of water must be from a potable source and the machine should not be installed using an extension lead. 4. Remove the top and bottom covers of the machine. Inspect all water and electrical and water connections to make sure they have not come loose whilst in transit. 5. Remove the inline filter from the machine and attach a water feed directly into the inlet side, attach another length of water pipe to the outlet side and direct this into a bucket or a large container. Allow 10 litres of water to pass through the filter clearing any carbon fines that may need to be flushed out. (This process may need to be repeated) 6. Remove the cap from the top of the WL Max Ice Bank reservoir and place to one side. 7. Insert your water feed into the top of the Ice Bank reservoir and fill the reservoir until the water level is 2mm away from the top. 8. Replace the cap on the top of the reservoir. 9. Make the water connection using an installation kit. Waterlogic recommends the use of a pressure reducing valve, a shut off valve and a non return valve. These should be fitted before the water intake to the machine. Minimum operating pressure for the machine to work suitably is 2.6bar.The minimum incoming flow rate is 1.2 litres per minute. The ideal operating pressure is at 3bar, and at pressures higher than 3.2bar the machine will not function correctly and this can lead to leaks. The water should be from a potable source and should be allowed to run clear of any sediment before making the connection into the WL Max. 10. Check all the connections to ensure there are no water leaks within the WL Max machine. 11. Re-fit the top and bottom covers and secure them using the screws removed earlier. 12. Check the electrical wall socket (polarity) and then make the electrical connection to the WL Max by plugging the power lead into the socket on the rear of the WL Max. Then connect it to the electrical feed or wall power outlet. Turn on the power supply to the WL Max. 13. Depress the dispense button and flush through 10 litres of water. When the reservoir is full turn on the red switch at the rear of the machine. The machine will now begin to cool. 14. The water temperature is pre-set at the factory to 5°c. 15. The water should now be taste tested, any hint of a taste in the water means the machine needs to be flushed further with an additional 10 litres and then taste tested again. 16. The WL Max should be sanitized at installation. A suitable sanitizer such as Aqua Dosa should be used. WL Max Technical Manual - Version 1 - May 2013 12 13 Operating Instructions INSTALLATION KIT The WL Max must be installed according to the local guidelines and a pressure reducer must be installed as part of the installation. The pressure reducer should not be set higher than 3bar. • The WL Max should not be connected to water supplies of unknown bacterial quality or those not already fit for human consumption. The WL Max should only be connected to a Potable drinking water supply. • The filter on the WL Max must be changed every 6 months. • The UV lamp on the WL Max must be changed every 6 months. • The cold reservoir should also be flushed and sanitised every 6 months. • Waterlogic International strongly recommends the use of an anti-flood device. • Figure 1 is the recommended installation kit. The part number for the installation kit shown below is “P-KIT INSTALLATION”. Your WL Max is generally ready for use. Dispensing your choice of water is very simple, as follows: 1. Place your cup centrally in the dispensing area for single faucet or on the edge for the double faucet machine 2. Select and hold the momentary dispense button until your cup has reached the desired level, and then release the button. 3. If using the auto-fill option, select the button until your container has reached the desired level, then de-select the button CONTINUOUS DISPENSE Select the continuous dispense button, then remove your finger from the button. When the container has reached the desired level deselect the dispense button. STOP DISPENSE Put the dispense button into the central position to stop the dispensing of water PRESS AND HOLD DISPENSE Fig 1. Waterlogic Installation Kit Select and hold the dispense button, release the button to stop the dispensing of water 1 - 15mm Compression Inlet 2 - Double Check Valve (great for carbonated water) 3 - Adjustable Pressure Reducing Valve 4 - Integral Isolator 5 - Pressure Gauge Port 6 - Waterblock 7 - 1/4” Pushfit Outlet WL Max Technical Manual - Version 1 - May 2013 14 15 Maintenance and Servicing • Every six months or every 6 000 UV lamp cycles we strongly recommended that the UV lamp be changed. • Every six months or after 10 000 litres it is strongly recommended that the filter be changed. • The Firewall quartz spiral needs to be removed, inspected and cleaned where necessary. • No paperwork or cleaning records should be stored inside the WL Max. Items Required for the 6 Month Service Procedure • Rubber Gloves • Phillips/ Cross head screwdriver • Replacement filter cartridge - CBC cartridge part number: FT-0036 • Replacement UV lamp - UV lamp part number: