Insinger CA-3 User manual

TECHNICAL MANUAL

FOR

POT & PAN

WASHER

MODELS

CA-3

DA-3

CA-3C

TECHNICAL MANUAL

including Installation, Operation, and Maintenance Instructions

FOR

POT & PAN WASHERS

MODELS

CA-3

CA-3C

DA-3

POT and PAN WASHER

Models: CA-3/CA-3C/DA-3

Table of Contents

Part 1 - Technical Information

4 Introduction

4 Catalogue Cut-sheet and Installation Drawing

4 Warranty

4 Authorized Service Agency Network Listing

Part 2 - Installation and Operation Instructions

4 Section A, Installation Instructions

4 Section B, Operation and Cleaning Instructions

Part 3 - Maintenance and Repair Procedures

4 Section A, Maintenance and Repair Procedures

4 Basic Service Guide

Part 4 - Electrical Schematics and Electrical Replacement Parts

4 Machine Wiring Diagrams

4 Control Panel Layout and Component Drawing

Part 5 - Replacement Parts

4 Overall Assembly Drawing for:

4CA-3

4CA-3C

4DA-3

4 Drain Assembly

4 Discharge Line Assembly

4 Upper and Lower Manifold Assembly's

4 Spray Nozzle Assembly, wash

4 Spray Nozzle Assembly, rinse

4 Motor Assembly's

4 Door and Counter Balance Assembly

4 Level Float Installation

4 Final Rinse Piping Assembly

4 Utility Rack

POT & PAN WASHERS

MODEL: CA-3/CA-3C/DA-3

TECH MANUAL INTRODUCTION

Part 1, Section A

A. INTRODUCTION

A.1 Purpose

The purpose of this Tech Manual is to provide installation, operation, cleaning and

maintenance directions. A section is provided for replacement parts.

A.2 Scope

This manual contains all pertinent information to assist in the proper installation, operation,

cleaning, maintenance, and parts ordering for Insinger's Pot & Pan Washers model CA-3, CA-3C &

DA-3.

The installation instructions are intended for qualified equipment installers. The operation and

cleaning instructions are intended for the daily users of the equipment. The maintenance and parts

sections are intended for qualified service and/or maintenance technicians.

Replacement parts may be ordered directly from our factory or from your local Insinger Authorized

Service Agency. For the name of your local Insinger Authorized Service Agency please reference

the Service Network Listing in Section 1 of this manual. You can also speak to the Insinger

Technical Services Department, 800/344-4802, or e-mail us at [email protected].

When calling for warranty information or replacement parts please provide the model and serial

number of your Insinger equipment. These important numbers should be noted in this manual on

the spaces provided on the opening page.

A.3 Start-Up Program

Insinger is proud to offer our exclusive Surefire™ Start-up & Check-out Program to our commercial

customers. This service is included in the purchase price of your new Insinger dishwasher. We will

provide an authorized factory service technician for the initial start-up of your new Insinger

dishwasher to ensure it is running correctly. Please call the factory or your local Insinger Sales

Representative to schedule this service.

A.4 Definitions

Throughout this guide you will find the following terms: WARNING, CAUTION, & NOTE. When

used, these terms will be outlined in a box to draw attention:

WARNING indicates potential physical danger.

CAUTION indicates potential equipment damage.

NOTE indicates helpful operating hints or tips.

CA-3 and DA-3

POT AND PAN WASHERS

DESIGN

Automatic door type utensil washer with a

timed wash-and-rinse cycle. Fully

automatic operation with power on/off

button. CA-3 capacity is 25-24" x 28"

racks per hour, or 150 bun pans/hr or 100

steam table (2" thick) pans/hr. DA-3

capacity is 46 - 24" x 28" racks per hour,

or 276 bun pans/hr or 184 steam table

(2" thick) pans/hr. Cycle starts when doors

are closed. Designed for straight through

operation.

