TEMPSTAR HH GP
INSTALLATION && OOPERATION
MANUAL
November 27, 2001 P/N 7610-002-51-09 (Revision B)
Visit Jackson on the Internet at:
www.jacksonmsc.com
Jackson MSC Inc.
P.O. Box 1060
Barbourville, KY. 40906
(606) 523-9795
GAS-HEATED, HOT WATER SANITIZING
UPRIGHT DOOR DISHMACHINE
MANUFACTURERS WARRANTY
ONE YEAR LIMITED PARTS & LABOR WARRANTY
ALL NEW JACKSON DISHWASHERS ARE WARRANTED TO THE ORIGINAL PURCHASER TO BE FREE FROM
DEFECTS IN MATERIAL OR WORKMANSHIP, UNDER NORMAL USE AND OPERATION FOR A PERIOD OF (1) ONE
YEAR FROM THE DATE OF PURCHASE, BUT IN NO EVENT TO EXCEED (18) EIGHTEEN MONTHS FROM THE DATE
OF SHIPMENT FROM THE FACTORY.
Jackson MSC agrees under this warranty to repair or replace, at its discretion, any original part which fails under normal use due to faulty
material or workmanship during the warranty period, providing the equipment has been unaltered, and has been properly installed, main-
tained and operated in accordance with the applicable factory instruction manual furnished with the machine and the failure is reported to
the authorized service agency within the warranty period. This includes the use of factory specified genuine replacement parts, purchased
directly from a Jackson authorized parts distributor or service agency. Use of generic replacement parts may create a hazard and void war-
ranty certification.
The labor to repair or replace such failed part will be paid by Jackson MSC, within the continental United States, Hawaii and Canada, dur-
ing the warranty period provided a Jackson MSC authorized service agency, or those having prior authorization from the factory, performs
the service. Any repair work by persons other than a Jackson MSC authorized service agency is the sole responsibility of the customer.
Labor coverage is limited to regular hourly rates, overtime premiums and emergency service charges will not be paid by Jackson MSC.
Accessory components not installed by the factory carry a (1) one year parts warranty only. Accessory components such as table limit switch-
es, pressure regulators, pre rinse units, etc. that are shipped with the unit and installed at the site are included. Labor to repair or replace
these components is not covered by Jackson MSC.
This warranty is void if failure is a direct result from shipping, handling, fire, water, accident, misuse, acts of god, attempted repair by unau-
thorized persons, improper installation, if serial number has been removed or altered, or if unit is used for purpose other than it was origi-
nally intended.
TRAVEL LIMITATIONS
Jackson MSC limits warranty travel time to (2) two hours and mileage to (100) one hundred miles. Jackson MSC will not pay for travel time
and mileage that exceeds this, or any fees such as those for air or boat travel without prior authorization.
WARRANTY REGISTRATION CARD
The warranty registration card supplied with the machine must be returned to Jackson MSC within 30 days to validate the warranty.
REPLACEMENT PARTS WARRANTY
Jackson replacement parts are warranted for a period of 90 days from the date of installation or 180 days from the date of shipment from the
factory, which ever occurs first.
PRODUCT CHANGES AND UPDATES
Jackson MSC reserves the right to make changes in design and specification of any equipment as engineering or necessity requires.
THIS IS THE ENTIRE AND ONLY WARRANTY OF JACKSON MSC. JACKSON’S LIABILITY ON ANY CLAIM OF ANY KIND, INCLUDING
NEGLIGENCE, WITH RESPECT TO THE GOODS OR SERVICES COVERED HEREUNDER, SHALL IN NO CASE EXCEED THE PRICE
OF THE GOODS OR SERVICES OR PART THEREOF WHICH GIVES RISE TO THE CLAIM.
THERE ARE NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING FOR FITNESS OR MERCHANTABILITY, THAT ARE NOT SET
FORTH HEREIN, OR THAT EXTEND BEYOND THE DURATION HEREOF. UNDER NO CIRCUMSTANCES WILL JACKSON MSC BE
LIABLE FOR ANY LOSS OR DAMAGE, DIRECT OR CONSEQUENTIAL, OR FOR THE DAMAGES IN THE NATURE OF PENALTIES,
ARISING OUT OF THE USE OR INABILITY TO USE ANY OF ITS PRODUCTS.
ITEMS NOT COVERED
This warranty does not cover cleaning or deliming of the unit or any component such as, but not limited to, wash arms, rinse arms or strain-
ers at anytime. Nor does it cover adjustments such as, but not limited to timer cams, thermostats or doors, beyond 30 days from the date of
installation. In addition, the warranty will only cover the replacement of wear items such as curtains, drain balls, door guides or gaskets dur-
ing the first 30 days after installation. Also, not covered are conditions caused by the use of incorrect (non-Commercial) grade detergents,
incorrect water temperature or pressure, or hard water conditions.
