WATER METER SERVICE MANUAL
Contents
1. SERVICE MANUAL HOBART Model HWM BAXTER Model SP600 M1 Model SP600 M3 NOTICE This Manual is prepared for the use of trained Hobart Service Technicians and should not be used by those not properly qualified If you have attended a Hobart Service School for this product you may be qualified to perform all the procedures described in this manual This manual is not intended to be all encompassing If you have not attended a Hobart Service School for this product you should read in its entirety the repair procedure you wish to perform to determine if you have the necessary tools instruments and skills required to perform the procedure Procedures for which you do not have the necessary tools instruments and skills should be performed by a trained Hobart Service Technician Reproduction or other use of this Manual without the express written consent of Hobart Corporation is prohibited A product of HOBART CORPORATION TROY OHIO 45374 Form 24692 February 2001 WATER METER GENERAL TABLE OF CONTENTS GENERAL 2 N 3 aon ga on aan a aa 3 sabes 3 DGIVEFY SYSICIN dew aon dea dea don dou eee dea 3 QUiantity Measuring 3 Temperatur2. 9 Fan Motor 9 Calibration 9 Delivery Amount Calibration 9 Correction TEST a EEE a aai 10 Solenoid Correction Calibration 10 Flush Time Calibration Applies to Units 10 WITS LOCKOUT 10 BlEECTIRIGAL OPERATION 11 Component FUNGON 11 GOMPpPOMENt LOCATON 0 11 13 SCHEMALC Diagram 14 TROUBLESHOOTING 15 CONDENSED SPARE PARTS LIST 16 HOBART CORPORATION 2001 Form 24692 February 2001 Page 2 of 16 WATER METER GENERAL GENERAL INTRODUCTION All of the information illustrations and specifications contained in this manual are based on the latest product information available at the time of printing The water meter will deliver a specific amount of water at a specific temperature and is microcomputer controlled A chiller can be connected
3. Solenoid Correction Calibration NOTE This procedure compensates for the time delay when the water solenoid shuts off Any changes should be made one increment at a time and checked after each adjustment 1 To change this setting Press Set Temp key Enter 32 Press Set Amount key Enter 92202 922lbs 202 Press Start key 1 Current stored value is displayed in the water temperature setting window F Enter desired value between 0 and 200 This represents flow meter pulses added to compensate for the time delay NOTE Default value is 4 pulses G Press Start key to save new pulse rate and return to normal operation mode Form 24692 February 2001 Flush Time Calibration applies to M 3 units only NOTE Flush is used on chiller meters to flush water until the temperature has equilibrated Flush time required may vary depending on locations 1 To change this setting Press Set Temp key Enter 32 C Press Set Amount key D Enter 91101 911165 102 E Press Start key 1 Current stored value is displayed in the water temperature setting window F Enter desired value between 0 and 120 This represents time in seconds NOTE Default value is 30 seconds G Press Start key to save new time and return to normal operation mode Units Lockout NOTE This prevents or allows changing the dispensing units between Celsius Fahrenheit and Pounds Liters 1 c
4. 14 of 16 WATER METER TROUBLESHOOTING TROUBLESHOOTING Unit is plugged in but no displays lit Unit is plugged in displays lit but no response to keypad input Hand held temperature display reads 32 at all times Typically indicates open temperature sensor circuit Hand held temperature display reads 99 at all times Typically indicates shorted temperature sensor circuit Temperature of water delivered is out by more than 2 F Temperature is best measured by delivering at least 20 pounds of water into a large plastic not metal container after the meter temperature has stabilized Delivery amount is out by more than 1 Delivery amount is best measured by delivering at least 20 pounds of water using an accurate scale to measure Temperature won t adjust Temperature won t settle into set temperature goes above and below set point by more than 3 degrees Page 15 of 16 Tripped breaker Loose wire connections Transformer malfunction Control board malfunction Control board memory corrupted Unplug meter for at least 8 hours to reset memory Memory is backed up by a capacitor which will discharge when meter is unplugged Loose keypad cable connection Keypad malfunction Control board malfunction Loose hand held probe plug connection Loose internal wiring Probe malfunction Control board malfunction Probe malfunction Shorted internal wiring Control board malfunction T
