Waterlogic 4 Firewall
Waterlogic 4 Firewall
Waterlogic 4 Firewall
Technical Manual
Machine Overview 4
Pre Delivery Inspection Procedures (PDI) 10
Installation Procedures 11
Operational Instructions 14
Maintenance and Servicing 16
Sanitizing the Machine 19
Cleaning a Waterlogic Machine 20
Troubleshooting the WL2500 21
Safety and Warranty Information 22
Wetted Parts Illustration 24
Main Parts Illustration - Freestanding model 26
Main PCB Schematic Diagram 29
Specifications 32
2 3
Machine Overview
Waterlogic 2500 Technical Manual - Issue B, October 2013 Waterlogic 2500 Technical Manual - Issue B, October 2013
4 5
Filters Compressor
The filtration systems on the WL2500 designed to reduce dirt and sediment The compressor operates at 220-240V and at 50Hz. It uses R134a non-Ozone
particles from the water. Furthermore, the Activated Carbon process will remove a depleting refrigerant gas. The compressor is controlled by an electromechanical
whole range of contaminants e.g. chlorine and pesticides. There are many kinds of thermostat that controls the temperature of the water in the cold tank unit.
different filter combinations available from Waterlogic to suit local water conditions.
Water Pipe and Fittings
UV Lamp The inlet and the internal water circuit pipe size is 1/4” and 5/16”. The entire internal
The UV light is TUV lamp at a wavelength of 253.7 nm, which is very efficient at water circuit and all the components which come in contact with water are food
destroying Bacteria found in water. UV radiation kills Bacteria by destroying the grade NSF approved. The Cold & Ambient water tubing inside the machine should
DNA nucleus of Bacteria. An 8 watts UV lamp is fitted for freestanding machine and not be exposed to water above 25˚C.
4 watts UV lamp for Mini machine. The UV lamp is immersed in the centre of cold
tank and protected by a quartz sleeve which allows UV radiation to pass through to Water Valves
the water. A UV sensor alarm is fitted which will alert the customer in the unlikely Dispensing of water to the customer is achieved by means of a 24V DC electrical
event of a UV lamp failure. The UV lamp should be changed for every six months. solenoid valve. The valves are energized every time when customer pushes the
When the lamp is changed the quartz sleeve should be removed and cleaned also. dispense button for a drink. DC voltage is used to give a positive and quieter action
of the solenoid valve. Plastic Panels The moulded panels are made from recyclable
PCB ABS plastic. All the ABS plastic panels are UV resistant and meet the standards of
The PCB (Printed Circuit Board) is the control unit for the WL2500; it is responsible CE and UL. Please note that the machine should not be exposed to direct sunlight.
for the selection and dispensing of water, and extra hot water boost. The PCB drives Placing machines in direct sunlight from a window, or close to a radiator, or on in
an LED which informs the user of the status of the unit. The PCB has a power on a room of high ambient temperature will effect the efficiency of the refrigeration
indicator and also indicates to the user what option of water is currently selected by circuit.
changing colour. Cold water will always be as a default option; hot water, extra hot
water must be selected and then dispense.
6 7
Main Parts Layout
Hot and Cold
IN (Water)
AIR VENT
SOLENOID
VALVE
COLD WATER OUT
SOLENOID
VALVE COLD
SENSOR
COLD
TANK
FILTER
CONDENSER
HOT
TANK
FILTER
DRYER
COMPRESSOR
8 9
Pre Delivery Installation Procedures
Inspection Procedures (PDI)
1. Unpack and carry out a visual inspection of the unit for any transit damage. Important notice: This procedure should only be carried out by an engineer or
2. Remove the top cover and the lower front panel and visually inspect the staff trained by Waterlogic International or an approved distributing agent.
internals of the machine for any wires or pipes that may have come loose in
transit. 1. Site the machine as close to the electrical and mains drinking water supply as
possible with a 50mm air gap at both sides and back of the machine. Mount the
3. Connect the water supply. machine on a firm flat surface so that it cannot topple over. Please remember that
4. Ensure the switch on the rear of the machine is in off position and connect the the machine should not be exposed to direct sunlight or heat sources above 32°C.