SECTION TITLE/DESCRIPTION PAGE
I. Specifications of the Tempstar HH GP 1
II. Installation Instructions 2
Gas Connection 3
Detergent Control 4
III. Operation Instructions 5
Water Consumption Issues 6
Overview of Operation 7
Thermostat Adjustment Procedure 9
Auto-Calibration Procedure 10
Electronics Control Board (ECB) 11
Testing the Thermistors 12
Control Board LED Light Indications 13
IV. 120V/60 Hz/Single Phase Schematic 14
208 & 240V/50 & 60 Hz/Single Phase Schematic 15
208 & 240V/50 & 60 Hz/Three Phase Schematic 16
V. Jackson Maintenance and Repair Centers 17
VI. Important Information Data Sheet 22
TABLE OF CONTENTS
I
1
PERFORMANCE/CAPABILITIES
OPERATING CAPACITY (RACKS/HOUR)
RACKS PER HOUR 53
DISHES PER HOUR 1325
GLASSES PER HOUR 1325
OPERATING CYCLE (SECONDS)
SELECTION (A)
WASH TIME 45
RINSE TIME 15
TOTAL CYCLE TIME 60
SELECTION (B)
WASH TIME 103
RINSE TIME 15
DWELL TIME 2
TOTAL CYCLE TIME 120
SELECTION (C)
WASH TIME 163
RINSE TIME 15
DWELL TIME 2
TOTAL CYCLE TIME 180
SELECTION (D)
WASH TIME 283
RINSE TIME 15
DWELL TIME 2
TOTAL CYCLE TIME 300
ELECTRICAL REQUIREMENTS
WASH PUMP MOTOR HP 2.0
FULL LOAD AMPS
VOLTS PHASE AMPS
115 1 24.4
208 1 12.2
230 1 12.2
208 3 12.2
230 3 12.2
WATER REQUIREMENTS
INLET WATER TEMPERATURE 110
°F
WASH TEMPERATURE (MINIMUM) 150°F
RINSE TEMPERATURE (MINIMUM) 180°F
GALLONS PER RACK 1.36
WATER LINE SIZE I.P.S. (MINIMUM) 3/4”
DRAIN LINE SIZE I.P.S. (MINIMUM) 1-1/2”
FLOW PRESSURE P.S.I. (OPTIMUM) 20
GAS REQUIREMENTS
MAX. BTU INPUT RATE 55,000
MAX. INLET LINE PRESSURE (NATURAL) 12” WC
MAX. INLET LINE PRESSURE (PROPANE) 10” WC
FRAME DIMENSIONS
WIDTH 25 3/4”
DEPTH 25 1/4”
HEIGHT 68 1/2”
STANDARD TABLE HEIGHT 34”
MAXIMUM INSIDE CLEARANCE 27”
RACKS
DISH 20” X 20”
OPTIONAL
GLASS & SILVER 20” X 20”
OPTIONAL
SPECIFICATIONS OF THE TEMPSTAR HH GP
VISUAL INSPECTION: Before installing the unit, check the con-
tainer and the machine for any damage. A damaged container
could be an indication of damage to the unit. If there is damage to
both the container and the unit, DO NOT throw away the contain-
er. The dishmachine has been inspected and packed at the facto-
ry with the expectation that it will arrive to you in new, undamaged
condition. However, rough handling by carriers or others may
damage the unit while in transit. If this situation does occur, do not
return the unit to Jackson; instead contact the carrier and ask
them to inspect the damage to the unit and to complete an
inspection report. You must contact the carrier within 48 hours of
receiving the machine. Also, contact the dealer you purchased the
machine through.
UNPACKING THE DISHMACHINE: Remove the machine from
the container and inspect for any missing parts. If an item appears
to be missing, contact Jackson immediately to report it.
LEVEL THE DISHMACHINE: The dishmachine(s) covered in this
manual are designed to operate on a level surface. Ensure that
the machine is level from side to side and from front to back;
adjust the unit’s bullet feet as required. Failure to level the dish-
machine may cause decreased washing performance.
PLUMBING THE DISHMACHINE: All plumbing connections must
comply with all applicable local, state and national plumbing
codes. The plumber is responsible for flushing the incoming water
line prior to connecting it to remove all foreign debris that may get
trapped in the valves or cause an obstruction. Any valves that are
fouled by matter left in the water line and the expenses resulting
are not the responsibility of the manufacturer.
CONNECTING THE DRAIN LINE: The Tempstar HH GP drain
requires a minimum 1-1/2” IPS piping that is pitched at least 1/4”
per foot. There must also be an air gap between the machine
drain line and the floor sink or drain. If a grease trap is required by
code, it should have a flow capacity of 5 gallons per minute.