5. keypad 5 flow meter out of unit to plaig 6 Reverse procedure to install 4 Pull rubber strip off pins NOTE Make sure flow sensor on top of flow meter is finger tight VACUUM BREAKER WARNING DISCONNECT THE MAIN POWER CORD 1 Shut off the hot and the cold water incoming water supplies 2 Unscrew dispensing hose from outlet of vacuum breaker 3 Unscrew vacuum breaker from welded fitting UNSCREW HOSE FROM FITTING 5 Separate keypad from mounting plate 6 Reverse procedure to install ___ 5614 FLOW 4 Remove fitting from old vacuum breaker install on new one NOTE Any wire ties removed should be replaced 5 Reverse procedure to install when service is complete WARNING DISCONNECT THE MAIN POWER SOLENOID VALVE CORD 1 Shut off the hot and the cold water Sear supplies 9 WARNING DISCONNECT THE MAIN POWER l CORD Remove FRONT COVER 1 Shut off the hot and the cold water incoming Identify and disconnect flow meter wires from water supplies terminal strip 2 Remove FRONT COVER 4 Unscrew fitting on both sides of flow meter terminal strip NOTE Keep wires twisted to reduce electrical noise 4 Loosen hose clamp at top of solenoid valve Form 24692 February 2001 Page 6 of 16 22222 REMOVAL AND 5 Unscrew fitting on right side of flow meter MIXER VALV
6. screws securing front cover 4 Lay cover on padded area to prevent damaging front surface 5 Reverse procedure to install 2 Identify and disconnect three connectors from control board Form 24692 February 2001 Page 4 of 16 WATER METER REMOVAL AND REPLACEMENT OF PARTS 4 Remove standoffs securing control board and CONTROL BOARD lift board off WARNING DISCONNECT THE MAIN POWER CORD CAUTION Certain components in this system are subject to damage by electrostatic discharge during field repairs A field service grounding kit is available to prevent damage The field service grounding kit must be used anytime the control board is handled 1 Remove FRONT COVER 2 Remove screws securing metal shield Watch for spacers on each screw underneath the shield 5 Reverse procedure to install KEYPAD ASSEMBLY WARNING DISCONNECT THE MAIN POWER CORD 1 Remove the CONTROL BOARD 2 Remove nuts and flat washers securing keypad assembly to front cover and lift assembly off 3 Disconnect connector from keypad NOTE On reassembly put RTV on top two studs to insulate them from the back of the control board PUT ON STUDS AFTER ASSEMBLY DISCONNECT 5of 16 Form 24692 February 2001 WATER METER REMOVAL AND REPLACEMENT OF PARTS 3 Remove nuts and lockwashers securing
7. to the meter and is controlled by a relay located inside the meter There are large digital displays and a temperature probe which senses flour dough or room temperature Features e Units of Measure English F Pounds Ounces or Metric C Liters centiliters may be selected for water temperature and amount e Set Temperature Displays actual and set temperatures Adjustment light indicates when meter is adjusting temperature due to new setting or fluctuations in line temperature or pressure Temperature range is between 32 F and 99 F or 0 and 37 C e Test Flow Allows meter to adjust water temperature before delivering to mixer e Set Amount and Amount Delivered Individually displayed Dispenses 5 1 000 pounds or 2 462 liters Delivery can be interrupted the amount set changed above the amount already dispensed and delivery resumed The total amount delivered is the last set amount entered and displayed e Start Resume Begins delivery cycle or resumes cycle when interrupted Power Failure Safe Memory Water meter remembers last setting during blackout or accidental disconnection from power Specifications Input hot water 140 F maximum 30 100 psi 1 2 pipe Input cold water 32 F minimum 30 100 psi 1 2 pipe e Requires 120V AC 60 1 outlet with ground fault protection Less than 1 amp draw Delivery accuracy 1 20 psi inlet pressure above 6 lb Delivery e Tempera
