L5000 and L5000 XL

• This presentation is intended for both experienced field personnel familiar with laundry and OPL installations, as well as new field service personnel who have only a rudimentary knowledge of accessing triggers from solenoids and washer terminal blocks.
• The objective is to train the installer to be able to install L5000 E and L5000 XL on most washers, and troubleshoot any unusual conditions they may encounter. To train new installers, we recommend using this presentation in conjunction with an actual installation or at least a lab installation followed by a site visit of a typical hotel account with various sizes of washers.
• Excluded from the scope of this presentation are tunnel applications and a detailed treatise on laundry chemistry
• Excluded from this presentation is detailed training on electrical safety, which should always be performed prior to attempting any high voltage installations. In brief, however, power to the dispenser should be shut off at the source prior to opening the pumpbox, and the power should never be turned on with the pumpbox open. In the case of internal trigger modules, the washer power should also be shut off at the source since high voltage signals from the washer can be present in the pumpbox.
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• L5000 E: Newer version of L5000. Programmer detachable, two line formula names, enhanced formula & setup copy, handles both small and medium 100 & 600 series pumps, enhanced latched mode, PC software compatible, power on light on front.
• L5000 XL: The extra large version of L5000 E, which functions with medium 600 series &/or large 2000 series (69 oz/min, 2000 ml/min) pumps
• Not covered by this presentation:
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• Physical installation: mounting, tubing, flush plumbing
• Electrical installation: power, trigger/signal wiring
• Programming
• System alarms and troubleshooting
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• Install the pumpbox(s) on the wall wherever you’re storing the chemicals
• The pumpbox should be closer to the chemicals than the washer, since using the pumps to pull the chemical a long distance will drastically reduce tube life and induce trouble calls
• For all but the smallest and largest installations, you’ll typically put the chemical drums in an aisle behind the washers, and hang the pumpbox above the chemicals
• Use a flush manifold if pumping over 20’ (7 meters) to the washer
Don’t install pumpbox far from chemicals
Install pumpbox near chemicals, not washer
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• Open pumpbox and put a level in the bottom. If mounting an XL, unscrew ground wires and remove pump plates so the unit will be light and easy to handle
• Hold unit level to wall at chest height and mark both keyhole type holes and small round holes in back of dispenser on wall
• Put dispenser down and drill out holes
• Put screws in hole slots, with wall anchors in the case of sheet rock
• Hang dispenser on keyhole slot screws
• Add screws to the other hole(s), to ensure pumpbox can’t be dislodged from wall
• If mounting an XL, hang pump plates as shown and reattach ground wires.