STANDARD EQUIPMENT

• Tank heat: 5 KW electric immersion

heater or steam injector

• Capillary Thermometer for Wash

• In-Line Thermometer tor Final Rinse

• Vacuum Breaker

• Rack Assortment (CA-31 General

Utility, 1 Bake Sheet, 1 Basket) (DA-3 2

General Utility. 2 Bake Sheet. 1 Basket,

1 Counter Pan)

• Manifold Cleanout Brush

• Inspection Door

• Vent opening with adjustable damper

(one for CA-3, two for DA-3)

• S/S frame with S/S Legs

• Automatic Tank fill

• Low Water Protection

• Detergent Connection Provision

• Hold down grid

• Rollers for Track on DA-3

• Fully Automatic Operation

• Manual Bypass Selector Switch

• Side Mounted Control Panel

(NEMA 12)

• Simplified Scrap Screen Design

• Door Safety Switch

• Interchangeable Upper & Lower Spray

Arms

• Standard Frame Drip Proof Motor

OPTIONAL ACCESSORY

EQUIPMENT

 Stainless steel steam coil tank heat

 Pressure Reduction Valve and Line

Strainer

 Steam booster

 Electric booster

 Security package

 S/S front panel

 Totally Enclosed Motor

800/344-4802

NOTES:

SPECIFICATIONS Note: For all rough in connections see Installation and Layout Detail Drawing.

CONSTRUCTION—Hood and tank constructed of 14 gauge 18-8 type 304 S/S. Hood unit of all welded seamless

construction. S/S base frame and legs. All internal castings are non-corrosive lead free nickel alloy or bronze.

DOORS—a front inspection/cleanout door and two simultaneously opening operating doors. Operating doors balanced

by externally mounted springs. Extra large die formed 18-8 type 304 S/S doors ride in all S/S channels. A triple ply

leading edge on the door channels made of S/S.

PUMP—Centrifugal type "packless" pump with a brass petcock drain. Construction includes ceramic seal and a

balanced cast impeller on a precision ground stainless steel shaft. All working parts mounted as an assembly and

removable as a unit without disturbing pump housing. CA-3 has one 5 HP motor. DA-3 has two 5 HP motors. Motors

are standard frame, horizontal C-faced, drip proof, squirrel-cage, induction run type, 60 cycle, 3600 RPM, internally

cooled with ball-bearing construction.

CONTROLS—Side mounted control cabinet, NEMA 12 rated housing motor controls and overload protection,

transformer, contactors and all dishwasher integral controls. All controls safe low voltage 24 VAC.

SPRAY SYSTEM—Wash and rinse spray systems made of 18-8 type 304 S/S schedule 40 pipe threaded into cast

hub assemblies. Upper and lower spray assemblies are interchangeable and are removable without the use of tools.

CA-3 Wash-2 power spinning wash arms above and 2 power spinning wash arms below each designed with 8 high

pressure action cleansing boles.

Final Rinse-2 power spinning rinse arms above and 2 power spinning rinse arms below each designed with 3 nozzles.

DA-3 Wash -4 power spinning wash arms above and 4 power spinning wash arms below each designed with 8 high

pressure action cleansing hole.

Final Rinse-4 power spinning rinse arms above and 4 power spinning rinse arms below each designed with 3 nozzles.

DRAIN—Drain valves externally controlled. Overflow assemblies with skimmer caps are removable without use of

tools for drain line inspection. Heaters protected by low water level control.

Capacity

per hour

CA3-25 racks

DA3-46 racks

Tank capacity

CA3-30 gals.

DA3-60 gals.

Motor size

CA3-5 hp

DA3-(2) 5 hp

Electric usage

CA3 DA3

5 5 kw wash tank

9 18 kw booster 40°

rise

17 36 kw booster 70° rise

Steam consumption

at 20 psi min.

CA3-20lbs./hr. tank

DA3-20lbs./hr. tank

Final rinse peak flow

at 20 psi min.

CA3-16 gals./min.

DA3 - 29.8 gals./min.

Current draw Steam Electric

amps CA3 DA3 CA3 DA3

208/3/60..............16.....33..........…30.....46

230/1/60.............. n/a....n/a...........n/a....n/a

230/3/60...........….15.....30............27.....42

380/3/60...........….10.....20............17.....27

460/3/60...........…..7......15............14.....21

Final rinse consumption at

20 psi min.

