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Summit E and Summit XL Installation, Troubleshooting, and Maintenance

Summit E and Summit XL Installation, Troubleshooting, and Maintenance. Scope of Presentation.

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Summit E and Summit XL Installation, Troubleshooting, and Maintenance

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  1. Summit E and Summit XLInstallation, Troubleshooting, and Maintenance

  2. Scope of Presentation • This presentation is intended for both experienced field personnel familiar with laundry 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 Summit E and Summit XL on all 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 a minimum a lab installation, followed by a site visit of a typical hotel account with various sizes of washers. • Excluded from this presentation: • Detailed training on electrical safety, which should always be performed before 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. • Summit E & XL comparison to the first version of Summit which used the white programmer

  3. Outline • Physical installation: mounting, tubing, flush plumbing • Electrical installation: power, trigger/signal wiring • Programming • System alarms and troubleshooting • Maintenance

  4. Pump Box Placement • 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

  5. Hanging Pumpbox on Wall • Open pumpbox and put a level in the bottom. If mounting an XL, unscrew ground wires and remove pump plates so the unit is 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 and tighten. • 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.

  6. Mounting a Flush Manifold • Mount the manifold on the wall 8 to 10 inches below the pumpbox • XL manifolds are wall-mount only, while the Summit E manifolds can also be attached to the bottom of the pumpbox

  7. Tunnel flush mounting • Remove the tunnel flush manifold cover, and hang it on a couple screws under the pumpbox • When attaching your chemical lines, note that each of the four outlets is for a different tunnel module • Add submanifold 1204847 if you need to flush to a fifth tunnel module Tunnel flush manifold 1204846

  8. Manifold Wiring • Remove one of the black plastic hole plugs in the bottom or side of the Summit XL and run the wire harness through it. • Connect the wire harness to the main PCB using the PCB harness adaptor. The PCB harness adaptor connects to the main PCB at the “J10 manifold” position. • If you don’t use the tiny PCB adapter, the manifold will not work. The small adapter PCB connects to the manifold with 4 wires for Summit E manifolds, and 6 wires for Summit XL and the tunnel flsuh manifolds, which also use a pressure switch

  9. Flush manifold water supply • Unless your water pressure is 10-50 PSI dynamic when flowing, install a pressure regulator to limit it to 30 PSI. • If a pressure regulator is required, 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 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: Older Summit manifolds without the inline integral solenoid, 120 have a flow washer, so a pressure regulator usually isn’t required up to 50 PSI.

  10. Tubing: Pump Chemical Pickup Connection • For Summit 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 and has a higher flowrate. • For Summit 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

  11. Tubing: OPL 3/8” ID Drum Pickup Lance Connection • For an OPL 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. • An alternate to tiewraps is cutting a 1” length of the standpipe and using PVC glue to glue it over the suction tube; the glue produces a chemical bond which is more impervious to chemical attack then the tiewraps • 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. 1/2” ID 18” long PVC snap in standpipe 1202756 T fitting, 3x3/8”B #092273

  12. Tubing: XL 1/2” and 3/4” ID Drum Pickup Lance Connection • For a single dispenser, put a hose clamp on the tube, slide it over the barb, and tighten. • For two dispensers, remove the barb fitting and use a T fitting with an MPT the same size as the lance. Secure hoses with hose clamps. • For three + dispensers, run a single suction line, with a three- barb T fitting below each dispenser. Secure hoses with hose clamps. 1/2” ID, 1/2” B, 34” long with footvalve#1202522 3/4” ID, 3/4” B, 34” long with footvalve#1202523 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

  13. Tubing Connection: From Pump to Washer • For 100 Series and 600 Series pumps 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 2000 Series pumps, use 1/2” ID tubing, or 3/4” ID tubing for viscous products.

  14. Tubing Connection: Flush Manifolds • 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 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’ (one meter) downstream from the flush manifold. 3/8”B to 3/8”B fitting # 1202524

  15. Tubing: Sour Flush Installation • 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 can reduce the possibility of clogs by routing bleach separately, and running sour into the upstream port on the manifold.