8. ATER VACUUM COLD WATER PRESSURE PRESSURE lt REGULATOR 1 55 GAUGE DISPENSING HOSE TEMPERATURE Page 11 of 16 Form 24692 February 2001 WATER METER ELECTRICAL OPERATION TRANSFORMERS TERMINAL STRIP VALVE MOTOR Form 24692 February 2001 Page 12 of 16 WATER METER ELECTRICAL OPERATION WIRING DIAGRAM WVYSVIC 5 145 eL 12 YILYM LN lt 1 pue LIN GION3 10S HOLIMS HOLIMS LHS 1481 AINO EIN Slsk 6 21122 22 2122 22 2 i 6 OULNOD 1 1441 AlddNsS Form 24692 February 2001 Page 13 of 16 WATER METER ELECTRICAL OPERATION SCHEMATIC DIAGRAM FAN MOTOR CONTROL TRANSFORMER 12 TRANSFORMER SOLENOID FLUSH WATER SOLENOID METER ONLY GEAR MOTOR 12 0 WATER CHILLER RIGHT FULL COLD PUMP RELAY SWITCH CONTACT LEFT FULL HOT SWITCH HAND HELP PROBE THERMISTOR 14 SIGNAL OUT SQUARE WAVE WATER METER SCHEMATIC Form 24692 February 2001 Page
9. E GEAR MOTOR _ Watch for fiber sealing washer SWITCHES WARNING DISCONNECT THE MAIN POWER CORD 1 Shut off the hot and the cold water incoming water supplies 2 Remove FRONT COVER Identify and disconnect motor wires from terminal strip 4 steps 4 5 and removing SOLENOID VALVE Lay assembly in bottom of box 5 Unscrew left fitting on flow meter and lay meter in bottom of box 6 Work solenoid valve fitting out of hose and lift valve assembly out of unit 7 Remove cover from coil junction box and disconnect wires Install wires on new valve 6 Unscrew thermistor compression nut and pull thermistor out of pipe Let thermistor hang free inside box or tuck it into the wiring harness 7 Identify and disconnect wires from switches 8 Remove fittings from solenoid valve and install 3 on new valve rik DISCONNECT SWITCH WIRES 9 Reverse procedure to install 7 of 16 Form 24692 February 2001 WATER METER REMOVAL AND REPLACEMENT OF PARTS 9 and nuts securing pipe support PRESSURE GAUGE STRAINER plates to sides of box CHECK VALVE NOTE Pressure regulator strainer and check valve must be installed correctly with arrow on body in direction of water flow NOTE If pressure regulator is replaced adjust new one for 20psi while water is flowing and mixing valve is centered between hot and cold position Set tempera
10. e MIXING 3 aara 4 Cleaning 7 00 4 AT 4 E E cua E ate 4 REMOVAL AND REPLACEMENT OF PARTS 4 Front GOVE 4 Control Board anata EAEE E 5 Keypad ASSEMBLY 5 FOW 6 VACUUM BEAKER 6 Solenoid a Ea aaa 6 Mixer Valve Gear Motor Switches 7 TL FAMSfOrMers Relay 8 Pressure Regulator Pressure Gauge Strainer Check Valve 8 SERVICE PROCEDURES AND ADJUSTMENTS 9 Solenoid Goll TES 9 Thermistor 9 PROBE 3333 9 Gear Motor
11. emperature fluctuates due to having other than 20 psi flow pressure at both inlets Pressure must be checked with the meter set to an intermediate temperature not when Full hot or Full cold lights on the meter are lit Internal water temperature probe malfunction Control board malfunction Flow meter out of calibration Calibrate as outlined in Service Procedures and Adjustments CALIBRATION PROCEDURE No water pressure no flow to both or one side hot or cold of water meter inlet Ensure proper 20 psi pressure to both hot and cold inlets Loose or bad wiring connections Water temperature sensor malfunction Mixer valve gearmotor malfunction Transformer malfunction Mixer valve limit switch malfunction Control board malfunction Temperature fluctuates due to having other than 20 psi flow pressure at both inlets Pressure must be checked with the meter set to an intermediate temperature not when Full hot or Full cold lights on the meter are lit Water supply temperatures fluctuating by large amounts hot water tank or chiller could have run out of tempered water or be on long line runs etc Form 24692 February 2001 WATER METER CONDENSED SPARE PARTS LIST CONDENSED SPARE PARTS LIST WATER METER Form 24692 February 2001 Printed in U S A