WATER SUPPLY CONNECTION: Install the water supply line
(3/4” IPS minimum) to the dishmachine line strainer using copper
pipe. It is recommended that a water shut-off valve be installed
between the main supply and the machine to allow for service.
The water supply line must be capable of 20 PSI “flow” pressure
at the recommended temperature as indicated on the data plate.
It is also recommended that a shock absorber (not supplied with
the Tempstar HH GP) be installed in the incoming water line. This
prevents line hammer (hydraulic shock), induced by the solenoid
valve, which can cause damage to the equipment.
PLUMBING CHECK: Slowly turn on the water supply to the
machine after connecting the incoming fill line and drain line.
Check for leaks and repair as required. Leaks must be repaired
prior to placing the machine in operation.
ELECTRICAL POWER CONNECTION: Electrical and grounding
connections must comply with all applicable portions of the
National Electric Code (ANSI/NFPA 70) and/or other electrical
codes that may apply.
Disconnect the electrical power supply and place a safety tag at
the disconnect switch to indicate that you are working on the cir-
cuit.
The dishmachine data plate is located on the left front corner of
the machine. Refer to this data plate for information concerning
the unit’s specific electrical requirements.
To install the incoming power lines, open the connection box by
removing the connection box lid. Install 1/2” coduit into the pre-
punched holes in the back of the connection box. Route the power
wires and connect to the power block and grounding lug. Install
the service wires (L1 and N) to the appropriate terminals as they
are marked on the terminal block. Install the grounding wire into
the lug provided. Wires should be firmly secured in place.
It is recommended that “De-Ox” or another similar anti-oxidation
agent be used on all voltage connections.
VOLTAGE CHECK: Ensure that the machine is off and apply
power to the machine. Check the incoming power at the terminal
block and ensure it corresponds to the voltage on the machine
data plate. Do not run the dishmachine if the voltage is too high or
too low. Shut off the service breaker and mark it as being for the
dishmachine. Advise all personnel of the location of the service
breaker. Replace all covers and tighten the screws.
INSTALLATION INSTRUCTIONS
2
It is very important that the type and inlet pressure of the gas used corresponds to the machine data plate. This machine is equipped
with a 1/2” female line for connection of gas. The gas line used should be of the type approved for use with natural gas or propane,
depending on the gas selected to be used in this machine. The gas line should be sized to carry the maximum flow of 55,000 BTUs.
Too small of a gas line will result in poor performance. A manual gas shut-off valve must be installed in the gas line, located within an
accessible area of the machine. The gas line should be kept as short as possible and installed in a way to protect it from damage.
When making pipe connections, use an AGA approved pipe dope, being careful not to use excessive amounts as to foul the gas valve
or clog the gas line. When tightening the gas line always support the gas valve to avoid damage to the gas train.
Note: In propane installations, the gas must be supplied from a regulated source.
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,
and an approved leak detector.
WARNING
ENSURE THAT THERE IS NO ELECTRICAL POWER APPLIED TO THE MACHINE WHEN MAKING GAS CONNECTION.
CHECK ALL GAS CONNECTIONS FOR LEAKS PRIOR TO APPLYING POWER.
THE GASES USED FOR COMBUSTION IN THIS DISH MACHINE ARE HIGHLY FLAMMABLE.
DO NOT SMOKE AROUND THIS MACHINE.
ENSURE THAT THE AREA WHERE THIS MACHINE IS TO BE INSTALLED IS WELL-VENTILATED TO PREVENT THE BUILD-UP
OF COMBUSTIBLE GASES.
ENSURE THAT ALL LOCAL HEALTH, FIRE, AND BUILDING CODES ARE BEING ADHERED TO WHEN INSTALLING THIS
MACHINE. VERIFY WITH LOCAL OFFICIALS IF THERE ARE ANY QUESTIONS.
INSTALL A SHUT-OFF VALVE AT THE GAS SOURCE AND SUPPLY THE MACHINE USING A 1/2” LINE. CONNECT TO THE 1/2”
NPT FITTING ON THE MACHINE.
GAS CONNECTION
3
Detergent usage and water hardness are two factors that contribute greatly to how efficient your dishmachine will operate. Using deter-
gent in the proper amount can become, in time, a source of substantial savings. A qualified water treatment specialist can tell you what
is needed for maximum efficiency from your detergent, but you should still know some basics so you’ll understand what they are talk-
ing about.