  16. Wiring: Main Power • 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 (4mm2) ground wire to one of the ring terminals on the bottom of the pumpbox. • Run power wire through a strain relief such as 090369 or conduit connection on bottom of unit. Keep the power to the unit and power switch off until the pumpbox is closed and you’re ready to verify system operation.

  17. Wiring Triggers: Choosing Operating Mode • 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 electric signals are available, you’ll run in triggerless sequence mode. • On old washers with only a drain signal, you’ll select sequence mode. • On newer washers which provide signals, you’ll run in smart relay mode, or TAFS mode if you want automatic formula selection. • Tunnel washers can be run in either smart relay mode or TAFS mode; TAFS mode takes approximately 30 extra minutes to learn, but produces more accurate results since varying trigger length won’t alter the amount of chemical dispensed

  18. Wiring Triggers: Connecting to the Washer • The trigger circuit board serves as the high-voltage 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. • You must use TR8000 for TAFS mode • With an internal trigger board going from the bottom up, connect trigger wire #1 to trigger #1“+”, trigger wire #2 to trigger #2“+” etc. 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 External trigger module Trigger wire connection Internal trigger module

  19. Wiring: Optional Low Level Alarm Input/Output • Connect the low-level sensor(s) input to the J15 ‘LEVEL IN’ position on the pumpbox circuit board using a connector. • 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 J14 ‘ALARM 24V’ can be connected to a sonic alarm such as #1200452 using the same connector. The alarm fits into the holes on the bottom of the Summit E. For each pumpbox using low level inputs, order a removable connector 1201005, shown above with the blue and brown wires attached. Order two per pumpbox if you’re using a sonic alarm.

  20. Wiring: Optional Temperature Probe Connection • Connect the dispenser temperature probe to the TR6000 or TR8000 trigger module. • Clean surface, and put heart-shaped 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.

  21. Wiring: Data PCB Mounting • Align Data PCB with top left corner of main PCB, carefully fitting Data PCB connector onto main PCB pins Main PCB without Data PCB Main PCB with Data PCB mounted on it

  22. Wiring: Data PCB Connection • The Data Module connects to a computer using a protocol converter. • A two-wire cable is run from the J2 terminal block on the Data Module to protocol converter. • Connect the A wire from the protocol converter to the B input on the data PCB. Connect the B wire from the protocol converter to the A input on the Data PCB. • Connect the protocol converter to the computer (laptop or desktop) using a 25 pin male to 9 pin female cable which can be purchased commercially. • Power the protocol converter using the power supply provided.

  23. Data PCB Setup • Assign the dispenser a network ID. • Select an ILS from the main menu window on ManageNet. • If ManageNet is asked to poll the system, it will identify the Summit E or Summit XL as an ILS. • Programming of the dispenser must be done using the programmer, not via ManageNet.

  24. Data PCB & ManageNet • The Data PCB logs data such as pump run time, load count and chemical usage. • ManageNet provides reports for your customers such as this chemical usage report. • A data-capable Summit E or Summit XL can be setup for remote access using a modem. • The combination of the Data PCB and ManageNet allow for real-time monitoring of dispenser events. ManageNet Chemical Usage Report

  25. Wiring: Programmer Connection • 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 inside the pumpbox, TR-6000 or TR8000 module.

  26. Programming: Key Functions

  27. Programming • The programmer is used for: • Formula selection by laundry workers • Data viewing and priming by account laundry technicians • Programming by the installer 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 smart relay and TAFS modes, but needs it attached for typical formula mode applications so the workers can use it as a formula selector. If running using only one formula, the programmer isn’t necessary after installation.

  28. Laundry worker screen • Laundry workers use this screen to choose formula names, by pressing + or - to change the formula selected. • 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 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

  29. Diagnostic InformationSmart Relay, Latched, and Formula Modes • 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)

  30. Diagnostic information Sequence Mode • 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 by counting drain signals, so in sequence mode the bottom line shows whether the drain signal is on and which step you’re in (which is to correspond to how many times the drain signal has 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 (XL & other versions).