12. hange this setting Press Set Temp key Enter 32 C Press Set Amount key D Enter 94404 944lbs 407 Press Start key 1 Current stored value 000 or 001 is displayed in the water temperature setting window F Enter desired value 0 or 1 Code 000 means lockout disabled and code 001 means lockout enabled NOTE Default value is Disabled 0 G Press Start key to save code and return to normal operation mode Page 10 of 16 WATER METER ELECTRICAL OPERATION ELECTRICAL OPERATION COMPONENT FUNCTION CONTROL BOARD Controls operation of water meter MIXER VALVE SWITCHES Signals control board when mixer valve is in maximum hot or cold water position GEAR MOTOR Drives mixer valve according to signals received from control board FAN MOTOR Rotates fan to circulate air within the box FLOW METER SENSOR Monitors water flow and sends signals to control board Meter is a positive displacement paddlewheel style This flow meter sends out nominal 154 electrical pulses per gallon that are read by the microprocessor control THERMISTOR Monitors water temperature inside mixer valve and sends signals to control board TEMPERATURE PROBE Measures temperature of product in mixer bowl SOLENOID Controlled by control board to dispense water COMPONENT LOCATION HOT W
13. ion procedure can only be performed on control boards that have a program chip version 22 or higher installed If an earlier version chip is installed replace it with the latest version If error is more than 5 replace flow meter Delivery Amount Calibration NOTE This procedure adjusts the pulses per volume rate for the flow meter Any changes should be made one increment at a time and checked after each adjustment 1 change this setting Press Set Temp key B Enter 32 C Press Set Amount key Enter 93303 9336 Form 24692 February 2001 WATER METER SERVICE PROCEDURES AND ADJUSTMENTS E Press Start key 1 Current stored value is displayed in the water temperature setting window F Enter desired value between 100 and 500 which represent pulses per gallon NOTE Default value is 154 pulses per gallon G Press Start key to save new pulse rate and return to normal operation mode Solenoid Correction Test 1 Deliver 1 pound of water and measure the number of ounces of error Repeat step 1 three times Calculate the average error of the three deliveries NOTE Unless the flow meter is grossly out of calibration this amount is the error due to the closing speed of the solenoid valve 4 If deliver error due to solenoid is less than 5 ounces perform the solenoid correction calibration to correct If delivery error due to solenoid is more than 5 ounces replace solenoid
14. ominal 154 electrical pulses per gallon that are read by the microprocessor Temperature Mixing System The hot and cold water mixing system uses a three way valve which is controlled by a 12VDC gearmotor and two limit switches The mixed water s temperature is measured by the water thermistor This information is sent back to the control board which compares this temperature with the set temperature and turns the valve accordingly using the gearmotor thereby changing the water temperature This is done until the set water temperature is achieved or until one of the limit switches is reached Form 24692 February 2001 WATER METER REMOVAL AND REPLACEMENT OF PARTS OPERATION TOOLS For operation instructions refer to the documentation e Standard set of hand tools shipped with the unit VOM meter NOTE Any quality VOM with a sensitivity of 20 000 CLEANING ohms per volt can be used Thermometer For cleaning instructions refer to the documentation e tape Part 508473 shipped with the unit sealant clear General Electric RTV 108 or equivalent INSTALLATION For installation instructions refer to the documentation shipped with the unit REMOVAL AND REPLACEMENT OF PARTS NOTE Use Teflon pipe tape sealer on all pipe threads 3 Remove screw securing ground strap to front FRONT COVER cover Watch for spacer underneath shield DISCONNECT WARNING DISCONNECT THE MAIN POWER CORD 1 Remove six