First, you must understand that hard water greatly effects the performance of the dishmachine. Water hardness is the amount of dis-
solved calcium and magnesium in the water supply. The more dissolved solids in the water, the greater the water hardness. Hard water
works against detergent, thereby causing the amount of detergent required for washing to increase. As you use more detergent, your
costs for operating the dishmachine will increase and the results will decrease. The solids in hard water also may build-up as a scale
on wash and rinse heaters, decreasing their ability to heat water. Water temperature is important in removing soil and sanitizing dish-
es. If the water cannot get hot enough, your results may not be satisfactory. This is why Jackson recommends that if you have installed
the machine in an area with hard water, that you also install some type of water treatment equipment to help remove the dissolved
solids from the water before it gets to the dishmachine.
Second, hard water may have you adding drying agents to your operating cycle to prevent spotting, when the real problem is deposit-
ed solids on your ware. As the water evaporates off of the ware, the solids will be left behind to form the spotting and no amount of dry-
ing agent will prevent this. Again, using treated water will undoubtedly reduce the occurrences of this problem.
Third, treated water may not be suitable for use in other areas of your operation. For instance, coffee made with soft water may have
an acid or bitter flavor. It may only be feasible to install a small treatment unit for the water going into the dishmachine itself. Discuss
this option with your qualified water treatment specialist.
Even after the water hardness problems have been solved, there still must be proper training of dishmachine operators in how much
detergent is to be used per cycle. Talk with your water treatment specialist and detergent vendor and come up with a complete train-
ing program for operators. Using too much detergent has as detrimental effects as using too little. The proper amount of detergent must
be used for job. It is important to remember that certain menu items may require extra detergent by their nature and personnel need to
be made aware of this. Experience in using the dishmachine under a variety of conditions, along with good training in the operation of
the machine, can go a long way in ensuring your dishmachine operates as efficiently as possible.
Certain dishmachine models require that chemicals be provided for proper operation and sanitization. Some models even require the
installation of third-party chemical feeders to introduce those chemicals to the machine. Jackson does not recommend or endorse any
brand name of chemicals or chemical dispensing equipment. Contact your local chemical distributor for questions concerning these
subjects.
Some dishmachines come equipped with integral solid detergent dispensers. These dispensers are designed to accommodate deter-
gents in a certain sized container. If you have such a unit, remember to explain this to your chemical distributor upon first contacting
them.
As explained before, water temperature is an important factor in ensuring that your dishmachine functions properly. The data plate locat-
ed on each unit details what the minimum temperatures must be for either the incoming water supply, the wash tank and the rinse tank,
depending on what model of dishmachine you have installed. These temperatures may also be followed by temperatures that Jackson
recommends to ensure the highest performance from you dishmachine. However, if the minimum requirements are not met, the
chances are your dishes will not be clean or sanitized. Remember, a dish can look clean, but it may not be sanitized. Instruct your dish-
machine operators to observe the required temperatures and to report when they fall below the minimum allowed. A loss of tempera-
ture can indicate a much larger problem such as a failed heater or it could also indicate that the hot water heater for your operation is
not up to capacity and a larger one may need to be installed.
There are several factors to consider when installing your dishmachine to ensure that you get the best possible results from it and that
it operates at peak efficiency for many years. Discuss your concerns with your local chemical distributor and water treatment special-
ist before there is a problem.
DETERGENT CONTROL
4
PREPARATION: Before proceeding with the start-up of the unit,
verify the following:
1. The pan strainer and pump suction strainer are in
place and are clean.
2. The overflow tube and o-ring are installed.
3. That the wash and rinse arms are screwed securely
into place and that their endcaps are tight. The wash
and rinse arms should rotate freely.
POWER UP: To energize the unit, turn on the power at the service
breaker. The voltage should have been previously verified as
being correct. If not, the voltage will have to be verified. Verify that
the gas supply to the machine is on as well.
FILLING THE WASH TUB: Ensure that the delime switch is in the
NORMAL position, and place the power switch in the ON position.
The Tempstar HH GP should fill automatically and shut off when
the appropriate level is reached (the gas burners should also auto-
matically ignite as well). The appropriate water level si just below
the tub strainer. The wash tank must be completely filled prior to
operation of the wash pump to prevent damage to the pump and
motor.
WARE PREPARATION: Proper preparation of ware will help
ensure good results and less re-washes. If not done properly,
ware may not come out clean and the efficiency of the dishma-
chine will be reduced. It is important to remember that a dishma-
chine is not a garbage disposal and that simply throwing
unscraped dishes into the machine simply defeats the purpose
altogether of washing the ware. Scraps should be removed from
ware prior to being loaded into a rack.
