Ecolab Apex2 Manuale utente

Apex2

Installation and

Operation Manual

370 Wabasha Street N. St. Paul, MN 55102

www.ecolab.com

43569/5400/0112

Part No. 9223-2253

TABLE OF CONTENTS

Getting Started

Introduction and Features .................................................................................1-2

Speciﬁcations and Dimensions ...................................................................... 3-4

Installation Equipment: “What’s in the box” .................................................. 5

Installation

Hardware .................................................................................................................. 6

Find location for Controller ........................................................................ 6

Mount I/O Enclosure (new install) ............................................................. 7

Inductive Probe ............................................................................................. 7

Rinse Thermistor ...........................................................................................8

Rinse Additive Injection ...............................................................................8

Plumbing Detergent Valve .......................................................................... 9

Optional Pressure Switch ............................................................................ 9

New Install Wiring .................................................................................................10

Machine Signals and Apex2 Power ......................................................10-11

I/O Board Connections ................................................................................12

Sealing Block .................................................................................................13

Retroﬁt-Kit (Converting Apex to Apex2) .......................................................14

Apex Rinse Additive Signal Wire ..............................................................14

Apex 2 I/O Board ..........................................................................................14

Notice of Existing Machine Signals and System Power ......................15

Apex Board disposal ....................................................................................16

Setting Up Controller

Controller Setup ............................................................................................... 17-18

Alarms......................................................................................................................19

Activation and Deactivation Speciﬁcation .............................................19

Appendix

FAQ’s and Troubleshooting .........................................................................20-23

Performance Check ............................................................................................24

Replacement Parts Guide .........................................................................25

Apex2 Controller Menu Flow ..............................................................28-35

1.0 INTRODUCTION

This manual provides instructions for the safe installation, maintenance and

operation of this dispensing controller system. Read and understand the

contents of this manual before installing or operating the system. Retain this

manual for future reference. Safety instructions that appear in this manual

after a warning symbol and the words WARNING or CAUTION printed in bold

face are especially important.

means there is the possibility of death or serious

injury.

means there is the possibility of minor or moderate

injury.

NOTICE means the possibility of equipment or property damage only.

Principle of Apex2

The Apex2 System is a machine warewash control system that communicates

actionable and intuitive information to the customer and creates an efﬁcient

interface for Ecolab sales representatives. This control system will help the

customer achieve superior results with improved operational efﬁciency.

System Features

Overall System Features

The Overall System features include:

• High resolution wide screen display

• Full text, multi-language display

• Intuitive alarm notiﬁcations

• Video play back

• Real time data collection for every rack washed

• Automated rack time calibration for conveyor and ﬂight machines

• Customer facing Status menu for real time data

• Wireless data download and setup via Ecolab Service Manager (ESM)

• Universal main power input (100-240VAC , 50/60 Hz)

• Splash resistant enclosure

Detergent Control System

The Detergent Control System features include:

• An Inductive Probe that controls product dispensing when operating in

Probe Mode.

!WARNING

!CAUTION

Figure 1.1

- “Pulse Feed” of detergent provides overshoot control when the wash

tank concentration is near the desired set point.

• A Timed Mode that is available for alternate detergent control when not

using the probe.

• A Detergent Manager that monitors probe control dispensing and

automatically switches to a base lined feed condition when a dispensing

error is detected.

Rinse Injector System Features

The Rinse Injector System features include:

• Double roller peristaltic pump.

• Squeeze tubes with different delivery rates for high or low volume

installations.

• Variable speed DC motor, 8 - 30 RPM.

• Adjustable run time and start delay (on door machines)

• Optional Pressure Switch for alternate rinse signal input.

• Rinse Manager to disable the rinse injector system during a dish machine

ﬁll (on automatic ﬁll dish machines).

• Pump prime capability

Sanitizer Injector System Features (optional)

The Sanitizer Injector System features include:

• Double roller peristaltic pump.

• Squeeze tubes with different delivery rates for high or low volume

installations.