unit to a power supply. 2. It is advisable that the water supply and electrical supply be within 2 meters of
5. The unit is now live and suitable safety precautions should be taken. the machine for ease of installation.
6. Flush water through the hot tank first until the water runs clear of any carbon 3. Level the machine using the adjustable feet.
fines. Approximately 10 litres. 4. Remove the top cover of the machine. If you are installing a freestanding machine
7. Now flush water through the Cold Tank. Approximately 10 litres. (20 litres if also remove the lower front cover. This is retained by two screws located under the
cold only) front edge at the bottom of the cover and two clips in the same location. Remove
8. Once you are sure that water is running through both the cooling and heating the screws and push clips up to release. To gain access to the screws tilt the ma-
circuit then turn on the heater and compressor switch at the rear of the machine. chine backward at an angle of 10 degrees.
9. Carry out a visual inspection for any water leaks. 5. Make the water connection using an installation kit. Waterlogic recommends the
use of a pressure reducing valve, and shut off valve and a non return valve. These
10. The hot water will heat to approximately 85°C. The extra hot water will heat
should be fitted before the water intake to the machine. Minimum operating pres-
up approximately 95°C if selected.
sure for the machine to work suitably is 1.5 bar. The ideal operating pressure is of 3
11. To test the cold water wait until the compressor has shut off. Test the 2nd cup bar. At pressures higher than 3 bar the machine will not function correctly and can
of water taken. It should be between 5 and 8°C. lead to leaks.
12. Inspect the cold water produced for clarity and taste. If required flush more 6. Please flush the water supply pipe until it runs clear, before making the water
water to remove any adverse taste or carbon fines. connection to rear of the machine.
13. Return the switch to the off position and isolate the power and water to the 7. The power lead is located in a recess on the top packing cover of the machine re-
machine. gardless whether it is a mini or a free standing model. Inspect the electrical socket,
14. Drain the hot tank and cold tank. the machine plug and the power cable for any transit damage. Now plug the power
15. Replace all panels, clean the machine and repack the machine. lead into the back of the machine. As soon as you plug the machine into a suitable
power supply voltage will be available to the PCB and solenoid valves and you can
now start to flush water through the machine. Do not at this point turn on the heater
and compressor switch at the rear of the machine. This switch should only be turned
on once the hot tank is filled with water.
10 11
8. The hot water temperatures is set at 85°C and the cold water temperatures is set INSTALLATION KIT
at 5°C at the factory. It is not possible to adjust the hot water temperature, but the • The machine must be installed according to the local guidelines.
cold water temperature can be adjusted by regulating the thermostat situated at the
• Waterlogic strongly recommend that a pressure reducing valve set at 3 bar and a
back of the
nonreturn valve be used on all machine installations.
machine. This thermostat is set at a specific point at the factory. This point is marked
out by a small dot situated on the outside of the thermostat. It is advised that you do • The WL2500 should not be connected to water supplies of unknown bacterial
not adjust the cold thermostat past the factory set point of 5°C as this may result in quality or those are not already fit for human consumption. The machine should
the system freezing. only be connected to a Potable drinking water supply.
9. If installing a hot and cold model, do the following. Alternatively go to point 10. • The filter and UV lamp on the WL2500 must be changed every 6 months.
Select the hot water option and press the dispense button to start flushing water • The cold tank should also be flushed and sanitized every 6 months.
through the machine filter and hot tank. The filter will produce carbon fines at first • Waterlogic International strongly recommends the use of an anti-flood device.
and the water may have a black appearance. Continue to flush 10 litres of water.
10. Select the cold water option and press the dispense button and flush for 10 litres The part number for the installation kit shown below is “P-KIT INSTALLATION”.
of water through the cold tank. If you are installing a cold only machine then flush for
20 litres. This will generate the filter and clean any residual water from the machine.
11. Check the machine for any water leaks and ensure that all water fittings are se-
cured properly.
12. Once you are satisfied that water is passing through both the hot and cold tank
successfully then turn on the heater/compressor switch at the back of the machine.