CA3 -100 gals./rack / 5 gals./hr.

DA3 - 183 gals./rack / 4 gals./hr.

Exhaust hood

requirement

CA3-300 CFM

DA3-600 CFM

Peak rate

drain flow

CA3 - 9 gals./min.

DA3-16gals./min.

Shipping

weight

CA3-1050 lbs.

DA3-1650 lbs.

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

INSTALLATION INSTRUCTIONS

Part 2, Section A

2.A.1 PLACEMENT

2.A.1.1 Carefully uncrate machine. Take caution to not damage components which

may be mounted on the top or sides of the machine.

2.A.1.2 Set unit in place and adjust the feet to level the machine.

2.A.1.3 Fasten the tables to the load and unload side of the machine. Most

installations require fastening the turn-down lip of the dish tables to the side of the

machine with flathead counter-sunk screws. The table design should provide horizontal

clearance of 30" for servicing.

2.A.2 ELECTRICAL CONNECTIONS

2.A.2.1 Connect electrical lines sized for the correct voltage, current and phase of the machine.

These should agree with machine requirements indicated on the nameplate and labels in control

panel. This Fuse Sizing Chart should be used as a guide for proper line protection:

Caution

Connections must be made to a circuit breaker or fused disconnect

as provided by the end-user and required by local codes. A laminated

wiring diagram is inside the control panel

Fuse Sizing Chart

Model

208VAC/3Θ 230VAC/3Θ 380VAC/3Θ 460VAC/3Θ

CA-3(C)

steam heat

25A 20A 15A 10A

CA-3(C)

electric heat

35A 35A 20A 20A

CA-3(C)

gas heat

25A 20A 15A 10A

DA-3

steam heat

40A 35A 25A 20A

DA-3

electric heat

60A 50A 30A 25A

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

INSTALLATION INSTRUCTIONS

Part 2, Section A

2.A.2.2 On machines not provided with a single-point connection there is an electrical connection

required for the, 1. Pumps and control circuit, and Wash tank heater.

2.A.2.3 If an electrical booster is provided connect the power directly to the booster.

Caution

As with any 3 phase system, an electrician must check all motors for proper

phasing, i.e., Pump motors must be running in direction

indicated by arrow on housing.

2.A.3 MECHANICAL CONNECTIONS

2.A.3.1 Connect 140°F water lines for tank fills/booster as tagged and noted on the

installation drawings.

2.A.3.2 If machine is provided with steam heat connect the steam lines and steam

condensate lines as tagged and noted on installation drawings.

2.A.3.3 Connect the drain line.

Caution

Drain lines must be as specified on installation drawings. Drain line should

be properly vented and should have fall of not less than 1/4" to the foot of

proper flow. Some area plumbing codes require drains to flow into an open

gap with an opening twice the diameter of the pipe. Check with your local

plumbing codes for the type of drain connection required.

Caution

All lines must be flushed prior to use to remove debris.

Caution

Do not reduce the size of lines as specified in installation drawings. All

lines are sized to facilitate necessary flows, pressures, etc.

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

INSTALLATION INSTRUCTIONS

Part 2, Section A

2.A.4 HVAC

2.A.4.1 Ventilation system should be sized to provide adequate ventilation per machine specs.

Refer to spec sheet.

2.A.5 CHEMICALS

2.A.5.1 Upon completed installation of the dishwasher contact a local detergent/chemical supplier

for the correct chemicals for your area.

2.A.5.2 Electrical connection points for the detergent dispenser and rinse injector are located

inside the control panel. Refer to the wiring diagram for this machine for the proper connection

points. Dispensers may be connected on either the primary voltage side of the machine or the

24VAC control voltage side.

Caution

When connecting on the 24VAC control voltage side of the

transformer, total VA must not exceed 50VA.

2.A.5.3 The detergent density probe should be installed in the hole provided & labelled in the wash

tank.

