Insinger 45SA User manual

TECHNICAL MANUAL
Installation, Operation and Maintenance Instructions
45SA
Undercounter Dishwasher
45SA5-F1
45SA5-F2
45SA-F2C
45SA-F2D
45SA-F2
Insinger Machine Company
6245 State Road
Philadelphia, PA 19135-2996
800-344-4802
Fax: [phone]
www.insingermachine.com
~Jlnsinger

Insinger Model 45SA5
REVISION RECORD
Date of original manual: 1 March 1996
Rev. Date
A
1/13/97
B
3/19/97
C 4/11/97
D
11/10/97
E
4/1/98
F
7/15/99
G 4/17/00
H 3/23/01
J 6/15/04
SN 960071 and higher.
Effective
Serial No.
970080
970179
970224
970572
980210
990363
000280
010149
040220
Description
New overloads & float switches.
Fig. 7-4 ball float was
cantilever style.
Fig. 7-1 & 7-2, new style water
level indicator (item 39)
Pg. 7-2 & Fig. 7-9, new
contactors.
Add 6.2.9, New Figs 7-1, 7-2,
7-9, 8-3, 8-4, 8-5 for new timer
DE7-35 & single float switch.
Rev. 6.2.1 (strainer cleaning),
Fig. 7-1 & 7-2 (new S/S water
level indicator).
Fig. 7-2 (new PN for item 39
level indicator, SN 990363 &
higher).
New temp cont board DE9-251 &
sensor DE9-252, Fig. 7-9
New ball valves, final rinse
solenoid valve, wash tank stm.
sol. valve & level switch, drain
overflow tube & scrap screen,
captive end plugs & strainer,
front panel, start push button,
spring plungers on wash
manifolds, hi temp limit switch
for elect. tank heat.

Insinger Model 45SA5
FACTORY SUPPORT
_Insinger Machine Company:
6245 State Road
Philadelphia, PA 19135
800-344-4802
215-624-4800
215-624-6966 (Fax)
www.insingermachine.com
AUTHORIZED SERVICE AGENCIES
California:
Magna Mechanical
724 Ave. B, Suite A
National City, CA 91950
619-239-8008
Florida:
Speciality Marine Supply
2057 Mayport Road
Atlantic Beach, FL 32310
904-247-3303
904 - 24 7- 6403 (Fax)
The Source
589 West 14th St, Unit 5
Atlantic Beach, FL 32233
904-241-4982
904-241-4039 (Fax)
Virginia:
D. W. Boyd Company·
4003 Colley Ave.
Norfolk, VA 23508
757-423-2268
757-423-1868 (Fax)
The Source
502 Rotary Street
Hampton, VA 23661
757-825-1400
757 - 825 - 12 02 (Fax)
i

Insinger Model 45SA5
TECHNICAL MANUAL VALIDATION CERTIFICATE
To be assigned
ii

Insinger Model 45SA5
APPROVAL AND PROCUREMENT RECORD
NOT APPLICABLE
iii

Insinger Model 45SA5
IDENTIFYING TECHNICAL PUBLICATION SHEET
To be assigned
iv

Insinger Model 45SA5
SAFETY SUMMARY
The following general safety notices supplement the specific
warnings and cautions appearing in this manual:
All service except for routine shut-down procedures and
operator
1s
troubleshooting procedures must be performed by
qualified maintenance personnel.
Prior to any work on the Model 45SA5 dishwasher involving
service of electrical, steam, or water systems, the dishwasher
and booster heater must be de-energized by turning the
electrical supply power noff
11
and closing appropriate steam and
water valves.
The following is a summary of the warnings and cautions appearing
in the text of this manual to alert personnel to potentially
hazardous situations:
WARNINGS
Warning definition: :A warning designates
potential bodily harm if not followed.
Page 2 5: Do not open the door during the wash or rinse cycle
because hot water is being sprayed. An interlock is provided to
stop the cycle if the door is opened, but some hot water may
escape.
Page 2 5: Hot water and surface temperatures exist in the
machine. Allow the machine to cool to 110°F before proceeding.
Wear rubber gloves.
Page 2-6: Electric float switches, probes, and heating elements
must be cleaned daily. Accumulations of grease, minerals or
debris will cause faulty operation of tank fill and heating
systems. Use Scotch-Brite or equivalent cleaning pads on heavy
dirt.
Page 4 1: Inside of the machine is hot. Allow the machine to
cool to 110° F. before proceeding. Wear rubber gloves.
Page 4 3: Turn off power supply to the control enclosure. This
inspection should only be done by a qualified electrician.
V