The machine will now start to heat and chill.
13. The hot water will heat to 85°C approximately. The extra hot water will heat up
to 95°C approximately if the extra hot button is selected.
14. The cold tank will start cooling. When the machine has reached the target tem-
perature the compressor will stop running. The temperature will continue to drop as
any ice that has formed on the sides of the tanks will start to melt and equalize the Fig 1. Waterlogic
tank temperature. Installation Kit
15. To test the water temperatures then please ensure that you use an accurate
1 - 15mm Compression Inlet
previously calibrated thermometer.
2 - Double Check Valve (great for carbonated water)
16. Please ensure that the cold water produced has a good taste. If you detect a 3 - Adjustable Pressure Reducing Valve
plastic taste then it is an indication that the machine needs to be flushed again. 4 - Integral Isolator
17. Check the machine to make sure it is electrically safe. 5 - Pressure Gauge Port
6 - Waterblock
7 - 1/4” Pushfit Outlet
12 13
Operating Instructions
Hot & Cold
Operating the machine is very simple. It’s as simple as selecting the option you
want, and press the main dispense button. The machine will dispense fresh water
at your disposal.the main dispense button. The machine will dispense fresh water
HOT OPTION EXTRA HOT OPTION COLD OPTION AMBIENT OPTION at your disposal.
COLD WATER
Push Main button, LED shows green, it dispenses cold water.
HOT water
Push hot water button LED shows red, Push Main button,
it dispenses hot water
The option buttons are very simple to identify. The following table indicates the hot
and cold option, or cold and ambient option on the machine. EXTRA HOT water
Push extra hot water button LED shows orange;
hot water tank starts heating, then push main button,
it dispenses extra hot water at approximately 95°C.
AMBIENT WATER
Button 1: select hot water Button 3: select ambient Push Ambient button LED shows red, Push main button
water it dispenses ambient water.
14 15
Maintenance and Servicing
6 MONTH SERVICE PROCEDURE 10) Inspect the electrical and water connections of the machine.
11) Check the air gap around the machine to ensure it is not blocked.
FREE STANDING MODELS
12) Turn on red switch, on the back of the machine.
• The following instructions are for all machines (Hot & Cold; Cold & Ambient and
13) Check that the UV lamp is alight by observing a blue glow from the top of the
Cold Only).
UV cap. Do not remove the lamp from holder whilst ignited and do not look into a
• Every six months the filters and UV lamp should be changed.
ignited UV light.
• A machine with the hot water option may require removing any Calcium build-up
inside the hot tank, depending on local water conditions. 14) Close the front of the machine and the top of the machine by fitting the panels
• Only trained personnel should repair and service the Waterlogic 2500. back to their original position.
15) Flush ten litres of hot water and five litres of cold water through the machine to
1) Isolate the power to the machine, by turning off the switch from the back of the ensure that the filters are generated and the water is running clear of any carbon
machine and removing the plug from the socket. fines.
2) To access the filters, undo the screws and release the clips located in front of the 16) Turn on the heater and compressor switch and allow the machine to cool and
lower front panel and remove panel to gain access to interior of machine. To access heat the water.
the filters on a mini machine then remove the top cover. This is a high voltage area 17) Taste the water and check the machine is clean and functions to the customer’s
and the machine should be isolated from the power supply. satisfaction. If you are not satisfied with the quality of the water, flush two more
3) There is no need to turn off the water supply; the water is automatically isolated litres of water through the machine.
when you remove the filter.
4) To remove the Waterlogic filters, twist anti-clockwise and replace with a new MINI MODELS
Waterlogic twist filter, twist clockwise. • The following instructions are for all WL2500 mini machines (Hot & Cold)
5) Remove the Waterlogic UV lamp by unplugging the UV loom connector and • Every six months the filters and UV lamp should be changed.
pulling the lamp upwards. • A machine with the hot water option may require removing any Calcium build-up,
depending on local water conditions.
6) Unscrew the UV retaining nut and remove the Quartz Sleeve from the cold tank.