• Attach brackets to the bottom of the pumpbox or wall
• Newer manifolds have integral solenoid as part of manifold assembly; older manifolds have pumpbox mount solenoid as shown on the right
• Route wires through finger bushing near solenoid and attach to PCB and solenoid
• Snap manifold into the brackets, with check valves under the manifold
• Newer manifolds have more robust flow switches and translucent parts so you can instantly check for clogs or starch build up
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• Attach plastic manifold clips to metal mounting brackets.
• Screw plastic mounting brackets into the wall.
• Open right panel of dispenser enclosure (panel can be hung on bottom lip of dispenser enclosure).
• Remove hole plug and install finger bushing, either through the largest hole on the bottom of the dispenser (recommended) or through the hole on the left side of the dispenser enclosure. Route manifold wire harness through this hole. Plug wire harness into
“Manifold” connector on main PCB.
• Connect water supply to manifold in accordance with local plumbing codes.
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•Mount the manifold with the screws provided
•Use 3/8” tubing from the pumps to the manifold, as with other manifolds
•Run ½” ID tubing from the outlet barbs to the washer modules
•The manifold comes configured to flush to up to
4 injection points; it will flush to them simultaneously
Use 1204847 manifold expansion kit if you need to flush to a fifth manifold
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• For L5000 E pumps we recommend 10 mm ID or 3/8” ID tubing. The 600 series pump can use a smaller ID transport tube on these systems vs. XL since the XL uses a larger ID tube (o.375” i/o 0.25”) and has a higher flowrate
• For XL pumps use 1/2” ID (12 mm) tubing for typical chemical viscosities. If one of your products such as a built surfactant is particularly viscous, use 3/4” ID tubing
• Regardless of the pump size we recommend stiff tubing such as nylobraid when pumping viscous chemicals.
• Using smaller tubing than the recommended size will reduce tube life and may cause trouble calls. You should increase the tube ID on both the suction and discharge sides when pumping viscous chemicals over 15 feet/5 meters
3/8”B to 1/2”B fitting # 1202525
3/8”B to 3/4”B fitting # 1202526
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1/2” ID 18” long PVC snap in standpipe
1202756
• For an OPL 100 or 600 series pump with 3/8” ID transport tubing, use snap in standpipes as shown on the left. Leave about 0.25” (6mm) of room at the bottom so the tube can’t seal itself against the bottom of the drum
• Cinch a tie wrap over each standpipe where the tube goes in to be sure it won’t pop out when switching drums
• If using two standpipes per tube, also add tie wraps over each standpipe where they come together
• Use T fittings to branch off to separate washers
• For installations requiring a low level alarm lance, you can either use a separate low level lance, or a low level suction lance such as 1201071 which clamps onto the side of the drum
T fitting, 3x3/8”B
#092273
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• For a single washer, put a hose clamp on the tube, slide it over the barb, and tighten.
1/2” ID, 1/2” B, 34” long with footvalve#1202522
3/4” ID, 3/4” B, 34” long with footvalve#1202523 • For two washers, remove the barb fitting and use a T fitting with a MPT the same size as the lance.
Secure hoses with hose clamps.
• For three+ washers, run a single suction line, with a three barb T fitting below each dispenser.
Secure hoses with hose clamps.
T fitting, 1/2”MPT, 2x1/2”B, polypropylene #1202520
T fitting, 3/4”MPT, 2x3/4”B, polypropylene #1202527
T fitting, 3x1/2”B #092275
T fitting, 3x3/4”B #035516
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• For 100 & 600 series pumps on E use 10 mm or 3/8” ID tubing from the pumps to the washer. For particularly viscous products you can use 1/2” (12mm) ID tubing to increase your tube life
• For XL 600 & 2000 series pumps use
1/2” ID tubing, or 3/4” ID tubing for viscous products
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• Because of the short distance from the pumps to the manifolds, 3/8” tubing can be used with any pump size
• Whenever the chemical supply is over
20’ (7 meters) from the washer, it’s best to use a flush manifold to increase maximize tube life, especially if viscous chemicals are involved
• When pumping a particularly viscous starch known to produce check valve failures, rather than put it in through a check valve, inject it into the flush line with a T fitting 3’ downstream from the flush manifold
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3/8”B to 3/8”B fitting # 1202524

The pressure requirement ensures the 600 series spring loaded roller pumps will be able to pump into the chemical stream, since at pressures over 20 PSI the pump will operate but no chemical will be injected into the water stream. The pressure limitation is also designed for safety, so the system has low pressures and there’s no danger of chemical spray.
Note: Newer L5000 manifolds with integral solenoid have a flow washer, so a pressure regulator usually isn’t required up to about 40 PSI.
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• Unless your water pressure is 20 PSI dynamic when flowing, install a pressure regulator to limit it to 20 PSI.
• It’s best to use one pressure regulator per flush manifold, rather than one and then a T fitting to go to multiple manifolds. If the latter is done and all the flushes turn on at once, it’s possible the flow will be insufficient, and a no flow alarm and cancelled feeds will result
• Attach water supply to solenoid inlet barb with a hose clamp, using a 3/8” ID water supply line for an OPL manifold, or a 1/2”
ID line for an XL manifold
• Use an RPZ if required by local plumbing codes

• To prevent dangerous chemical interactions such as between acid and bleach, one of the incompatible chemicals such as sour or bleach must be routed separately. Traditionally the chemical to route separately is the acid sour.
• Rather than route sour all the way to the washer where chemical drip could cause corrosion in the feed hopper, it’s best to put the sour into the flushed line with a T fitting about 3’ or one meter downstream from the flush manifold
These parts are all in Sour Flush Kit #069505.
Note that if you are using a non-synthetic cornstarch based starch, you may be able to reduce the possibility of clogs by routing bleach separately, and running sour into the upstream port on the manifold.
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• Attach a constant source of 100-
240 VAC 50/60 Hz power to the right and left white terminal block connectors. Typically you can jump power from a power plug or junction box somewhere on the laundry wall, or from the main washer power inside the washer if installing right next to the washer
• Crimp a 10-12 GA (4mm 2 ) ground wire to one of the ring terminals on the bottom of the pump box
• Run power wire through a strain relief such as 090369 or conduit connection on bottom of unit
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Keep the power to the unit and power switch off until the pumpbox is closed and you’re ready to verify system operation