Pre-rinsing and pre-soaking are required, especially for silverware
and casserole dishes. Place cups and glasses upside down in
racks so that they do not hold water during the cycle. The dish-
machine is meant not only to clean, but to sanitize as well, to
destroy all of the bacteria that could be harmful to 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 start-up, it is recom-
mended to run the machine through 3 cycles to ensure that all of
the cold water is out of the system and to verify that the unit is
operating correctly. To cycle the machine, ensure that the power
is on and that the tub has filled to the correct level. Lift the doors
and the cycle light will illuminate. When the light goes out, close
the doors, the unit will start, run through the cycle, and shut off
automatically. Repeat this two more times. The unit should now be
ready to proceed with the washing of ware.
WASHING A RACK OF WARE: To wash a rack, open the doors
completely (being careful for hot water that may drip from the
doors) and slide the rack into the unit. Close the doors and the
unit will start automatically. Once the cycle is completed, the cycle
light will turn off, open the door (again watching for the dripping hot
water) and remove the rack of clean ware. Replace with a rack of
soiled ware and close the doors. The process will then repeat
itself.
OPERATIONAL INSPECTION: Based upon usage, the pan
strainer may become clogged with soil and debris as the workday
progresses. Operators should regularly inspect the pan strainer to
ensure it has not become clogged. If the strainer does, it will
reduce the washing capability of the machine. Instruct operators
to clean out the pan strainer at regular intervals or as required by
work load.
SHUTDOWN AND CLEANING: At the end of the workday, close
the doors. When the unit completes the cycle, turn the power
switch to the OFF position and open the doors. Remove and clean
the pan strainer. Remove the drain stopper from the tub and allow
the tub to drain (NOTE: The wash tank water will be hot so cau-
tion is advised). Once the wash tub is drained, remove the pump
suction strainer. Remove soil and debris from the strainer and set
to the side. Unscrew the wash and rinse arms from their mani-
folds. Remove the endcaps and flush the arms with water. Use a
brush to clean out the inside of the arms. If the nozzles appear to
be clogged, use a toothpick to remove the obstruction. Wipe the
inside of the unit, removing all soil and scraps. Reassemble the
wash and rinse arms and replace them in the unit. The arms only
need to be hand tight, do not use tools to tighten them down.
Reinstall the drain stopper and strainers and close the doors.
OPERATION INSTRUCTIONS
5
W
ATER CONSUMPTION ISSUES AND EFFICIENCY
The Tempstar HH GP provides you, the customer, with the ability to control the hourly rack capacity of the machine. Extending the wash
cycle to wash severely soiled ware, such as mixing bowls, does not increase the machine’s water consumption. However, selecting a
longer time cycle does lower the amount of dishes the machine will be able to wash per hour. It is important for operators to select the
correct wash cycle depending on the amount of washing required. Not every rack of dishes requires the machine to be set on the
longest wash cycle!
Using good prescrapping procedures and observing the results of individual racks of ware, operators will soon gain the experience and
knowledge required to ensure that the Tempstar HH GP operates at peak efficiency for your needs.
Water hardness and detergent usage will also effect the results of the Tempstar HH GP. This manual provides a page on detergent con-
trol. It is recommended that owners and operators take the time to carefully review this section in order to ensure that everything is
done to make sure the Tempstar HH GP operates at peak performance!
WATER CONSUMPTION ISSUES
6
The Tempstar HH GP heating system is designed to heat and maintain the wash tank water temperature at a minimum of 150
F as well as providing a constant 180 F rinse water temperature. Incoming water is supplied at a pressure of 20psi and between 110-
140 F. Incoming gas pressure should be between 7.0-10.5 WCI for natural gas, or 11.0-14.0 WCI for units supplied with propane. The
sequence of operation is as follows (please refer to the above diagram):
When the power is turned on at the ON/OFF switch the water level control board will sense a low water level in the wash tank
and the unit will begin to fill. This occurs as the rinse solenoid valve opens, allowing connected water to fill the booster tank, heat
exchanger and the rest of recirculating system, once the booster tank is full, water will fill the wash tank until the water level control sys-
tem is satisfied. Simultaneously with the fill, the rinse recirculating pump and the gas burner assembly are energized, this will begin
heat up of the unit. A transformer in the main control box supplies +12vdc to the electronics control drawer located 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 ignition relay on the board, which in turn provides +12vdc to the direct spark ignition board (DSI). The DSI
sends +12vdc to the combination gas cutoff valve to open it. This will supply gas to the burner assembly. The DSI begins sparking the
igniter probe, and monitors the flames presence. If the flame is not sensed during the ignition attempt, then the DSI will lockout until
the software resets the DSI approximately 60 seconds later.