15. p 4 With ohm meter check resistance between coil wires Reading should be approximately 100 ohms THERMISTOR TEST 1 WARNING DISCONNECT THE MAIN POWER CORD Remove FRONT COVER Identify and disconnect thermistor wires from terminal strip 4 With ohm meter check resistance between thermistor wires Initial reading should be approximately 12 000 ohms at room temperature 70 F NOTE With meter connected resistance may start changing PROBE TEST 1 WARNING DISCONNECT THE MAIN POWER CORD Disconnect probe connector With ohm meter check resistance between pins on probe plug Initial reading should be approximately 12 000 ohms at room temperature 70 F NOTE With meter connected resistance may start changing Page 9 of 16 GEAR MOTOR TEST 1 WARNING DISCONNECT THE MAIN POWER CORD Remove FRONT COVER Identify and disconnect gear motor wires from terminal strip 4 With ohm meter check resistance between motor wires Reading should be approximately 30 ohms FAN MOTOR TEST 1 WARNING DISCONNECT THE MAIN POWER CORD 2 Remove FRONT COVER Identify and disconnect fan motor wires from terminal strip 4 With ohm meter check resistance between motor wires Reading should be approximately 350 ohms CALIBRATION PROCEDURE Test 1 Deliver 20 pounds of water using an accurate scale to measure 2 If error is less than 5 calibrate delivery amount NOTE Calibrat
16. ture accuracy 2 e Temperature adjustment time Normally less than 30 seconds for any set temperature Page 3 of 16 Delivery System The meter has hot and cold water inputs The inputs have external pressure regulators and gauges supplied to adjust the incoming flow pressures to 20 psi Inside the meter the hot and cold water lines join at the mixing valve and exit the mixing valve from the mixer output line On standard meters HWM 5 600 1 this mixer output line contains the internal water temperature sensor the flow meter and the solenoid shut off valve The water exits through a backflow preventer and out through the delivery hose On chiller meters SP600 M3 the mixer output line branches out into two lines One line is the same as the standard meter The other line is a bypass line which has a separate shut off solenoid and can recycle water to the chiller or can go to a drain The second line allows the water temperature to stabilize without having to move the dispensing hose between a sink and desired delivery location which is necessary with the standard meter On both standard and chiller meters there is a relay supplied which when hooked up to the chiller will turn on the pump whenever Test Flow or Delivery is running Quantity Measuring System The meter uses a positive displacement paddlewheel style flow meter to measure the amount of water flowing through the system This flow meter sends out a n
17. ture at 95 F and allow water to flow until temperature is reached Adjust both hot and 4 cold regulators until gauges read 20 psi SUPPORT PLATES Refer to the INSTRUCTIONS MANUAL for NOT IN VIEW 2 complete instructions on setting the water pressure WARNING DISCONNECT THE MAIN POWER CORD 1 Shut off the hot and the cold water incoming water supplies and lifting out of box NOTE The right side plate is sealed with RTV The seal has to be broken in order to slide assembly to right Also note that left plate is welded to pipe and right plate slides on pipe 2 Unscrew fitting at water meter and plumber supplied union fitting if one was installed 11 Work insulation off pipe 12 Reverse procedure to assemble TRANSFORMERS RELAY FAN WARNING DISCONNECT THE MAIN POWER CORD 1 Remove FRONT COVER 2 Identify and disconnect wires from component or terminal strip for component being replaced 3 Remove screws securing component being replaced and remove component TRANSFORMERS RELAY 3 Replace component 4 Reverse procedure to install 4 Reverse procedure to install Form 24692 February 2001 Page 8 of 16 WATER METER SERVICE PROCEDURES AND ADJUSTMENTS SERVICE PROCEDURES AND ADJUSTMENTS SOLENOID VALVE COIL TEST 1 WARNING DISCONNECT THE MAIN POWER CORD Remove FRONT COVER Identify and disconnect solenoid valve wires from terminal stri
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