• How you connect wires to the pumping system depends on what type of washer you’re using
• On old washers with multiple solenoid signals, you’ll select formula mode and jump wires off the solenoid to the pumping system trigger module, so the system will know to start pumping based on when the solenoid comes on
• On very old washers where no absolutely no electric signals are available, you’ll run in triggerless sequence mode
• On old washers with a drain signal, you’ll select sequence mode
• On newer washers which provide signals, you’ll run in smart relay mode
• On tunnel washers you’ll either use smart relay mode, or use a batch transfer signal and formula classification triggers in TAFS mode (tunnel automatic formula selection mode)
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External trigger modules are mounted in the washer as shown above. This limits the number of high voltage lines and conduit going to the pumpbox
• The trigger circuit board serves as the highvoltage interface between the washer trigger signals and the dispenser. It also serves as the wiring connection point between the programmer and the pump box.
• Pumpboxes either come with an internal
TR6000 trigger board, or have an external trigger module purchased separately.
• TR6000 has six independent + & - connections, while TR8000 has 8 trigger inputs with one common.
• With an internal trigger board going from the bottom up, connect trigger wire #1 to trigger
#1“+”, trigger wire #2 to trigger #2“+” etc.

• Connect the low-level sensor input to LEVEL
IN on the pump box circuit board. If there are too many inputs to fit, combine all wires of the same color with wire nuts, and have another wire go from each wire nut to the input. Any contact closure across the input will cause the dispenser to display a LOW
CHEM alarm and activate the 24 VDC alarm output.
• The 24 VDC alarm output can be connected to a sonic alarm such as 1200452 shown with orange wire nut extensions mounted in the bottom of the pumpbox on the right
Advanced users may route the alarm output to a washer hold input on the washer or relay performing washer hold, or use the alarm signal to trigger a bulk tank refill. This is only used on special installations.
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• Connect the dispenser temperature probe to the TR6000 or TR8000 washer interface module.
• Clean surface, and put heartshaped adhesive insulating pad over probe, placing flat surface of probe against tank wall.
• Tape over the insulating pad to ensure it is adequately insulated and will not fall off.
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• Attach the programmer to the washer at about chest level, using the velcro strips provided. It can also be mounted by adding the mounting feet with the screws, and then screwing the feet into the washer.
• Choose a surface not prone to excessive vibration, direct water spray, or excessive steam.
• Using the cable provided, connect the programmer to the trigger board.
Note:
• Newer L5000 E & XL systems will not function with the white programmer. They use only the grey programmer.
• E & XL don’t need the programmer attached to function; they only need it for alarm display and formula selection
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+ or – keys change the value of the blinking number or letter. Pressing + and – simultaneously will change any alphanumeric character to “A”, and will change any numeric field to its minimum value.
CURSOR key: Moves the cursor around the screen, changing which field is selected .
ACTION key: Initiates an action such as priming. Does not change settings.
MENU key: Advances to the next menu screen.
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• The programmer is used for:
The “technician” password is available for access to prime and view data, without allowing them to change data or any programmed info. This maintains security while allowing your customer to service the unit so you don’t get a trouble call just to prime the lines.
On XL & E, the dispenser operates without the grey programmer for relay mode, but needs it attached for typical formula mode applications.
If running using only one formula, the programmer isn’t necessary after installation.
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• Laundry workers use this screen to choose formula names, by pressing + or - to change the formula selected.
• When you power up the unit, it’ll display software version numbers for a second or two, and then show this screen. Normally this is the only screen the laundry workers will need.
• Only three screens are visible without a password: this screen, the diagnostic screen, and the enter password screen
• Press the cursor key to see diagnostic info screen
• Or hold down the menu key for five seconds to enter a password and begin programming

• This screen is viewable without a password, by pressing the cursor key, and shows which triggers are active or being qualified.
• Allows the user to view whether pumps are stopped, running, or on hold per a programmed delay time or while another pump pumps into the flush manifold.
• Verify the system is accepting washer triggers, while watching solenoids turn on/off and comparing them to the trigger status on the screen.
• If the triggers aren’t showing up, try changing the voltage setting to accept low voltage triggers. If they come on too often, you may need to change the trigger filter time from
2 to 15 seconds, or run in latched or sequence mode.
(See trigger qualification screen)
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• In sequence mode, the bottom line of the diagnostic info screen shows info germane to sequence mode.
• Sequence mode matches pump actions with steps in the wash process, so the bottom line shows whether the drain signal is on and which sequence step you’re in (which corresponds to how many times the drain signal’s come on)
• The bottom line also shows what action is programmed for that step: an I for ignore signal
& wait for next signal to do the next step, an E for end of the pumping sequence for that wash load, or a pump icon when pumping or during a delay