Insinger Model 45SA5
WARNINGS (can't)
Page 5-1: Prior to any work on the Model 45SA5 dishwasher
involving service of electrical, steam, or water systems, the
shwasher and booster must be de-energized by turning the
ectrical supply power
11
0ff!! and closing appropriate valves.
Wear rubber gloves while performing the following steps. Do not
drink, eat or smoke.
Troubleshooting of certain electrical functions requires access
to 1 electrical circuits inside the electrical control
enclosure. Troubleshooting or repair of the electrical equipment
should only be done by a qualified electrician.
Page 6 1: Prior to any work on the Model 45SA5 dishwasher
involving service electrical, steam, or water systems, the
dishwasher and booster must be de-energi by turning the
electrical supply power noff
11
and closing appropriate valves.
Wear rubber gloves while performing the following steps. Do not
drink, eat or smoke.
Troubleshooting certain electri functions requires access
to live electrical circuits inside the electrical control
enclosure. Troubleshooting or repair the electrical equipment
should only be attempted by a qualified electrician.
Page 6-5: following steps require testing with machine power
on. These tests should only be made by a qualified electrician.
Page 8-1: All portions of the installation must comply with
applicable Navy shipboard regulations, specifications, and
requirements.
Page 8 1: Both the dishwasher and the booster heater must be
securely bolted to deck plates.
Page 8-3: Dangerous voltages are present on connections to the
electrical control enclosure and electric booster heater.
Observe normal safety precautions for high voltage electrical
equipment when connecting to local distribution system. All
work should be done by a qualified electrician.
vi

Insinger Model 45SA5
WARNINGS (can't)
Page 8-4: At startup, and after any draining of the electric
booster, turn off the 440 volt power to the booster during the
initial wash tank fill (2.3.6). This will allow the booster
reservoir to fill and trapped air to be purged without
overheating of booster heating elements.
CAUTIONS
Caution definition: a caution designates
potential equipment harm if not followed.
Page 2-1: The operator should become thoroughly familiar with
the equipment and these operating instructions prior to starting
the machine.
vii

Insinger Model 45SA5
TABLE OF CONTENTS
Section
1.0 GENERAL INFORMATION
1.1 Introduction
1.2 Scope of the Manual
1.3 Equipment Description
1.4 Equipment Supplied
1.5 Detergent and Rinse Additive Dispensers
2.0 OPERATION
2.1 Introduction
2.2 Controls and Indicators
2.3 Start-Up Procedure
2.4 Shut-Down Procedure
3.0 FUNCTIONAL DESCRIPTION
4.0 SCHEDULED MAINTENANCE
4.1 Introduction
4.2 Weekly Requirements for Inspection
and Maintenance
4.3 Quarterly Requirements for Inspection
and Maintenance
5.0 TROUBLESHOOTING
6.0 CORRECTIVE MAINTENANCE
6.1 Introduction
6.2 Maintenance and Repair Procedures
6.2.1
Clean Fresh Hot Rinse Strainer
viii
1 1
1-1
1-1
1-1
1-2
2 1
2-1
2 4
2 5
3-1
4 1
4-1
4 2
5-1
6-1
6-1

Insinger Model 45SA5
TABLE OF CONTENTS (con
1
t)
6.2.2 Removal and Replacement of
Electric Tank Heater 6-2
6.2.3 Removal and Replacement of
Thermometers 6-2
6.2.4 Overload Relay Settings and Functions 6 3
6.2.5 Adjust Wash Tank Temperature 6 3
6.2.6 Adjust Rinse Booster Temperature 6-4
6.2.7 Inspection and Repair of Solenoid
Actuated Valves 6 5
6.2.8 Removal and Replacement of
Recirculating Pump 6 6
6.2.9 Adjust Liquid Level Timer 6 7
6.2.10 Removal and Replacement of
Liquid Level Float Switch 6 7
7.0 PARTS LIST
7.1 Introduction
7.2 Parts Procurement
7.3 Standard Repair Parts
8.0 INSTALLATION
8.1 Unpacking
8.2 Installation
8.2.1 Mechanical and Piping
8.2.2 Electrical
8.2.3 Check-Out of the Installation
ix
7-1
7 1
7-2
8-1
8-1
8-3
8-4