2.A.5.4 The switch on the control panel labelled "Manual" and the switch labelled "Wash" may be

used when de-liming the machine. When activated, these switches keep the machine in an

indefinite wash cycle. This feature can also be used to wash heavily soiled ware.

2.A.6 Tabling

2.A.6.1 Load and unload tables should be pitched towards the machine to return excess water

into the machine.

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

OPERATION & CLEANING INSTRUCTIONS

Part 2, Section B

Insinger dishmachines are user-friendly, making them the easiest dishwashers to operate and maintain.

By following the operation procedure and general cleaning procedures your Insinger dishwasher will give

you years of trouble free service.

2.B.1 Operation Instructions

2.B.1.1 Ensure drain overflow tube is in place Close the tank drain valve.

2.B.1.2 Check for proper installation and cleanliness of all internal, removable

components such as suction strainers, scrap screens, and rotating spray pipes.

2.B.1.3 Ensure all water, and steam, lines are open. Ensure electrical circuits are on.

2.B.1.4 Close machine doors.

2.B.1.5 Move the power toggle switch to the "ON" position. The machine will fill the

tank, run through a complete wash/rinse cycle and shut-off.

2.B.1.6 When the tank is full the tank heat will operate automatically. Proper tank heat

is 150°F.

Caution

To ensure proper operation of the auto tank fill feature and the tank

heaters, level float(s) located in each tank MUST be cleaned daily

2.B.1.7 Open doors.

2.B.1.8 Insert a rack of soiled dishware in machine (two racks for the DA-3) and lower doors.

Machine will wash and rinse automatically. When the rinse indicator light goes off the cycle is

complete.

Note

Overloading racks will minimize the proper cleaning of ware.

Warning

Do not open the doors during the wash/rinse cycle as hot water is being

sprayed. An interlock is provided to stop the wash/rinse cycle if the doors

are opened but the momentum of the spinning hubs will cause hot water to

be sprayed.

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

OPERATION & CLEANING INSTRUCTIONS

Part 2, Section B

2.B.1.9 Raise doors and remove rack of clean ware. For continuous operation repeat

steps B.1.9 and B.1.10.

2.B.1.10 Upon completion of ware cleaning move the power toggle switch to the "OFF"

position.

2.B.1.11 Refer to the cleaning procedures for proper clean-up of the dishmachine.

2.B.1.12 Report any unusual occurrences to qualified service personnel.

The following cleaning procedures should be done daily, at the end of the shift.

2.B.2 Cleaning Procedures, Daily

2.B.2.1 Remove all internal removeable parts including rotating spray pipes, scrap screens, drain

overflow tubes, suction strainers and curtains.

2.B.2.2 Remove the end caps from the spray manifolds and clean with the brush provided. Flush

the manifolds.

Note

Do not remove wash and rinse spray arms from the hubs as these

are factory set. Cleaning should be done by removing the endcap on

each arm.

2.B.2.3 Flush scrap screens.

2.B.2.4 Clean drain overflow tube.

Note

V-cup seal on the drain overflow tube may become gummed and not

allow the overflow tube to seat properly. This will cause the drain to leak

water. Remove any build-up on the v-seal. When the seal becomes worn,

replace.

2.B.2.5 Clean suction strainers of build-up.

Note

Improper cleaning of suction strainers will cause the pumps to cavitate.

This will cause poor washing results.

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

MAINTENANCE & REPAIR PROCEDURES

Part 3, Section A

Following is a basic guide for the repair and replacement of common dishwasher parts. Refer to the

Basic Service Guide for troubleshooting tips.

3.A.1 MAINTENANCE

3.A.1.1 Daily - Refer to the operation and cleaning instructions provided in this manual for

daily cleaning procedures.

3.A.1.2 Weekly

3.A.1.2.1 The entire machine should be wiped down using an industrial

grade stainless steel cleaner.

3.A.1.2.2 Under the supervision of your detergent supplier the machine

interior must be properly de-limed.

Note

The water quality in some areas requires de-liming to be done more

frequently. Contact your detergent supplier for recommended de-

liming frequency.