• To access any screen other than the formula select and diagnostic screens, you need to enter a password
• Hold down the menu button for five seconds to bring up this screen
• Enter the default password 890 using the + & buttons to change the number shown, and the cursor button to switch from character to character
• Once the screen reads 890, press the menu button to proceed. The menu button will be used to take you from screen to screen, starting with the prime screen. You can press it repeatedly to loop around through the screens, or hold it down for five seconds to exit back to the laundry worker screen.
• If you enter an incorrect password, you will return to the laundry worker screen.
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Menu button
Cursor button

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Press the action button to prime
Change the pump number with + or -
Press the menu button to continue to the next screen

• Shows the latest formula count values, and how many formulas have had alarms.
• Use the + and - buttons to change the formula number and view data for other formulas
• Note that if a formula has more than one alarm condition, only one alarm is counted since all the alarms occurred during a single instance of that formula running.
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• The top line shows which triggers are on, 1=on, 0=off, with
T1 on the left and T8 at right.
• The bottom line shows the trigger counts for each trigger.
Once a trigger’s count has reached 9, it remains there until a new wash load begins.
• In the example at left, T2 is on and has occurred once.
• Use this screen to count drain signals for sequence mode programming, or count all triggers to be sure they don’t occur more than once per formula in other modes. The advantage of this screen vs. the trigger and pump status diagnostic screen is that this shows you a history for the last formula run, for troubleshooting after the load’s run.
For a trigger to be counted, it must meet the Trigger Qualification screen’s criteria for duration and
• The first trigger after the end pump’s trigger clears the count and it starts from 0, or it can be cleared manually in programmer level access by pressing the action key for two seconds.
voltage.
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• This screen automatically updates to show total run time in minutes for the selected pump.
The pump run time data may be reset to zero by pressing and holding the
ACTION key for 2 seconds .
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• This screen only appears if at least one formula is set to use hygiene verification. The screen shows current water temperature in real time, including the offset value.
• The temperature is displayed as 000-099º C (if units are set to “ml”) or 032-210º F (if units are set to “oz”).
• If no temperature probe is connected, “---” is displayed as the temperature.
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• The following screen allows you to select the units of measure (metric or imperial) and trigger mode (Smart Relay, Formula,
Latched or Sequence).
• When the unit of measure is changed to ml, all other menus update to show values in ml
• Press the CURSOR key to move to the bottom line and select trigger mode.
• Press and hold the “+” or “–” key for 2 seconds to scroll between “Formula”,
“Latched”, “Relay” and “Sequence”.
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• Speed control increases tube life and dosing accuracy with thick chemicals.
• Speed control should be used with thicker chemicals which have 1/2 or less the flowrate of the other chemicals.
• Reduce the pump speed to 50% speed if the thick chemical’s pump calibrate at 1/2 the flowrate or less than thin chemical pumps
• Recalibrate any pump for which you change the pump speed, to be sure the pumpbox calculates pump runtime based on an accurate calibration value
You only need to change pump size when swapping out one pump size for another, or adding a pump onto a system.
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• L5000 pumps chemical based on volumetric calibration.
• The calibration amount you pump is larger for bigger pumps:
– 100 series pump=1 oz
– 600 series pump=4 oz
• The flowrate from the most recent calibration is displayed on the bottom right.
• In the example on the left, pump 1 (P1) pumps 67.6 ounces (2 liters) per minute, calibrated from a pump volume of 10 ounces.
Volumetric programming means once pumps are calibrated no formula adjustment is required for differing flow rates when changing chemicals or compensating for tube wear. This reduces installation errors and saves installation time by allowing the installer to program volumes they want pumped without having to calculate and program runtime based on flowrate.
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• To calibrate, position the end of the selected pump’s discharge tube over measuring cylinder. Use the default calibration amount of 30 oz (900 ml) for 2000 Series pumps. Press “+” to change it to 4 oz (100 ml) if using 600
Series pumps, or 1 oz (30 ml) if using the 100 series pump.
• Hold down the action key to run the pump until the calibration amount shown on the screen has been pumped.
• The new flowrate will be automatically calculated, displayed in place of the 67.6 oz or 2000 ml default setting, and saved to memory.
• If the pump’s only run a short time so the calibration value isn’t yet deemed valid, “----” will be displayed. Press the
ACTION key again to resume calibration; each time you press the action key, the flowrate will increment.
• If you pump too much and need to start over, change the pump number to another pump and back; that will allow you to to run the pumps and recalculate the calibration amount from the beginning.
Try to get to the calibration amount within 2-3 presses of the
ACTION key, because tapping the
ACTION key repeatedly to pump the whole calibration amount will make the calibration inaccurate.
If installing without a flush manifold, calibrate at the washer to be sure transport tubing effect on flowrate is factored in.
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• Program the top line of the formula name, Line 1, and then highlight the Line 1 with the cursor key and press
+ to change it to Line 2, so you can enter the bottom line of the formula name.
• Use the cursor to switch from character to character, and the +/- to change each character to the formula name desired. Press + & - simultaneously to change a character to “M”.
As with other L5000 screens, you don’t ever need to press a “save” button; all info is automatically saved.
To avoid having to program formula names for each washer, we recommend programming them and the formulas for one washer, and downloading the info to other washers.