Clean the Quartz Sleeve and remove any surface lime scale that may have adhered
1. Isolate the power to the machine, by turning off the switch from the back of the
to the sleeve surface. Check the black O Ring for signs of perishing and replace if
machine and removing the plug from the socket.
necessary.
2. To access the filters, undo the screws located at the back of the top cover and
7) Fit the Quartz Sleeve back into the cold tank taking great care at this stage not to
remove the top cover.
crack the Quartz Sleeve by over tightening the UV retaining nut.
3. There is no need to turn off the water supply; the water is automatically isolated
8) Replace the UV lamp assembly and re-connect it. Do not touch the UV lamp with
when you remove the filter.
bare hands.
4. To remove the Waterlogic filters, twist anti-clockwise and replace with a new
9) Remove, check and inspect the blue faucet nipple and if it is cracked or has
Waterlogic twist filter, twist clockwise.
Calcium build up, replace it. Please ensure that you use cleaning gloves when
handling parts that come in direct contact with the drinking water.
16 17
5. Remove the Waterlogic UV lamp by unplugging the UV loom connector and Sanitizing the Machine
pulling the lamp upwards. 1) You will need to have an Ametek filter housing to follow this procedure. Also
6. Unscrew the UV retaining nut and remove the Quartz Sleeve from the cold tank. sanitizer, disposable rubber gloves, and bacterial wipes or spray.
Clean the Quartz Sleeve and remove any surface lime scale that may have adhered 2) Mix a solution of sanitizer in the Ametek filter housing.
to the sleeve surface. Check the black O Ring for signs of perishing and replaced if
necessary. 3) Turn off the water supply to the machine and release the internal water pressure
by depressing the dispense button momentarily and remove the water supply pipe.
7. Fit the Quartz Sleeve back into the cold tank taking great care at this stage not to
crack the Quartz Sleeve by over tightening the UV retaining nut. 4) Isolate the power to the machine.
8. Replace the UV lamp assembly and re-connect it. Do not touch the UV lamp with 5) Bypass the internal twist filter to avoid mixing sanitizing solution with the active
bare hands. carbon.
9. Remove, check and inspect the blue faucet nipple and if it is cracked or has 6) Connect the outlet of the Ametek housing to the inlet of the machine and connect
Calcium build up, replace it. Please ensure that you use cleaning gloves when supply water pipe to the inlet of the Ametek housing.
handling parts that come in direct contact with the drinking water. 7) Turn on the power and water supply to the machine.
10. De-scale the hot tank. 8) Depress the dispense button until the sanitation fluid starts to flow out of the
11. Inspect the electrical and water connections of the machine. faucet nipple.
12. Replace the top cover 9) Allow the sanitation fluid to stand in the machine for 20 minutes.
13. Turn on the red switch, on the back of the machine. 10) Do not let any sanitation fluid enter the hot tank.
14. Check that the UV lamp is alight by observing a blue glow from the top of the UV 11) Then flush the cold water until the water runs clear of sanitizer.
cap. Do not remove the lamp from holder whilst ignited and do not look into ignited 12) Again isolate the water to the machine and release any internal water pressure
UV light. now isolate the power.
15. Check the air gap around the machine to ensure it is not blocked. 13) If this procedure is being done in conjunction with the 6 monthly services then
16. Reconnect the power to the machine and flush 10 litres of water through the hot change the filter.
tank and 5 litres through the cold tank. 14) Remove the Ametek filter housing from the back of the machine and re-connect
17. Turn on the heater compressor switch, on the back of the machine and allow the the water supply pipe to the back of the machine. Reconnect the filter.
water to heat and cool. 15) Turn on the power and water flush the machine until the water runs clear.
18. Taste the water and check the machine is clean and functions to the customer’s 16) Visually inspect water connections for any leaks.
satisfaction. If you are not satisfied with the quality of the water, flush more water 17) Remove the faucet nipple and inspect to see if there are any cracks or scratches
through the machine. or limescale build up on the nipple, if so then replace it. If the faucet nipple is OK
then sterilise it and put back using clean rubber gloves.