OVERVIEW OF OPERATION
7
VACUUM BREAKER
PRESSURE
GAUGE
CHECK VALVE CHECK VALVE
BOOSTER
TANK
BURNER
ASSEMBLY
COMBINATION GAS
CUTOFF VALVE
WASH TANK
COILS
RECIRCULATING
PUMP
RINSE ARM
HEAT
EXCHANGER
FILL / RINSE SOLENOIDREGULATOR
WASH TANK
T
RINSE TEMP
>180 F
T
WASH TEMP
150-165 F
TS
THERMOSTAT
WL
WATER LEVEL
PROBE
T-MID
ECO
MODULATING
VALVE
The operator may turn the power off at the ON/OFF switch for approximately 5 seconds, and then back on. This will also reset
the ECB and the DSI. If flame is lost during normal burn, the DSI will attempt a reignition.
The ECB monitors the 12vdc signal from the DSI to the combination gas cutoff valve. The software in the ECB also reads the
temperature at the middle of the heat exchanger with the T-mid thermistor. After the 5.5 second ignition time, the software will increase
gas flow to the burner to minimum burn by increasing voltage to the modulating valve (MV). If the heat exchanger temperature is far
away from the stabilization temperature, the software will increase gas flow to maximum burn.
Once the heat exchanger temperature nears the stabilization temperature the gas flow is slowly reduced until the minimum
burn is attained. The software will keep the unit in minimum burn until the heat exchanger temperature exceeds stabilization tempera-
ture and then the gas will be shut off. Over many minutes, the software will turn the burner off and on repeatedly until all the water in
the system reaches the stabilization temperature. At this point the software will only turn the burner on every 1-2 minutes to maintain
the stabilization temperature. Now the unit is ready for operation.
As the dishwasher rinses with hot water from the booster tank, it is replaced with cooler water. The need to heat the new water
is sensed by the software and the burner is turned on. The software will modulate the gas flow between minimum and maximum gas
flow attempting to recover the stabilization temperature and always keeping the tank temperature 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 reheated. This hot water then flows back
to the rinse booster tank and repeats the cycle.
The thermostat,(in conjunction with the wash temp relay) is used during idle times to prevent wash tank temperature from
exceeding 170° F, during normal operation the wash tank will self regulate between 150-165°. However, when idle, the temperature in
the wash tank will slowly rise towards booster tank temperature until the temperature reaches 170° F. The wash tank thermostat will
cycle the heat exchanger & recirculating pump off. When the wash tank temperature lowers, the heat exchanger and recirculating pump
will energize. This will continue during all idle time. At any time that the unit is placed into operation, the wash
temp relay will energize and immediately power the heat exchanger and the recirculating pump, regardless of the thermostats position.
Excessive high temperatures in the system are avoided by the following: 1. High temperature limit control by input from T-mid
thermistor, 2. energy cutoff temperature lockout (ECO) by means of a bi-metallic switch independent of the microprocessor which will
break voltage to the combination gas cutoff valve if temperature in the system exceeds 210 F.
Excessive high pressures that potentially could be created in the system are vented directly to atmosphere by means of the
rinse booster tank and rinse arms.
OVERVIEW OF OPERATION (CONTINUED)
8
THERMOSTAT ADJUSTMENT PROCEDURE
9
1) Start up unit
2) Allow to fill, and start warm-up
3) Turn thermostat trim screw counter-clockwise (CCW) 2 full revolutions
4) Allow wash temperature to reach 170"F on wash temperature gauge
5) Turn thermostat trim screw 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 temperature maintains at 170"F during idle time.
AUTO-CALIBRATION PROCEDURE
10
Figure 1 Figure 2
Note: This procedure must be completed every time you replace either a control board or a modulating valve.
1. Turn the unit off at the main power switch and let stand for one minute.
2. Remove the lower front panel and set aside.
3. Remove the cover of the rectangular control box.
4. Locate the control board (see Figure 1).
5. Locate and remove the jumper labeled ACAL (see Figure 1) from the control board. Be careful to remove the metal jumper and not
just the plastic insulator. Make a note of the exact position that the jumper was located. Set the jumper aside for later re-installation.
6. With your multimeter set on DC volts, attach to the Molex plug going to the modulating valve. Note: do not disconnect the Molex
plug. Insert the probes in the rear of one side so contact is made with the metal pins inside of the plug (see Figure 2).
7. Turn the machine on. The burner will ignite and run through a series of steps. Watch the readings of your multimeter. They will run
approximately 11.9 VDC at the highest flame; step down to about 6.0 VDC and then step down again slightly to 5.7 or 5.8 VDC before
shutting the burner off. This whole process takes about 1 - 2 minutes.