• The programming screen for the mode selected in the Setting Mode & Units of Measure screen will appear next.
• For training purposes we’ll look at the screen which will appear for each mode, but when actually using a unit only the screen for the mode selected will show up.
• In supplemental screens, also, there are some differences between the modes, and we’ll show all versions of a screen here while in programming only the relevant version will show up.
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• This screen shows all the Formula Mode programming parameters. These parameters show that in Formula 1 we want trigger 1
(T1), to tell pump 1 (P1) to pump 10 ml of formula 1 (F1) after a 10-second delay.
• The “+” to the right of the “a” indicates we have programmed T1 to initiate additional pump actions (“b” and/or “c”).
• To program, press the cursor key to highlight the pump volume, and the + key to select the volume you want pump one to pump in formula one when trigger one is received.
• Use the cursor key to highlight the trigger number press + to change from T1 to T2, and then put in what pump and volume you want to run for T2.
• Repeat for all triggers, then change the formula # to F2 & repeat.
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• Latched Mode is the same as Formula Mode, except:
• Latched mode programs the same as formula mode, but you need to assign an
“End” pump on the End Pump Assignment screen so the dispenser knows when the formula has completed and can “unlatch” the trigger.

• In Smart Relay Mode, the L5000 pumps chemical based on the trigger signal’s on-time.
L5000 pumps a programmed amount of chemical for each second the trigger is on.
• Chemical dose=trigger seconds x call rate
• So, for a 6-ounce dose, using the default call rate of 2.0 ounces, program a 3-second trigger from the washer. For a 20 ounce dose, use the same 2.0 ounce call rate and a 10-second trigger.
• Smart relay mode reduces installation time vs. normal relay mode which just runs the pump while the trigger’s on, by allowing the installer to program in target volumes, rather than check flowrates for each pump and then calculate the trigger times they need per pump per formula.
Never use a washer trigger time of one second or less!
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• Sequence Mode performs pump actions in an order, based on either drain signals from the washer, or delays programmed during installation.
“End” is the default value for each sequence step, and is changed to I (ignore) or a pump action after watching the drain signals and wash process
• Count the number of drains to determine when to dose chemical. For example, if for
“ bright colors” (or some other load class), we find that the washer drains twice before pre-wash, we would program step 1 and step 2 as “I” (Ignore). To do this, we’d press the cursor key to highlight the “E”, and press + to change it to I, then change
S1 to S2, and also change that to I.
• Step 1 is performed when the sequence is started, typically by pressing the ACTION button. Step 2 would be performed when the first drain signal is received after the pre-wash.
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• For step 3, which would be the main wash, we’d highlight the E and change it to a pump icon, as shown on the right. The programming of the bottom line is as in formula and latched mode, with the delay time, pump number, and pump volume.
• If there were 2 rinses after main wash, before final rinse, we would set steps 4 and 5 to “I” (Ignore), and step 6 to a pump action to add softener.
• We would then set step 7 after the last pump action to “E” (End), which logs the load as completed in the Formula Count screen.
• Sequence mode configuration options:

• The “End Pump” determines which pump action will log the formula as complete in Formula,
Latched, and Smart Relay Modes.
• Set the last pump that will run for each formula to be the end pump, usually the softener.
• You can specify a different end pump for each formula.
• The end pump unsets the latch in latched mode
• Never set as the end pump a pump which will not be triggered, since that’ll prevent formula counts from taking place and in the case of latched mode will leave the latch on indefinitely, causing a trouble call.
• If you set the end pump as a pump which runs twice per formula, the formula count will be twice the actual number of times run.
Because the end of the formula is programmed in sequence mode, this screen doesn’t appear when sequence mode’s selected.
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• Formula copy reduces your programming time, by allowing you to copy formulas and then quickly fine tune them, instead of entering all the formula info for each formula.
• Input a common formula similar to many others on a formula programming screen.
• Select the common formula you wish to copy
FROM on the top line.
• Press the CURSOR key to advance to the bottom line and scroll to the desired formula number to copy TO.
• Press and hold the ACTION key for 2 seconds to copy the formula shown on the top line to the formula shown on the bottom line.
• Scroll to formula “All” to copy over all formulas

• Change passwords using the “+” and “–” keys and the CURSOR key to move across the screen.
• Technician password gives the operator access to only Technician-Level screens of data viewing and priming, so they can prime and report diagnostic info but not alter the programming.
• The Programmer password allows access to all screens. Entering a “000” password for either level means that no password is required for that level of access.
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The example shows that trigger 1 (T1) is
“rising” (+). A rising trigger edge indicates that the trigger activates when voltage turns on, where a “falling”(–) trigger edge indicates that the trigger activates when voltage disappears.
Usually “-” is only used in sequence mode.
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• The bottom line has minimum trigger voltage and duration requirements, to prevent erroneous triggering from low voltage and/or short duration electrical noise.
• If your triggers are sometimes not being recognized, you may need to change the voltage setting to “L”.
• The filter time (f/t) is the amount of time you want the trigger to be active before the dispenser acts upon it. If you are getting too many triggers, you may need to try using a 15 second trigger time, so the dispenser will only act on a trigger after it’s been on for 15 seconds.

• The filter time setting is not applicable to
Smart Relay Mode triggering. The voltage selection, however, is applicable to all triggering modes to prevent erroneous triggering by electrical noise.
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• Cloning copies your formulas and formula names from one programmer to another. This both prevents duplicate programming, and allows you to quickly preprogram all your dispensers before going to an account to install the units.
• “Receive” uploads the program from the dispenser.
The arrow will flash during the data transfer, and stop flashing once when complete.
• “Send” downloads the program to other
dispenser(s). The arrow will flash during the data transfer, and stop flashing once when complete.
• Be sure to calibrate systems after cloning the program, especially if cloning between systems with different pump sizes
Upload/download time will depend on the amount of data/program complexity
If “error” is displayed on the bottom line, check the cable connections, ensure no cables are draped over high voltage power

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• Pressing the “+” or “– ”keys takes you through the different language options.
• When you select another language, all programming menus will be displayed in that language
• Selecting Japanese allows programming of formula names in katakana

• Hygiene verification issues an alarm whenever the wash water fails to maintain a certain temperature for a certain amount of time.
Hygiene verification is typically used when health inspectors aren’t satisfied with sanitation based on the dryer or press temperatures, but require it in the washer as well.
• 3 different criteria, (a, b, or c) may be set for hygiene verification. This is intended to accommodate time/temperature options such as
71º C for 3 minutes OR 80º for 1 minute.
• Each criteria can be turned on or off for each formula, but there are only three. So, while you can only program three criteria a, b, c, you can pick which formulas each apply to.
• Only one criteria needs to pass per formula. An alarm will only occur if the formula fails
ALL criteria. For example, if either a (71º C for 3 minutes), or b (75º for 7 minute) or c is met, the formula passes. If neither a, b nor c is met, the formula fails.
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• The temperature offset value can be set to correct for a known amount of temperature loss when reading the wash temp through the wall of the washer. Check the temp of the drain water and the temp reading on the hygiene probe to verify what the difference is, and put it in this field.
• For example, if you know that your temperature probe reading is 10 degrees below the actual temperature of the wash water, you can create an offset value of 10.
The programmer will incorporate this offset value in its temperature reading, so the health inspector will always see the actual temperature of the wash water when on the temperature probe screen.