3.A.1.3 Quarterly

3.A.1.3.1 Remove and clean the strainer screens on water and steam lines. If

the screens cannot be cleaned, replace.

3.A.1.3.2 Inspect condition of solenoid valve seats and diaphragms. Replace

where necessary.

3.A.1.3.3 Inspect drain O-Rings for leakage. Replace where necessary.

3.A.1.3.4 Check door spring tension and adjust where necessary.

3.A.1.3.5 Check wash and rinse hub bushing/bearing and replace where

necessary.

3.A.2 MAINTENANCE PROCEDURES

3.A.2.1 Solenoid Valve Disassembly

3.A.2.1.1 Disconnect power supply to machine. Turn off Water supply.

3.A.2.1.2 Remove cap on top of coil. Remove coil.

3.A.2.1.3 Remove 4 hex bolts and lift bonnet from valve body. Note positioning

of spring and plunger.

3.A.2.1.4 Remove main piston.

3.A.2.1.5 Inspect for dirt, wear or lime build-up. Clean or replace as required.

3.A.2.1.6 Reassemble in reverse of disassembly.

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

MAINTENANCE & REPAIR PROCEDURES

Part 3, Section A

3.A.2.2 Line Strainer Disassembly

3.A.2.2.1 Shut off water or steam supply.

3.A.2.2.2 Remove large hex nut on bottom of strainer body.

3.A.2.2.3 Remove strainer screen. Inspect and clean or replace as necessary.

3.A.2.2.4 Reassemble in reverse of disassembly. Water flow must be same

direction as arrow on line strainer body. Use new gaskets to insure a tight seal.

3.A.2.3 Pump Disassembly

3.A.2.3.1 Before disassembling pump ensure there are no obstructions in the pump intake.

Remove and clean the suction strainer (inside tank).

Note

It is not necessary to remove the pump housing from the machine

to disassemble the pump.

3.A.2.3.2 Remove the pump motor and impeller adaptor by removing the 4 hex

bolts attaching them to the pump housing.

3.A.2.3.3 Repair or replace the pump parts as required.

3.A.2.3.4 Reassemble in reverse of disassembly.

3.A.2.4 Immersion Heater Replacement

Note

Immersion heaters MUST be completely submerged at all times. Running

the heaters in air will cause the heater to prematurely fail

3.A.2.4.1 Remove the housing covering the wiring terminations. Disconnect the immersion

heater wires.

3.A.2.4.2 Remove the immersion heater by loosening and removing the large hex nut..

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

MAINTENANCE & REPAIR PROCEDURES

Part 3, Section A

3.A.2.4.3 Install in reverse of removal.

Note

To reduce the possiblity of leaking, use plumbers putty on the

immersion heater nuts.

3.A.2.5 Wash Tank Temperature Adjustment

3.A.2.5.1 A temperature control board is provided in the control panel for easy

adjustment of tank temperature. Though tank temperature is adjusted during the

machines factory test it is sometimes necessary to re-adjust the temperature.

3.A.2.5.2 Locate the temperature control board (P/N DE9-96). Use the control

panel layout drawing located in Part 4, Electrical Schematic and Replacement

Parts.

3.A.2.5.3 Adjust the tank temperature to the desired temperature by turning the

potentiometer located on the temperature control board. An arrow on the

potentiometer indicates increase.

3.A.2.5.4 If the temperature does not change refer to section A.2.6,

Troubleshooting Tank Temperatures.

3.A.2.6 Troubleshooting Tank Temperatures

3.A.2.6.1 Electric Heat

3.A.2.6.1.1 If temperature cannot be adjusted per section A.2.5 check the

temperature control board P/N DE9-96 proper operation. If the temperature

control board is faulty, replace.

3.A.2.6.1.2 Verify tank heat contactor is working correctly. If not, replace.

3.A.2.6.1.3 Verify all immersion heaters are working properly and not limed. If

not, replace.

3.A.2.6.2 Steam Heat

3.A.2.6.2.1 See Section A.2.6.1.1.

3.A.2.6.2.2 Verify steam pressure per machine specifications.