Insinger Model 45SA5
Number
1-1
2-1
5 1
5-2
LIST OF TABLES
Title
Data Characteristics
Controls and Indicators
Operator's Troubleshooting Guide
Maintenance Troubleshooting Guide
X
1-3
2-1
5 2
5-4

Insinger Model 45SA5
Number
6-1
6-2
6-3
6-4
6-5
6 6
6-7
6-8
6 9
6 10
7-1
7 2
7-3
7-4
7 5
7-6
7-7
7-8
LIST OF ILLUSTRATIONS
Title
Pressure Reducing Valve
Electric Heater Installation
Overload Relay Settings
Wash Tank Temperature Control Board
Steam Booster Temperature Controller
Electric Booster Thermostat
Solenoid Valve, Final Rinse
Solenoid Valve, Steam
Liquid Timer
Liquid Level Float Switch
Parts
st Drawing Sht 1 of 2
Parts List Drawing
-
Sht
2 of
2
Parts List Drawing
-
1/2
Hp. Pump
Piping Assembly
- Steam Booster
Steam Booster Assembly
Steam Coil Assembly
Hatco
9 &
18 KW Electric Booster
Hatco 11.4 KW Booster
xi
Page No.
6 11
6-12
6-13
6-14
6-15
6-16
6-17
6-1
6-19
6 20
7-6
7-7
7-8
7 9
7-10
7-11
7-12
7 13

Insinger Model 45SA5
Number
7-9
8-1
8-2
8 3
8 4
8-5
8-6
8 7
LIST OF ILLUSTRATIONS (con't)
Title
Control Panel Layout
Installation - Right Side Booster
Installation - Left Side Booster
Electrical Wiring Schematic
Steam Heated Machine
Electrical Wiring Schematic
ectrically Heated Machine
Field Wiring Interconnections
Detergent Dispenser & Rinse Injector
Connection Examples
ectrical Enclosure
xii
Page No.
7-14
8-5
8-6
8-7
8 8
8-9
8-10
8 11

Insinger Model 45SA5
This intentionally left blank.
xiii

Insinger Model 45SA5
CHAPTER 1
1.0 GENERAL INFORMATION
1.1 INTRODUCTION
This technical manual provides information for the installation,
operation, inspection and maintenance of the Model 45SA5 series
of dishwashers manufactured by the Insinger Machine Company,
Philadelphia, PA.
1.2 SCOPE OF THE MANUAL
Chapters 1, 2, 3, and 8 provide information required for start
up, operation, and installation of the equipment. Chapters 4, 5,
6 and 7 provide information on maintenance operations.
1.3 EQUIPMENT DESCRIPTION
The Model 4SSAS dishwasher is a single tank, front loading,
undercounter dishwasher used for the washing of plates,
glassware, and small utensils in 16
11
by 16
11
racks. The machine
processes up to 45 racks per hour through timed wash and final
hot rinse cycles.
1.4 EQUIPMENT SUPPLIED
Dishwashers are supplied with wash tank and final rinse water
booster heating options as follows:
Model
45SA5 Fl
4SSA5-F2
45SA5-F2C
45SA5-F2D
45SA5 F2NM
Wash Tank Heat
Steam Coil
Electric
Electric
Electric
Electric
Booster Heat
Steam
9 KW Electric (Hatco)
9 KW Electric (Hubbell)
18 KW Electric (Hatco)
11.4 KW Electric (Hatco)
The standard location for steam or electric booster is to the
right of the dishwasher (Fig. 8-1). An optional booster
location, when specified, is to the left of the dishwasher (Fig.
8-2) .
In addition to the wash tank and booster heat options listed
above, the 45SA5-F2NM minimizes the amount of magnetic material
by using a bronze pump housing and impeller and a 300 series
stainless steel booster water tank.
1-1