• Variable speed DC motor, 8 - 30 RPM.

• Adjustable run time and start delay

• Pump prime capability

2.0 SPECIFICATIONS

Dimensions and Space Requirements

Controller and IO Box Dimensions

Controller Dimensions

• Height 5.6” (14.2 cm)

• Width 8.0” (20.3 cm)

• Depth 2.6” (6.6 cm)

IO Box Dimensions

• Height 9.2” (23.4 cm)

14.7” (37.3 cm) w/door open

• Width 10.7” (27.1 cm) one pump

• Depth 5.5” (14.0 cm)

Electrical Requirements

The Apex2 Controller operates within the following:

• Incoming Power

• 100 to 240VAC , 50/60Hz

• Detergent and Rinse Signal inputs

• 24 to 240VAC , 50/60Hz, or 24VDC .

5.553

9.235

12.005

10.772

14.699

Figure 2.1

Figure 2.2

8.000

3.540

NOTICE

If the primary voltage is 440/480 volts, separate, externally mounted

transformers are required (P/N 9230-1022).

Inputs (See Mechanical Installations for Wiring

Diagram section 4)

The Apex2 Controller operates with the following inputs (I/O Enclosure):

• Inductive Probe (mandatory for operation in probe mode)

• Rinse Thermistor (mandatory for all Apex2 Installations)

• Product Lid Switches

• Detergent Lid Switch that prevents detergent valve from opening while

the lid is open

• Solid Rinse Additive Lid Switch input that prevents rinse additive pump

from running while the lid is open.

Note: This is an optional feature used with certain external dispensers.

A jumper wire has been installed in the factory to electrically connect

this input.

• Sanitizer Lid Switch that prevents sanitizer pump from running while

the lid is open.

Note: This is an optional feature used with certain external dispensers.

A jumper wire has been installed in the factory to electrically connect

this input.

• Out-of-Product Signals

• Solid Rinse Additive Out-of-Product Signal

• Liquid Rinse Additive Out-of-Product Signal

Outputs to External Dispensers

Apex2 operates with the following outputs (I/O Enclosure):

• Solid Rinse Additive Dispenser

• Two wire output to provide 24VDC power to dispenser

Plumbing Requirements

Water supply tubing from the building water supply to the solenoid valve in the

Apex 2 I/O will normally be 1/4” O.D. copper tubing.

Note: Refer to the Installation and Operation Manual of the appropriate

Detergent and Rinse Dispensers used for this application to aid in the

installation of the Apex2 Controller.

3.0 INSTALLATION EQUIPMENT

Apex2 New Customer Install Kit (9223-1072)

Contents:

• Apex2 User Interface Module

• Apex2 I/O Enclosure, including:

• I/O Board, Power Supply, & Signal Wiring Harness

• Rinse Additive Pump

• Detergent Valve

• Inductive Probe (12’)

• RS-485 Communication Cable

• Rinse Thermistor

Apex2 Retroﬁt Kit (9223-1071)

Contents:

• Apex2 User Interface Module

• Apex2 I/O Enclosure Cover & I/O Board assembly

• Inductive Probe (12’)

• RS-485 Communication Cable

• Rinse Thermistor

Apex2 New Customer Install Kit Dual Pump

(9223-1070)

Contents:

• Apex2 User Interface Module

• Apex2 I/O Enclosure, including:

• I/O Board, Power Supply, & Signal Wiring Harness

• Rinse Additive Pump

• Third Product Pump

• Detergent Valve

• Inductive Probe (12’)

• RS-485 Communication Cable

• Rinse Thermistor

4.0 INSTALLATION

Apex2 Controller Installation

Disconnect electrical power supply and follow lockout/tagout procedures

before installing or performing service on the system.

Electrical and grounding connections must comply with the applicable portions

of the National Electrical Code, ANSI/NFPA 70 (latest edition) and/or other

electrical codes.