3.A.2.6.2.3 Verify steam trap is not clogged. IF so, clean or replace.

3.A.2.6.2.4 Verify proper operation of steam solenoid. If not, replace.

3.A.2.6.3 Gas Heat

3.A.2.6.3.1 See Section A.2.6.1.1.

3.A.2.6.3.2 Verify gas supply.

3.A.2.6.3.3 Verify pilot is lit. If not, light. If pilot does not stay lit, replace.

3.A.2.6.3.4 Verify gas solenoid is working correctly. If not, replace.

POT and PAN WASHER

MODEL: CA-3/CA-3C/DA-3

MAINTENANCE & REPAIR PROCEDURES

Part 3, Section A

3.A.2.7 Motor Overloads

3.A.2.7.1 All motors used on Insinger Machines are provided with motor overloads. Motor

overloads are adjusted when the machines are factory tested. Should it be necessary to

adjust the motor overloads first verify the motor current draw for the voltage the machine is

using.

3.A.2.7.2 Using the Control Panel Component Layout Drawing located in Section 4 to

identify the overload, adjust by turning the dial to the appropriate current draw.

3.A.2.8 Level System

3.A.2.8.1 The level control system consists of one timer (P/N DE7-31) and two

level floats (P/N DE5-60) per tank.

3.A.2.8.2 The level timer will not allow the tank heat to energize without water in

the tank.

3.A.2.8.3 Should the tank heat energize with out water in the tank troubleshoot

the system to find the problem.

Caution

Dirty level floats may cause the tank heat to energize with no water in the

tanks. LEVEL FLOATS MUST BE CLEANED DAILY.

3.A.2.9 Wash and Rinse Cycle

3.A.2.9.1 The timing sequence consists of two timers. The CA-3, CA-3C, and DA-3 use 1,

five minute timer adjusted to 120 seconds for the wash cycle (P/N DE7-28)and 1, one

minute timer adjusted to 15 seconds (P/N DE7-27). Should either of these become

defective, replace.

BASIC SERVICE GUIDE

SYMPTOM POSSIBLE CAUSE Solution

a. No Power a. Check power supply

b. Blown fuse or tripped breaker b. Replace fuse; reset breaker

1. Machine will not operate

c. Motor overloads tripped c. Reset overload

a. Drain not closed a. Close drain

b. Drain overflow not seated or installed

b. Reseat or install drain overflow

2. Tank will not hold water

c. Pump petcock opened c. Replace V-seal

3. Tank fills beyond overflow a. Obstruction in overflow tube or drain

line

a. Remove obstruction

a. Doors not seating a. Reseat doors 4. Water leaks around door

b. Clogged spray pipe b. Clean spray pipe with brush provided

a. Clogged spray pipe a. Clean spray pipe with brush pipe

b. Manifolds not installed properly b. Ensure proper placement of upper

and lower pipes

c. Obstruction in pump c. Clear obstruction through pump

inspection plate

d. Pump rotation reversed d. Arrow on pump housing indicates

direction, correct electrically

5. Weak or ineffective spray

e. Suction strainer clogged e. Clean suction strainer

BASIC SERVICE GUIDE

SYMPTOM POSSIBLE CAUSE Solution

a. Lime deposits in spray nozzles a. Clean or replace nozzles

b. Low water pressure b. Adjust to 20 PSI

c. Clogged line strainer c. Remove line strainer and

clean

6. Weak or ineffective final rinse

spray

d. Closed water supply valve d. Open ball valve

7. Water hammer a. Excessive water line pressure a. Install water hammer limiting

device

a. Pump rotation reversed a. Arrow on pump housing

indicates direction, correct

electrically

8. Machine vibrates or is noisy

b. Pump bearings worn b. Replace pump bearings

a. Final rinse solenoid valve

clogged

a. Disassemble valve and clean

internal parts of scale or

replace

b. Diaphragm worn b. Replace with solenoid valve

repair kit

9. Final rinse will not shut off

c. Solenoid valve still powered-up c. Check final rinse actuating

circuit for proper operation

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