Notes: 18) Remove and clean the drip tray, and grill. If the grill is damaged or heavily stained
Allow 45 minutes for the full servicing of the unit. and you are unable to clean it then it is advisable to replace the grill.
Waterlogic recommend the use of sterilizing solution, vending machine surface 19) Wipe all surfaces around the drip tray and faucet nipple area with a bacterial
cleaner, and Bacterial Wipes. Please do not use any abrasive or cream surface wipe or spray.
cleaners. 20) Return the drip tray to position.
18 19
21) Flush a further 15 litres of water if you have changed the filter and ensure there Troubleshooting the WL2500
are no carbon fines and all sanitation fluid has been removed from the water system. The following is a list of different problems that may be found while installing and
22) All personnel should be aware of the company requirements for their own operating the WL 2500.
personal health and hygiene.
23) Test for taste before leaving and ensure that the water quality of the machine is 1. No flow of water: In this case, make sure that there is a water supply to the
adequate. machine and is turned on. Please ensure that the anti flood device is reset. Ensure
that the filter is twisted in all the way home into the head; otherwise the valve inside
Cleaning a Waterlogic Machine the filter head will not be opened. Check to see that the filter is not blocked with
• It is recommended to clean the machine at least once per week. The cleaning sediment.
cycle may be required more often depending on the amount of use of the machine 2. There is flow for the hot water, but no flow for the cold water: This may be a
and the surrounding environment. result of the water inside the cold tank mechanism being frozen. Ensure that the
thermostat is set at the factory setting. Disconnect the power mains from the back
• Turn off the power at the wall socket and remove the power cord at the rear of the of the machine and allow the ice inside the cold tank to melt.
machine. 3. Water dispensed by the machine is neither hot nor cold: Make sure that the
• Please wear clean rubber gloves to carry out the cleaning functions. heater/compressor switch at the back of the machine is on.
• Remove the top cover and replace the blue faucet nipple. Clean and soak the 4. The Power indicator is not on: Make sure that the machine is plugged in correctly
removed nipple in sterilizing solution ready for the next cleaning cycle. Discard any and that the switch is on. If the machine is properly set up, then remove the top
faucet nipples that are cracked, or split. Be careful not to drip water on the PCB. cover of the machine and check the fuse on the back of the machine.
5. Bad taste: Flush the machine for a period of 15 minutes. If the bad taste persists
• Remove and clean the drip tray assembly.
taste the water coming directly from the filter, if still bad change the filter, or contact
• Clean all machine surfaces with non-abrasive vending machine cleaner/sanitizer. your authorised service provider.
• Replace the drip tray. 6. Low flow of cold water: If this happens in the cold water circuit, there may be a
• Wipe the faucet nipple and all plastic surfaces with an anti Bacterial Wipe. problem with freezing. Please refer to point number 2 and follow the instructions
7. Low flow of water for all circuits of the machine: Ensure that the filter is not
• Re-connect the machine and turn on the power and check for correct operation. blocked. The filter may require changing, or there is low water supply pressure.
8. Low flow of hot water. Indicates that the hot tank needs to be de-scaled.
Parts required to clean a Machine 9. Hot water is cold: If all the electrical connections are fitted properly, there is a
• Rubber Gloves chance that the overload mechanism has been triggered. In this case, isolate the
• Paper Towel power supply to the machine, remove the upper and lower front panels to gain
• Surface Cleaner access to the hot water tank. On the side of the hot tank there is a manual reset
• Blue Faucet Nipple button for the overload mechanism. Press the button and reassemble all the panels.
• Bacterial Wipes Reconnect all the power supplies and make sure that the machine continues to heat
• A Replacement drip tray/grill if required up the water as normal.
• Allow 15 minutes 10. Cold water is warm. Make sure that you are not testing the ambient option.
Check the thermostat is at the set point. Make sure the machine is not in direct
sunlight or a room with a high ambient temperature (32ºC +). Ensure the heater/
compressor switch is on. If none of the prior then assume standard refrigeration
fault finding procedures.
11. UV failure. Make sure the lamp is connected to the PCB board, check if the lamp
is functioning, checking the ballast. Change the UV lamp.