Mounting Controller

1. Choose an installation location that:

• Allows visual display of the Apex2 Controller (see ﬁgure 4.1 below)

• Permits shortest possible tube, wire, and conduit lengths.

• Provides accessibility for adjustments and servicing.

• Provides as much protection from moisture/steam and heat as possible.

2. Secure Controller

• Mount to the top or side of the dish machine using the wall mount and

L-bracket

• To ﬂush mount to the wall or dish machine use only the wall mount

bracket

Note: Avoid mounting the controller in areas near the dish pre-scrap area, and

the rinse section of the dish machine due to excessive water, heat and food soil.

Connect RS-485 Communication Cable to Apex2 Controller

1. Remove the back cover from controller by removing the two retaining

screws.

2. Insert one end of the RS-485 communication cable to the open plug on

the controller board. Note: The other end of this cable will be connected

in the I/O enclosure

3. Install the back cover using the two retaining screws.

Mount and adjust the controller

1. Mount the controller to the wall mount bracket. It is necessary to ﬁrst

depress the release tab before sliding the controller on to the wall

bracket.

2. Adjust the viewing angle of the controller by depressing the release tab

and sliding the controller on to the wall bracket. Make sure the release tab

engages with the back of the controller at one of the three positions.

!WARNING

Figure 4.1

Figure 4.2

Figure 4.3

Mount Apex2 I/O Enclosure

Attach the Apex2 I/O mounting bracket to the wall using the supplied screws

and plastic wall anchors. The installation should be secure, neat, and level. See

Figure 4-4

Inductive Probe Installation

For optimal equipment performance and reliability choose a location that is:

• A minimum of 2” (5 cm) from the tank bottom, side wall, overﬂow piping,

etc.

• As far as possible (2” [5 cm] minimum) from heater elements or coils

• Protected from physical hazards.

• Always underwater, with entire Probe constantly submerged, particularly

on shallow tank machines.

Before drilling the hole in the wash tank, identify and avoid any obstructions

both inside and outside the wash tank.

Installations Steps

1. Drill/Cut a 7/8” (22 mm) hole into the wash tank wall.

2. Install the rubber sealing washer onto the probe (over the threads and

against the ﬂange on the probe).

3. From the inside of the tank, route the wire through the hole until the

probe is against the wall of the wash tank. Secure the Inductive Probe

to the wash tank using the provided retaining nut with the O-Ring against

the outside surface of the tank wall. The nut end of the Inductive Probe

must be on the outside of the machine wall, refer to Figure 4-5.

!WARNING

Figure 4.4

Figure 4.5

Rinse Thermistor/Injection Installation

The rinse aid injection point must be installed downstream of the vacuum

breaker, and a minimum of 6” (15.2 cm) vertically below the vacuum breaker.

Note: Some international installations require this distance to be 30 cm (11.8”).

The enclosure must be mounted so that the top of the rinse dispenser pump is

below the injection point.

NOTICE

Install ﬁttings using Teﬂon tape or pipe sealant to prevent leaks

1. Identify point at which rinse additive will be injected into ﬁnal rinse line.

a. If ports are available on the machine rinse line for separate

installations of the rinse injection line and the thermistor, use the

supplied 1/8” FNPT x 1/8” MNPT brass bushing ONLY.

-OR-

b. If the thermistor and rinse line must be installed in the same port, use

the supplied 1/8” brass street tee and follow the diagram below

Note: The Rinse Additive tube must be installed 1.5” (3.0 cm) past the end of

the brass tee ﬁtting for accurate rinse temperature measurement.

2. Assemble the Visual Flow Indicator (required for NSF listing) on the

outlet side of the rinse dispensing pump by inserting the 1/8” tube fully

into one of the two 1” sections of 1/4” OD x 1/8” ID PVC tubing provided

[See Figure 4.7]

3. Install the check valve between the visual ﬂow indicator and the rinse aid

injection point.

1.500

6”

Figure 4.6

Figure 4.7

Figure 4.8

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