8. Once the burner goes out, turn the dishmachine off.
9. Wait one minute.
10. Replace the jumper on the control board in the exact same position as it was removed.
11. Turn the dishmachine back on.
12. Check for normal operation.
ELECTRONICS CONTROL BOARD (ECB)
11
The control board regulates the temperature of the water in the heat exchanger system. This water is also used as the rinse water for
the rinse cycle of the dishwasher. It does this by regulating the flame of the burner by increasing or decreasing the voltage to the mod-
ulating valve. The modulating valve, in turn, increases or decreases the gas pressure going to the burner manifold depending on the
voltage it is getting from the control board. From time to time it may be necessary to check or adjust the setting of this water tempera-
ture. 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 flash-
ing 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 factory
setting is 4.25 VDC which corresponds to 198"F (92"C). Adjustments to the set point are made on the BLUE POTENTIOMETER direct-
ly below the BLUE test point. With a very small slotted screwdriver rotate the trim screw on the potentiometer clockwise (CW) to
increase the voltage (and temperature) and counterclockwise to decrease.
Testing and Setting the Set Point Temperature
TESTING THE THERMISTORS
12
There are two thermistors that are used in controlling the temperature of the water in the heat exchanger system. The T- in that sam-
ples the temperature of the water going into the heat exchanger and the T-Mid that samples the temperature halfway through the heat
exchanger. The control board constantly monitors the temperature at the T-Mid thermistor and adjusts the burner pressure by way of
the modulating valve according to how far away that temperature is away from the set point temperature.
Thermistors are devices that change their resistance value with changes in temperature. By running a constant voltage through the
thermistor, one can read the change of voltage caused by the change of resistance thus determining the temperature of the thermis-
tor. There are test points on the control board (see above) that can be read with a multi-meter on the direct current volt (DCV) scale for
each thermistor.
T
o test the 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 (com-
mon/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 taken. Find
the voltage on the chart below and find the corresponding temperature.
To test the temperature at the T-Mid Thermistor
Using the same BLACK test point with the NEGATIVE probe of the multi-meters in testing the T-in thermistor above, also find the YEL-
LOW test point on the left side of the board just under the large plug (see above). Insert the positive probe of the multi-meter and read
DC volts. Since the two thermistors have the same values, the same chart is used.
Gas Pack Thermister Conversion
0
0.5
1
1.5
2
2.5
3
3.5
4
50(10)
60(15.6)
70(21.1)
80(26.7)
90(32.2)
100(37.8)
110(43.3)
120(48.9)
130(54.4)
140(60)
150(65.6)
160(71.1)
170(76.7)
180(82.2)
190(87.8)
200(93.3)
210(98.9)
Temperature °F (°C)
Voltage DC
CONTROL BOARD LED LIGHT INDICATIONS
13
The electronic control board (ECB) has two LED light indicators that can be seen at its upper left hand corner.
The following conditions for each light may be seen during operation of the unit.
1) Green LED is off.
A) Dishmachine is turned off, therefore no power to ECB.
B) Wash thermostat has cycled off, therefore breaking power to 12 volt transformer in the main control box.
This will also disrupt 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 off.
A) This is the normal operating condition.
5) Red LED is illuminated and steady, or flashing.
A) This is an indication of a malfunction of the T-MID thermistor. Thermister may be unplugged, grounded, have frayed
wiring, or other damage.
TEMPSTAR HH GP
ELECTRICAL SCHEMATIC
120V/60 HZ/SINGLE PHASE
14
TEMPSTAR HH GP
ELECTRICAL SCHEMATIC
208V & 240V/50 HZ & 60 HZ/SINGLE PHASE
15
TEMPSTAR HH GP
ELECTRICAL SCHEMATIC
208V & 240V/50 HZ & 60 HZ/THREE PHASE
16
JACKSON MAINTENANCE & REPAIR CENTERS
ALABAMA
JONES-McLEOD
APPLIANCE SVC
1616 7TH AVE. NORTH
BIRMINGHAM, AL 35203
(205) 251-0159
800-821-1150
FAX: (205) 322-1440
JONES-McLEOD
APPLIANCE SVC
854 LAKESIDE DRIVE
MOBILE, AL 36693
(334) 666-7278
800-237-9859
FAX: (334) 661-0223
ALASKA
RESTAURANT APPLIANCE
SERVICE
7219 ROOSEVELT WAY NE
SEATTLE, WA 98115
(206) 524-8200
800-433-9390
FAX: (206) 525-2890
ARIZONA
AUTHORIZED COMMERCIAL
FOOD EQMT. SVC
4832 SOUTH 35TH STREET
PHOENIX, AZ 85040
(602) 234-2443
800-824-8875
FAX: (602) 232-5862
GCS SERVICE INC. #78
5052 SOUTH 40TH STREET
PHOENIX, AZ 85040
(602) 474-4510
800-510-3497
FAX: (602) 470-4511
ARKANSAS
BROMLEY PARTS & SVC
10TH AND RINGO
P.O. BOX 1688
LITTLE ROCK, AR 72202
(501) 374-0281
(800) 482-9269
FAX: (501) 374-8352
COMMERCIAL PARTS & SVC.