  31. Password Screen • To access any screen other than the diagnostic screen, you have to press and hold the menu button and make this screen appear, and then enter a password. • 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.

  32. Prime Pumps Press the action button to prime. Change the pump number with “+” or “-”. Press the menu button to continue to the next screen.

  33. Formula & Alarm Count 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.

  34. Trigger Status & Counter • 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. • 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 For a trigger to be counted, it must meet the Trigger Qualification screen’s criteria for duration and voltage.

  35. Pump Run Time Data • 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.

  36. Temperature Probe Reading • This screen only appears if at least one formula is set to use hygiene verification. The screen shows current water temperature in real time. On non-OPL models such as XL & E, this value includes 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.

  37. Setting Mode & Units of Measure • The following screen allows you to select the units of measure (metric or imperial) and trigger mode (Smart Relay, Formula, Latched, Sequence, or TAFS). • 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”, “Sequence”, and TAFS.

  38. Speed Control • 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.

  39. Calibration #1 • Summit 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 • 2000 series pump=30 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.

  40. Calibration #2 • To calibrate, position the end of the selected pump’s discharge tube over measuring cylinder. • 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 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.

  41. Programming formula names • 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 Summit 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.

  42. Mode Programming • 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.

  43. Formula Mode • 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 1 to pump in formula 1 when trigger 1 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.

  44. Latched Mode • Latched Mode is the same as Formula Mode, except: • Triggers are ignored or “latched out” after they have occurred once. • Whenever the “End pump” signal is received the latch is reset so triggers will be accepted again • Latched mode has an “add prewash feeds to main wash” optional feature you can turn on and use • 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.

  45. Smart Relay Mode #1 • In smart relay mode, the Summit E and Summit XL pump chemical based on the trigger signal’s on-time. Summit dispensers deliver 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, use the default call rate of 2.0 ounces, and 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 is on, by allowing the installer to program in target volumes, rather than check flow rates 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!

  46. Smart Relay Mode #2 • In the sample on the left, we fill in our target dose per pump per formula for a standard 100 lbs machine. • Then you just divide dose size/call rate (Excel will do this automatically) • By adding columns for other machine sizes (1/2 the seconds for ½ the standard washer size, twice the seconds for double the standard washer size etc, we get an easy-to-read programming guide for all the sales reps in the company.

  47. Smart Relay Mode #3 • If you’re replacing a different dispenser and you’re going to keep the chemicals and formulas the same, you can avoid reprogramming the washer: • check the flowrate on each pump on the old dispenser • Divide flowrate by 60 to get flowrate per second • Set Summit E call rate to be the previous flowrate per second • Perform pump calibration normally • No washer programming is required, because the Summit will pump the same amount as the previous dispenser would for any given trigger on time. • For OEM installs to get straight aka ‘dumb’ relay mode: • If 100 series pump, change to ml, change call rate to 2 ml/second of trigger on time. System will then run a bit over 20% longer than trigger time • If 600 series pump, don't change anything, and system will run a bit longer than 10% over the trigger on time.

  48. TAFS Mode Operation • TAFS = tunnel automatic formula selection • Designed to optimize tunnel dosing accuracy, TAFS can also be used on washer extractors for automatic formula selection, so laundry workers don’t have to choose the formula name on a formula selector • AFS uses a single trigger which comes on to determine formula number • Many washers have variability in the length of the signal, even when programmed, especially at higher numbered formulas • This variability causes formula set errors in come cases, and the wrong chemical is dosed • TAFS relies on several triggers coming on, so trigger length variability won't cause the wrong formula number to be selected • Program as in formula mode, with a delay time and pump volume per formula per pump • No trigger is shown since TAFS mode automatically knows where the laundry is in the tunnel based on batch transfer signals and pump assignment to modules

  49. TAFS Mode: Trigger Connections

  50. Sequence Mode Programming • Sequence mode performs pump actions in an order, based on either drain signals from the washer or delays programmed during installation. • 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. “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.

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