CT-2085 • Aqua Dosa (or similar) sanitizing fluid • Peroxide test strips • A container that can hold 5 litres • Non-abrasive anti-bacterial wipe or cloth SERVICING PROCEDURE 1. Put on the rubber gloves to minimise the chance of any contamination to the machine and to protect yourself whilst the servicing procedure is being carried out 2. You will need to stop the water supply to the machine by turning the isolation valve to the off position and releasing the pressure by depressing the dispense button until water stops dispensing 3. Isolate the power to the WL Max by turning off the red power switch at the rear of the machine and completely removing the power lead 4. The filter is located in the WL Max base cabinet behind the lower back panel 5. To replace the filter detach the water pipes from the elbow fittings at the top, then the filter can then be removed from the retaining bracket. Unscrew the filter housing by twisting it clockwise, this will expose the CBC carbon cartridge. The cartridge can then be removed from the filter housing and replaced by a new one 6. The new filter cartridge will require flushing prior to being re-fitted into the WL Max. To do this connect a water feed directly into the inlet side of the filter and attach another length of pipe to the outlet side and direct this into a bucket/large container or drain, then allow 10 litres of water to pass through the filter, to ensure that any loose carbon fines are fully removed to avoid any damage being caused to the machine and to sufficiently generate the new filter cartridge 7. After the filter has been flushed it can be replaced in the WL Max and the water pipes can be reconnected 8. Remove the UV lamp by unplugging the UV loom connector and pulling the lamp upwards. Then remove the top cover from the Firewall housing and remove the quartz spiral 9. Check the spiral for any scale build up and clean were necessary 10. Replace the quartz spiral into the Firewall housing and insert the new UV lamp assembly making sure not to touch the new UV lamp with bare hands as this will shorten the life of the lamp. Connect the UV lamp connector and replace the Firewall housing top cover 11. Inspect all of the electrical and water connections on the machine, and take any action necessary to prevent a fault from occurring 12. Check the faucet nipple for any calcium build up or any visible damage and clean or replace it if necessary 13. Reassemble the machine and secure all panels with screws 14. Check that the air gap around the machine is sufficient and there is nothing blocking the ventilation 15. Reconnect the power lead and insert it into the rear of the machine 16. Flush through 5 litres cold water to ensure the water is running clear of any carbon fines and that the taste of the water is clean and to the customers satisfaction. If you are not happy with the quality of the water continue to flush an additional 2-5 litres of water until you are satisfied with the taste 17. The red compressor switch can now be turned on, allow the machine to cool the water 18. Clean the outside of the machine with a non-abrasive anti-bacterial wipe or cloth 19. Taste the water one final time and check it is cooling the water. WL Max Technical Manual - Version 1 - May 2013 16 17 SANITISING 1. Put on the rubber gloves to minimise the chance of any contamination to the machine and to protect yourself whilst the servicing procedure is being carried out. 2. You will need to stop the water supply to the machine by turning the isolation valve to the off position and releasing the pressure by depressing the dispense button until the water stops dispensing. 3. Isolate the power to the WL Max by turning off the red power switch at the rear of the machine and completely removing the power lead. 4. The filter is located in the WL Max base cabinet behind the lower back panel; you will need to remove this panel to access the filter. 5. To remove the filter detach the water pipes from the elbow fittings at the top, then the filter can then be removed from the retaining bracket. Unscrew the filter housing by twisting it clockwise, this will expose the CBC carbon cartridge. The cartridge can then be removed from the filter housing, put this to one side as you will need it again later. 6. Add the required amount of sanitisation fluid (e.g. Aqua Dosa) to the empty filter housing and screw the filter body to the filter head, making sure it’s securely tightened. 7. Fit the filter assembly with the sanitisation fluid into the machine and reconnect the water pipes into the elbow fittings. 8. Replace the lower back panel and fix it in place with the screws you removed earlier. 9. The water supply to the machine can now be turned on. 10. Reconnect the power lead and insert it into the rear of the machine. 11. Dispense cold water until the sanitisation fluid leaves the faucet. Whilst you are dispensing the cold water hold a peroxide test strip under the dispense area and test the flow of water to check that the sanitisation fluid is present in the ice bank coil. 12. Leave the sanitisation fluid to stand in the ice bank coil for 20 minutes. Once this time has passed select the dispense button and then select the dispense button and flush enough water to remove the sanitisation fluid from the machine (usually about 10 litres). Use the same method as before and check all the sanitisation fluid has left the tank by using a peroxide test strip. 