3717 CHERRY ROAD
MEMPHIS, TN 38118
(901) 366-4587
800-262-9155
FAX: (901) 366-4588
CALIFORNIA
BARKERS FOOD MACHINERY
EQUIPMENT
5367 SECOND STREET
IRWINDALE, CA 91706
(626) 960-9390
800-258-6999
FAX: (626) 337-4541
GCS SERVICE INC. #24
1100 EAST PICO BLVD.
LOS ANGELES, CA 90021
(213) 683-2090
800-327-1433
FAX: (213) 683-2099
GCS SERVICE INC. #24
650 S. GRAND AVE. STE 111
SANTA ANA, CA 92705
(714) 542-1798
800-540-0719
FAX: (714) 542-4787
GCS SERVICE INC. #52
360 LITTLEFIELD
S. SAN FRANCISCO, CA 94080
(650) 635-0720
800-969-4427
FAX: (650) 871-4019
GCS SERVICE INC. #84
9030 KENAMAR DR. STE 313
SAN DIEGO, CA 92121
(858) 549-8411
800-422-7278
FAX: (858) 549-2323
P & D APPLIANCE SVC
100 SOUTH LINDEN AVE.
S. SAN FRANCISCO, CA 94080
(650) 635-1900
800-424-1414
FAX: (650) 635-1919
P & D APPLIANCE
4220-C ROSEVILLE ROAD
NORTH HIGHLANDS, CA 95660
(916) 974-2772
800-824-7219
FAX:(916) 974-2774
COLORADO
GCS SERVICE INC.
4251 S. NATCHES CT. #60#
UNIT C
SHERIDAN, CO 80110
(303) 371-9054
800-972-5314
FAX: (303) 371-4754
METRO APPLIANCE SERVICE
1640 S BROADWAY
DENVER, CO 80210
(303) 778-1126
800-525-3532
FAX: (303) 778-0268
CONNECTICUT
GCS SERVICE INC. #06
302 MURPHY ROAD
HARTFORD, CT 06114
(860) 549-5575
800-423-1562
FAX: (860) 527-6355
DELAWARE
FOOD SERVICE EQMT.
2101 PARKWAY SOUTH
BROOMALL, PA 19008
(610) 356-6900
FAX: (610) 356-2038
GCS SERVICE INC. #44
817 N THIRD STREET
P.O. BOX 3564
PHILADELPHIA, PA 19123
(215)925-6217
800-441-9115
FAX: (215) 925-6208
ELMER SCHULTZ SERVICE
36 BELMONT AVE.
WILLMINGTON, DE 19804
(302) 655-8900
800-225-0599
FAX: (302) 656-3673
EMR SERVICE DIVISION
106 WILLIAMSPORT CIRCLE
SALISBURY, MD 21804
(410) 543-8197
FAX: (410) 548-4038
FLORIDA
COMMERCIAL APPLIANCE
SERVICE
8416 LAUREL FAIR CIRCLE
BLDG 6, SUITE 114
TAMPA, FL 33610
(813) 663-0313
800-282-4718
FAX: (813) 663-0212
commercialappliance@
worldnet.att.net
GCS SERVICE INC #15
3373 NW 168TH ST.
MIAMI, FL 33056
(305) 621-6666
800-766-8966
FAX: (305) 621-6656
GCS SERVICE INC #13
4305 VINELAND RD STE G-12
ORLANDO, FL 32811
(407) 841-2551
800-338-7322
FAX: (407) 423-8425
GCS SERVICE INC #14
3902 CORPOREX PARK DR.
SUITE 350
TAMPA, FL 33619
(813) 626-6044
800-282-3008
FAX: (813) 621-1174
JONES-McLEOD
APPLIANCE SVC
854 LAKESIDE DRIVE
MOBILE, AL 36693
(334) 666-7278
800-237-9859
FAX: (334) 661-0223
GEORGIA
GCS SERVICE INC #16
3127 PRESIDENTIAL DR.
ATLANTA, GA 30340
(770) 452-7322
800-334-3599
FAX: (770) 452-7473
SOUTHEASTERN
RESTAURANT SVC.
2200 NORCROSS PKWY.
SUITE 210
NORCROSS, GA 30071
(770) 446-6177
800-235-6516
FAX: (770) 446-3157
WHALEY FOODSERVICE
REPAIRS
109-A OWENS INDUSTRIAL
DRIVE
SAVANNAH, GA 31405
(912) 447-0827
888-765-0036
FAX: (912) 447-0826
HAWAII
FOOD EQMT. PARTS &
SERVICE CO.
300 PUUHALE RD.
HONOLULU, HI 96819
(808) 847-4871
FAX: (808) 842-1560
17
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