• Use the “+” and “– ” keys to set the transport flush time (t), 0 to 99 seconds (default setting is 10). Use 1 second per meter (3’)
• This screen is only visible when the flush manifold wire harness is plugged into the pump box PCB prior to turning on the power. If you’re using a flush manifold and this screen doesn’t appear, turn the power off and then back on.
• The transport time setting (t) tells the system how long the flush water must flow after pumping chemical. In the example shown, the solenoid will stay on for 10 seconds after pumping chemical.
• You can also use this screen to do a manual flush, pressing to turn on, and pressing to turn off, with a max on time of 60 seconds.
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• If you have a low-level sensor connected to the Level input on the pump box I/O board, a
“Low Chem” message appears when the lowlevel condition is detected by contact closure.
• Press the action key to cancel the alarm.
• If you clear this alarm without correcting the low-product condition, the alarm will reactivate after 15 minutes.
• The intent of the low-level alarm is to warn the operator that the product supply is about to run out, so the pumpbox will continue pumping despite the alarm.
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• If a no flow alarm occurs, the pump action is cancelled.
The dispenser will attempt subsequent feeds. A no-flow alarm occurs when:
– An electrical or mechanical problem prevents a pump from working.
– Water pressure goes outside the range of 10-
20 psi, or water flow is under 0.4 l/min or .1
GPM during a flush. (A flow switch wiring short can also produce this.)
– A trigger is active for longer than 5 minutes in
Smart Relay Mode. No more feed commands will be sent to the pump box for that trigger until the trigger turns off and back on.
– The pump box detects that a pump has been running continuously for five minutes, at which point it turns off.
– You try to prime a pump or run the flush with the the flush manifold attached but no water supply; the alarm will appear on reverting to run mode from the programming screens

• A Hygiene alarm occurs when wash water temperature fails to meet the temp and duration requirements programmed on the hygiene verification screen.
• A hygiene alarm will be logged when either a hygiene or a low chem alarm occurs.
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• A system alarm indicates system components (trigger module, pump box, or programmer), cannot communicate.
• System alarms usually indicate a wiring problem, such as field splicing leading to intermittent communication, a dirty plug, or a defective cable
• System alarms can be caused by electrical noise, such as when communication cables are coiled on top of the power supply, routed over 100’, or near other high voltage
• System alarms can also be caused by using the wrong programmer; with XL & E use the grey programmer, with old L5000 OPL
(no power light) the white programmer