13. Turn off the water supply at the isolation point. 14. Select the dispense button until no more water is being dispensed. 15. Completely remove the power lead from the unit. 16. Remove the lower back panel from the WL Max and disconnect the water pipes from the elbow fittings on top of the filter. Remove the filter from the retaining bracket and unscrew the filter body from the filter head by turning the base in an anti-clockwise direction. 17. Pour away the excess water and re-fit the filter cartridge to the filter head, making sure it firmly and securely fitted. Screw the filter body to the filter head so it is securely tightened. 18. Re-fit the filter into the retaining bracket and re-connect the water pipes into the elbow fittings. 19. Replace the lower back panel and fix it in place with the screws you removed earlier. 20. The water supply to the machine can now be turned on. 21. Reconnect the power lead and insert it into the rear of the machine. 22. The red compressor switch can now be turned on, allow the machine to cool the water. 23. Clean the outside of the machine with a non-abrasive anti-bacterial wipe or cloth. 24. Taste the water one final time and check it is cooling the water. WL Max Technical Manual - Version 1 - May 2013 18 19 FAULT FINDING All fault finding procedures must be carried by a technician trained by Waterlogic International or their nominated distributor. Please take great care and suitable health and safety measures when fault finding on live electrical parts. 1. No flow of water: Ensure that there is a water supply to the WL Max from the building and that the installation isolation valve is turned on. If the installation kit has an anti-leak device included in it (as Waterlogic Installation kit) then make sure it has not tripped. 2. No flow of water: Check that the water filters are not blocked and that they are in date. Waterlogic recommend filters are changed at 6 months. 3. The cold water is not cold: Make sure the compressor switch is turned on. 4. The cold water is not flowing: This may be due to the cold water reservoir being frozen. If so disconnect power supply for one hour to allow the tank to defrost, and then flush the cold water system. Check the temperature settings are correct. If the cold reservoir is not frozen then check the solenoid valves are operating correctly and being turned on and off when you push the dispense button. 5. Low flow of cold water: Check the building water pressure to the WL Max is 45 PSI. Check the filters are not partially blocked, and that the solenoid valves function correctly, check if cold reservoir ice buildup needs to be defrosted. 6. Bad or plastic taste: If the WL Max is new it may need flushing for a longer period, make sure the machine has been sanitized at installation. 7. Water leaks: Most leaks will trip the Waterlogic block located on the installation kit. Should you see water leaking from the WL Max, isolate the supply and start normal fault finding procedures. 8. No power: Check the building electrical supply to the WL Max is on and that the power cord is plugged in. Test the WL Max fuse. Check that the top. If all these points are OK then start normal fault finding procedures. WL Max Technical Manual - Version 1 - May 2013 20 21 Technical Specifications and Warranties SAFETY Subject to the standard terms and conditions of sale (a copy of which has been provided to you), neither Waterlogic International Limited (“Waterlogic”), nor any affiliated companies shall be liable for any damage which could affect, directly or indirectly, any person or property. Please be aware that any warranties accompanying the sale of our products will be invalidated by any of the following: • Incorrect installation • Incorrect use of the WL Max • Unsuitable electrical and water supply • Major short-coming of maintenance • Technical interventions or alterations of an unauthorized nature • Adoption and use of unapproved spare parts • Engagement of untrained personnel Waterlogic has a policy of constant and continual improvement and therefore reserves the right to change specifications without prior notice, other than in the case of significant changes. Description WL Max 1 Water Distribution WL Max 2 Water Distributions W 321 mm, H 1413.5 mm, D 335 mm W 321 mm, H 1413.5 mm, D 335 mm 34.5Kg 36Kg 220-240 Volt / 50Hz 220-240 Volt / 50Hz 330mm 330mm N/A N/A 230V/50Hz (R134a) 230V/50Hz (R134a) UV Lamp 13W 2 x 13W Unit Total 300W 313W Refrigeration Gas R134a 165g 165g Cold Tank Capacity Direct Chill Direct Chill Water Connection 1/4” Hose 1/4” Hose 0.26 (2.6) 0.26 (2.6) 0.32 (3.2) 0.32 (3.2) 0.3 (3.0) 0.3 (3.0) 1.2 lpm 1.2 lpm 65lph 65lph 5 - 8°C 5 - 8°C Machine Size Machine Weight Power Supply Dispense Area Height Fan Compressor Minimum Water Pressure Megapascal (Bar) Maximum Water Pressure Megapascal (Bar) Recommended Water Pressure Megapascal (Bar) Minimum Incoming Flow Rate (litres per minute) Cold Water Dispensing Capacity Cold Water Temperature WL Max Technical Manual - Version 1 - May 2013 22 23 End of Life Non Eu Countries At the end of this products life, please ensure that it is disposed of in an environmentally friendly manner which is in line with your Country requirements/ guidelines. WEEE (EU ONLY) Please be aware that our products are covered by the Waste Electrical and Electronic (WEEE) directive (2002/96/EC). The symbol shown above denotes that the product should not be disposed of with general/household waste. Please contact your supplier/service agent who will arrange for the collection and disposal of this product. ROHS All Waterlogic machines comply with EC Directive (2002/95/EC) on the Restriction of the Use of Certain Hazardous Substances in Electrical and Electrical Equipment (RoHS). FREQUENTLY ASKED QUESTIONS ABOUT BioCote®: Why use BioCote®? BioCote® will help reduce the risk of cross-contamination. You may not want to think about it, but every surface in the working environment is a potential breeding ground for Bacteria. How is it applied? BioCote® is applied via an additive into the manufacturing process and will, therefore, be present throughout the moulded or painted parts. How long will BioCote® last? BioCote® will last for the usual life expectancy of your water dispenser. It will not wear or wash out with use or cleaning. What bacteria is BioCote® effective against? BioCote® is effective against most common bacteria, moulds and fungi. Please note: BioCote® is an additional line of defense to protect between cleaning routines, it is not a replacement for your normal cleaning and sanitization processes. BioCote® (ANTI-MICROBIAL SOLUTION) For your added protection this product incorporates BioCote® antimicrobial technology. Silver, in the form of silver ions, is the active ingredient utilized in BioCote®. This silver technology is manufactured into the surface of our products, giving them built-in sustainable antimicrobial protection. BioCote’s silver technology has been tested by an independent laboratory to show its ability to inhibit the growth of bacteria, mould and fungi by up to 99.9% over a 24 hour period and for the duration of the machine life. WL Max Technical Manual - Version 1 - May 2013 24 25 Electrical Wiring Diagram 230V DANGER HIGH VOLTAGES PRESENT ON THIS PCB CARE MUST BE TAKEN WHEN LIVE TESTING WL Max Technical Manual - Version 1 - May 2013 26 27 Wetted Parts Illustration Single Faucet 1 9 7 8 N° Part No. Part Description 1 2 3 4 5 6 7 8 9 PU-4031 PU-4028 PU-4031 FT-0034 PU-4008 JG 1/4" PE Pipe JG Bulkhead Connector Union 1/4" * 1/4" JG 1/4" PE Pipe 10" Inline CBC Filter 1 Micron JG Equal Elbow Connector 1/4" Stainless Steel Coil 5/6" JG Equal Straight Connector 1/4" Solenoid DC 24V 500mm Quartz Spiral PU-4010 PU-4017 FU-0007 7 1 7 1 2 5 3 6 4 WL Max Technical Manual - Version 1 - May 2013 28 29 Wetted Parts Illustration Double Faucet 1 7 5 8 7 9 8 7 N° Part No. Part Description 1 2 3 4 5 6 7 8 9 10 PU-4031 PU-4028 PU-4031 FT-0034 PU-4008 JG 1/4" PE Pipe JG Bulkhead Connector Union 1/4" * 1/4" JG 1/4" PE Pipe 10" Inline CBC Filter 1 Micron JG Equal Elbow Connector 1/4" Stainless Steel Coil 5/6" JG Equal Straight Connector 1/4" Solenoid DC 24V 500mm Quartz Spiral Two Way Divider PU-4010 PU-4017 FU-0007 10 1 7 1 2 3 5 4 WL Max Technical Manual - Version 1 - May 2013 30 31 Main Parts List WL Max Main Parts Illustration 10 11 12 9 6 8 7 5 4 13 15 14 17 23 18 16 19 21 20 22 27 24 25 26 29 30 39 2 3 1 28 35 36 37 33 34 31 32 38 40 41 42 43 50 44 45 47 49 N° Part Description 1 2 3 4 Front Panel Drip Tray Grill Drain Valve Band 1 Switches Band 2 Switches 3 Position Switch Upper Panel Firewall Housing Top Cover UV Rubber Mount UV Sensor Rubber Mount UV Sensor 15W UV Lamp JG 1/4" Elbow Quartz Spiral JG 1/4" Straight Connector Firewall Housing Solenoid Valve 24V DC Back Cover JG 1/4" Straight Connector JG 1/4" Divider Ballast 15W 220 V Firewall display PCB Relay PCB Transformer Power Switch Fuse Holder 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 46 48 Parts list continued on next page WL Max Technical Manual - Version 1 - May 2013 32 33 N° Part Description 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 EMI Filter Electrical Panel Cover Electrical Case Power Cord Inline CBC Filter JG 1/4" Bulkhead Connector Filter Clip JG 1/4" Elbow JG 1/4" Straight Connector Drain Hose Reservoir Tank Lid Pump Reservoir Thermostat Drain Connection Condenser Grill Condenser Filter Condenser Rubber Feet Fan Fan Motor Compressor Capacitor Relay Compressor Cover WL Max Technical Manual - Version 1 - May 2013 34 35 USA, Canada and Mexico Rest of the world [email protected] + 1 402 884 7212 [email protected] + 353 1 293 1960 Waterlogic USA, 4141 N. 156th Street, Omaha, NE 68116 WLI Trading Ltd. Suite 4, 2nd Floor Beacon Court, Sandyford, Dublin 18, Ireland www.waterlogic.com 36 ENG0332-28/06/13 Speak to a Water Expert
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