Insinger Model 45SA5
Each dishwasher is supplied with the following loose components,
which are to be mounted adjacent to the machine by the installing
activity:
Electrical control enclosure.
Thermometer bracket.
(2) Plate racks.
(2) Cup, bowl and cutlery racks.
(2) Manifold cleanout brushes.
1.5 DETERGENT AND RINSE ADDITIVE DISPENSERS
This machine must be operated with an automatic detergent feeder,
including a visual means to verify that the detergents are
delivered or a visual or audible alarm to signal if detergents
are not available for delivery to the washing system. Please see
instructions for electrical and plumbing connections located in
this manual and in the feeder equipment manual.
The requirement for a detergent dispenser and a rinse additive
dispenser to be supplied by the manufacturer of this dishwasher
has been deleted by the Navy's Life Cycle Manager for Shipboard
Food Service Equipment.
Contact your local port detergent supplier for detergent and
rinse additive dispensing equipment to meet the above
requirement.
Questions should be addressed to:
Naval Surface Warfare Center
Carderock Division
Ship Systems Engineering Station
Naval Business Center
5001 South Broad Street
Philadelphia, PA 19112
POC's:
James Brechka, 215-897-7311
[email protected]
Janice Murphy, 215-897-1647
[email protected]
1-2

Insinger Model 45SA5
TABLE 1-1
DATA CHARACTERISTICS
Manufacturer:
Insinger Machine Company, Philadelphia, PA
Type:
Insinger Model 45SA5 with tank heat and booster options.
Characteristics:
Type: Single tank, front loading, undercounter dishwasher.
Wash tank capacity: 9.0
Capaci 45 racks (16
11
by 16
11
) per hour, manually loaded.
Rinse Water Requirements:
Rated flow: 4.1 gpm peak at 20 psig.
36 gal/hr average flow.
Supply temperature: 140° F. minimum.
Electrical Power Requirements:
Power supply: 440 vac, 3 phase, 60 Hz.
Operating current - 45SA5-Fl: 1.4
amps
45SA5
F2: 3.1 amps
9.9
amps
45SA5 F2C:
3.1
amps
11. 8 amps
45SA5-F2D:
3.1
amps
19.8 amps
45SA5-F2NM: 3.1
amps
12.6 amps
1-3
(dishwasher
& booster)
(dishwasher)
(9 KW booster)
(dishwasher}
(9 KW booster)
(dishwasher)
(18 KW booster)
(dishwasher)
(11. 4 KW booster)

Insinger Model 45SA5
TABLE 1-1 (con't)
DATA CHARACTERISTICS
Steam Requirements (45SA5-Fl only):
Pressure (dry saturated steam):
16 psig. minimum.
50 psig. maximum.
Pressure to booster must be regulat
Flow Rate (tank heat plus booster):
19 lb/hr average.
94 lb/hr peak.
Component Ratings:
Wash heater: 1.5 KW
Elect c booster: 9, 11.4, or 18 KW
Wash pump: 0.5 hp
Weight:
Shipping: 381 lbs.
ing: Dishwasher - 180 lbs.
Electrical Control Panel
Volume:
Crat 59" lg. x 40" w. x 76" h.
1 4
30 lbs.
to 16-25 ps

Insinger Model 45SA5
CHAPTER 2
2.0 OPERATION
2.1 INTRODUCTION
The Model 45SA5 dishwasher is a heavy duty machine
daily use in a naval shipboard environment.
igned for
CAUTION
The operator should become thoroughly
familiar with the equipment and these
operating instructions prior to starting the
machine.
2.2 CONTROLS AND INDICATORS
TABLE 2-1
CONTROLS AND INDICATORS
ITEM #
CONTROL
TYPE
FUNCTION
1 Power Switch.
Toggle switch on Turns control
cont panel. power on & off.
2 Power
On. pilot
light on
Signals
con-
control panel. trol
power on.
3 Wash Cycle Toggle
tch on Manual
-
will
Switch.
control panel.
remain in
continuous
wash
cycle
extended wash or
de
liming
procedure.
Auto
-
normal
operation
for
timed and
rinse cycles.
2-1