Symptom
Pumps turn on but flush doesn’t run
Bulging pump tube between pump and manifold
Problem
Pump box doesn’t recognize manifold
Clogged check valve
Rampant no flow errors 1.
2.
Water pressure over 20 PSI
Flow inadequate
Flush stays on too long Time programmed is too long
Solution
1.
2.
3.
Verify manifold is plugged in
Turn power on and off to see if transport time programming screen shows up
Unscrew flow switch and check for deposits or corrosion
Switch to anti-clog check valves, with the valve positioned under the manifold. In the case of thick starch, the most foolproof way to avoid clogs is to inject the starch into the flush line downstream from the manifold with a T fitting and no check valve
1.
If pressure is over 20 PSI, install a pressure regulator. Note it’s safest to install a separate pressure regulator per manifold, since there’s some flow drop after the regulator and in some cases the flow may not be sufficient if the water line
2.
is split to multiple manifolds downstream from the regulator
Verify flow is adequate
Reduce flush time programmed in the flush transport time screen
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Symptom Problem
Pumps don’t run
Pump box doesn’t recognize triggers
System won’t power up
1.
2.
Incorrect power wiring
Incorrect cable wiring
Solution
1.
2.
3.
4.
1.
2.
Verify trigger wires are coming from solenoid or other valid sourceCheck whether triggers appear on the diagnostic screen
If triggers flash for more than two seconds but do not get qualified, change trigger filter time from 15 to 2 seconds
If triggers do not appear, change the voltage setting for them from high to low
If triggers are under 24 VAC, hook them up to the contact closure side of a relay, which use to break one leg of a high voltage supply to the trigger input concerned. You should only do this if you have extensive experience with electrical wiring; if you don’t get help.
Verify with voltmeter system is receiving power between 90-260 (or 240 max to comply with CE)
Be sure pumpbox PCB cable goes to a trigger module, and trigger module goes to programmer. System won’t run without trigger module, even in triggerless sequence mode
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Symptom Problem
Pump runs backwards
Reversed connection to motor
Solution
Reverse polarity of wires where they’re connected on the back of the motor
Pump runs late
Pumps consistently turn on and off
1.
2.
Delay programmed
Trigger polarity was changed to – in programming screen, so it only triggers when the
3.
trigger turns off
Trigger filter time is
15 seconds
Smart relay mode call rate low
1.
2.
3.
Reduce delay time programmed for the pump,or try eliminating an Ignore step if in sequence mode
Change trigger polarity back to +
With a 15 second trigger filter time, pump actions won’t start until the trigger’s qualified. Reduce the trigger filter time to 2 seconds if thiere isn’t a lot of electrical noise creating erroneous trigggers
The system is designed so the pumps can cycle on and off. Running in this manner will not effect performance or motor longevity.To prevent pumps from turning on and off, use a call rate larger than the flow rate shown on the calibration screen. For example, if the flow rate is 20 oz/min, use a call rate that is over 0.3 oz/min, such as 0.5 oz/min.
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Symptom
OPL system turns off after 2 seconds when power applied
“Error” displayed while attempting to clone
Problem
Manifold connector plugged in backwards
Wiring problem
Solution
1.
Verify manifold connector is plugged in in the right direction
Check for wires and damaged cables and try again
Pump runs, but chemical isn’t dispensed
Too much suction tube vacuum
Short chemical tube life 1.
2.
Chemical attack
Hydraulics
1.
Make sure supply line is not sealing itself via suction against the side or bottom of
2.
the chemical drum.
Supply lines may be too small for viscous chemicals, or run is too long.
3.
4.
1.
Check for kinks in intake supply.
Pump tube may be worn, or there may be an air leak on intake side of pump.
Verify there are no solvents in the chemical concerned. If there are, use a
2.
viton tube
Verify internal diameter (ID) of discharge and suction are at least as large as that recommended, and that both sides are the same size.
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• In many cases, the last chemical pumped is softener, using a rinse solenoid. If this solenoid turns on and off during final rinse, the softener pump will not be an acceptable End pump because each time the “End” pump signal is received the formula will be counted as complete in the data. In this situation perform the following steps:
• Add a second pump action after the softener, running pump with a “0” volume with enough delay time for the load to finish.
• Set pump 8 to be the End pump, so the latch won’t clear until pump 8’s pump action completes. For example, if your last pump action for formula 1 was as follows:
• You would change the “a” to a “b” so that there would be a second pump action for T6 as follows:
• With P8 as the End pump, the latch will clear 10 minutes after T6 is received, giving enough time for the rinse to complete, due to the 10-minute (600-second) delay.
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Washer extractor with no triggers?
• Use triggerless sequence mode
Tunnel with empty pocket formulas, & no batch transfer for empty pockets
• Use relay mode
• If TAFS mode is required:
– Tie both pump 8 output and normal batch transfer signal to batch transfer signal input
– Program pump 8 be for module 1
– For formulas which will be followed by an empty pocket, program a delay time=batch transfer time, and small pump 8 dose
– Pump 8 pump drive will provide batch transfer signal
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Maintenance is comprised of four items:
1. Motor life: Track the motor life
A new round tube is shown on the left, which becomes oval as seen on the right over time.
Time based on the minutes of pump runtime. Motor and tube life varies with hydraulic circumstances of the installation, but usually motor life will be double or greater tube
life. In lab tests with light hydraulic load, motors typically last over 1000 hours runtime.
– Tube life: Tubes soften and their flow rate increases early in their life, and then over the long term their flow rate decreases as their shape changes to become oval. Record the flow rate during calibration when you install, and replace the tube before it’s flow rate drops to 50% of the original value.
In order to draw up chemical, peristaltic pumps rely on the ability of the tube wall to spring back to its original shape after the roller passes. E has a special thick wall tube that lasts longer.
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3. Manifold strainers: Periodically check manifold strainers for build up and clean them. Newer non-tunnel manifolds have a clear strainer so you can check this visually, instantly.
4. Manifold check valves: Clogs in check valves are one of the notorious issues with flush manifolds. Newer check valves have larger internal dimensions so it takes longer for them to clog. Also, they are translucent so you can spot a clog or precipitates beginning to form.
Carry a spare check valve and replace any which look like they have precipitates forming. Note that the chemically resistant translucent material is soft, so you need to be careful in order to prevent them from breaking, especially if they’ve had hot water running through them. To replace one. pour cold water over it to reduce softening, and disconnect tubing check valve barb.
Newer manifolds and strainers are translucent, so you can catch clogs before they occur, and visually verify flow with colored chemicals.

L5000 and L5000 XL