Note. Fault finding of Waterlogic 2500 must only be carried out by trained personnel.
20 21
Safety and Warranty
Information
Caution
Subject to the standard terms and conditions of sale (a copy of which has been
provided to you), neither Waterlogic International Limited (“Waterlogic”), nor any
affiliated companies shall be liable for any damage which could affect, directly or
indirectly, any person or property. Please be aware that any warranties accompanying
the sale of our products will be invalidated by any of the following:
• Incorrect installation
• Incorrect use of the WL2500
• Unsuitable electrical and water supply
• Major short-coming of maintenance
• Technical interventions or alterations of an unauthorized nature
• Adoption and use of unapproved spare parts
• Engagement of untrained personnel
22 23
Wetted Parts Illustration
Wetted Parts List
N° Part Description
1 JG Bulkhead Connector Union 1/4" * 1/4"
15 2 JG LLD PE Tube - Blue O.D.1/4"
21
14 3 Valved Twist Filter Head
14 4 Carbon GAC Filter
16
13 5 JG LLD PE Tube - Blue O.D.1/4"
6 JG Equal Tee Connector 1/4"
22 7 Solenoid Valve DC24V 1000mm
1 8 JG Reducing Elbow Connector 5/16" * 1/4"
5 9 JG LLDPE Tube - Blue 8mm
3 11 10 UV Cold Tank Ass'y 4L with UV Holder
12 11 JG LLDPE Tube - Blue 8mm
Faucet HC & CA
2 20
Facuet Nipple Blue
12 Stainless Steel Insert for Faucet
7
6 Natural Faucet O-Ring (Silicon White)
Stainless Steel Gauze for Faucet
13 Silicon Tube 5/16"
4 10 14 JG LLD PE Tube - Blue O.D.1/4"
8 15 JG Equal Tee Connector 1/4"
16 Silicon Tube 5/16"
9 17 Solenoid Valve DC24V 1000mm
19 17
18 JG Reducing Elbow Connector 5/16" * 1/4"
18
19 JG LLDPE Tube - Blue 8mm
20 Drawn Hot Tank Ass'y 1.5L 220V/50Hz 800w
21 Silicon Tube 5/16"
22 Silicon Tube 5/16"
24 25
Main Parts Illustration Spare Parts Numbers
Free Standing Model
N° Part Description
14
26 27
Main PCB Schematic Diagram
Hot and Cold
N° Part Description
26 Front Down Insert Panel with paint
Faucet HC & CA
Facuet Nipple Blue
27 Stainless Steel Insert for Faucet WL850
Natural Faucet O-Ring (Silicon White)
Stainless Steel Gauze for Faucet
28 Front Panel for Drip Tray Insert
29 WL2500 Display PCB HC
30 Silicon Button Key Mat HC
31 WL2000 Front Hatch Panel Charcoal
32 Button Label HC & CA
33 Drip Tray Grill
34 Drip Tray Body Charcoal
35 FS Silver Side Panel
36 UV Lamp Fixing Rubber (Silicon)
37 UV Lamp Retaining Threaded Nut
38 UV Lamp 8W Philips
39 O-ring (Black Quartz Sleeve)
40 Quartz Sleeve D310mm for 8W Lamp
41 Main PCB Fixing Bracket (FS)
Main PCB HC
42
Plastic PCB Support
43 Power Transformer UV 220V/50Hz
44 Chinese Ballast Metal Cover 220V/50Hz
45 Upper Base
46 Hot Tank Fixing Bracket
47 Drawn Hot Tank Ass'y 1.5L 220V/50Hz (Sensor) 800w
48 UV Cold Tank Assembly 4L with UV Holder
49 Wire Condenser
28 29
Main PCB Schematic Diagram Main PCB Schematic Diagram
Cold and Ambient Cold only
30 31
Technical Specifications
32 33
Rest of the world
Speak to a Water Expert USA, Canada and Mexico
info@waterlogicusa.com exportsales@waterlogic.com
+ 1 402 884 7212 + 353 1 293 1960
ENG0394-20/11/13
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