CMA Dishmachines CMA-180UC Service Manual

MODEL CMA-180UC

SERVICE & PARTS MANUAL

Rev 1.10

CMA DISHMACHINES 12700 KNOTT AVENUE

GARDEN GROVE, CALIFORNIA 92841

800-854-6417

FAX 714-895-2141

www.cmadishmachines.com 0203

TABLE OF CONTENTS

MODEL CMA-180UC

1. SPECIFICATIONS.........................................................................................2

1.1. CMA-180UC.................................................................................................................................. 2

1.2. CMA-180UC OPERATIONAL CYCLE............................................................................................... 3

2. GETTING STARTED .....................................................................................4

2.1. INTRODUCTION TO CMA-180UC.................................................................................................... 4

2.2. RECEIVING AND INSTALLATION ...................................................................................................... 5

2.2.1. Electrical ................................................................................................................................ 5

2.2.2. Plumbing................................................................................................................................. 5

2.2.3. Detergent And Rinse Dispenser ............................................................................................. 5

2.2.4. CMA Supplied Detergent and Rinse Dispenser (Optional) .................................................... 7

2.2.5. Booster Heater Setup.............................................................................................................. 9

2.2.6. Installers Checklist................................................................................................................. 9

3. OPERATION................................................................................................10

3.1. INITIAL SETUP............................................................................................................................... 10

3.1.1. Rinse Pressure Regulator..................................................................................................... 10

3.1.2. Rinse and Wash Temperatures ............................................................................................. 10

3.1.3. Post Instructions................................................................................................................... 10

3.2. STARTUP PROCEDURES ................................................................................................................. 10

3.3. OPERATING AND CLEANING INSTRUCTIONS .................................................................................. 11

3.4. TROUBLESHOOTING....................................................................................................................... 12

4. PARTS MANUAL ........................................................................................15

4.1. INITIAL PARTS KIT (P/N 1100.66)................................................................................................. 15

4.2. OPTIONAL DRAIN PUMP KIT.......................................................................................................... 16

4.3. OPTIONAL DRAIN PUMP—INSTALLATION INSTRUCTIONS............................................................. 17

4.4. MECHANICAL DRAWINGS.............................................................................................................. 19

4.4.1. Cabinet Assembly ................................................................................................................. 19

4.4.2. Door Assembly...................................................................................................................... 20

4.4.3. Electrical Tray...................................................................................................................... 21

4.4.4. Control Panel ....................................................................................................................... 22

4.4.5. Plumbing System Assembly................................................................................................... 23

4.4.6. Drain System Assembly......................................................................................................... 24

4.4.7. Wash System......................................................................................................................... 25

4.4.8. Rinse System......................................................................................................................... 26

4.4.9. Pump System Assembly......................................................................................................... 27

4.4.10. Heater Assembly................................................................................................................... 28

4.5. ELECTRICAL DIAGRAM ................................................................................................................. 29

www.cmadishmachines.com 0203

1. Specifications

1.1. CMA-180UC

METRIC

EQUIVALENT

WATER CONSUMPTION

PER RACK .86 GAL. (3.25 L) PER HOUR 20.6 GAL. (77.8 L)

OPERATING CYCLE

WASH TIME-SEC 94 94 RINSE TIME-SEC 16 16 DWELL TIME-SEC 10 10 TOTAL CYCLE 2 MIN. 2 MIN.

OPERATING CAPACITY

RACKS PER HOUR 24 24 WASH TANK CAPACITY 2.5 GAL. (9.46 L) PUMP CAPACITY 38 GPM (144 LPM)

WATER REQUIREMENTS

140°F (60°C) WATER INLET ½” — DRAIN CONNECTION 1” — RINSE PRESSURE SET 24 PSI 1.7 kg/cm CYCLE TEMPERATURES

WASH-°F 155°F – 160°F (68°C/71°C) RINSE-°F 180°F – 195°F (82°C/90°C) FRAME DIMENSIONS DEPTH 26” (66.04 cm) WIDTH 24” (60.96 cm) HEIGHT 33 ¼” (84.45 cm) MAX CLEARANCE FOR DISHES 15” (38.1 cm)

ELECTRICAL RATING*

208 VOLTS

1 PH—60 Hz

33 AMPS 35 AMPS

230 VOLTS

1 PH—60 Hz

BOOSTER HEATER 5.3 kW 6.5 kW WASH PUMP MOTOR ¾ HP ¾ HP

*MUST CONNECT TO DEDICATED 50 AMP SUPPLY CIRCUIT. USE #8 AWG (MIN) 90°C STANDARD COPPER WIRE

THIS SYSTEM REQUIRES THREE POWER WIRES, WHICH INCLUDES A CURRENT CARRYING NEUTRAL. AN ADDITIONAL FOURTH WIRE MUST BE PROVIDED FOR MACHINE GROUND.

SHIPPING WEIGHT APPROXIMATE 193# (87.54 kg)

MODEL CMA-180UC SERVICE & PARTS MANUAL Rev. 1.10 Page

1.2. CMA-180UC Operational Cycle

The CMA-180UC Operational Cycle has a total cycle time of 2 minutes (120 seconds). The Timing Diagram and the steps listed below detail the individual functions that are executed during each Operational Cycle.

Seconds: 0 10 20 30 40 50 60 70 80 90 100 110 120

Instant

Start Relay

Cam Timer Motor Cam

Rinse Cycle

Cam

Wash Cycle

Cam

Optional Drain

Pump Cam

1. With the machine powered up toggling the START switch begins a cycle. a) Toggling the START switch energizes both the Cam Timer motor and the Instant Start

Relay. The Instant Start Relay latches ON the power to the Cam Timer motor so that the START switch can be released a moment after it has been toggled without the Cam Timer motor losing power.

b) After about 1.5 seconds the Cam Timer’s first cam—the Cam Timer Motor Cam—

latches ON the power to the Cam Timer motor and drops out the Instant Start Relay. The Cam Timer motor continues to run for a total of 2 minutes, at which time it switches OFF—resetting the Cam Timer—and waits for the next START command.

2. The Cam Timer’s third cam controls the Wash Pump. The Wash Pump comes ON about 3 seconds into the Operational Cycle and continues to run for 94 seconds. This 94-second period is the Wash Cycle.

3. At the same time that the Wash Pump comes ON the Cam Timer’s fourth cam powers ON the Optional Drain Pump—if one is present—and keeps it running for about 7 seconds before powering OFF. This cam turns ON again midway through the Rinse Cycle and stays ON for 10 seconds, turning OFF 2 seconds after the Rinse Cycle has completed.

4. About 3 seconds after the Wash Cycle has completed the Cam Timer’s second cam, which controls the Rinse Cycle, turns ON—energizing the Water Solenoid—and stays ON for 16 seconds. This 16-second period is the Rinse Cycle.

MODEL CMA-180UC SERVICE & PARTS MANUAL Rev. 1.10 Page

Getting Started

2. Getting Started

2.1. Introduction to CMA-180UC

The CMA-180UC is a hot water sanitizing, single rack, under-coun ter dishmachine. It is a standalone machine featuring a self-contained booster heater. The only external connections necessary are power supply, water supply, drainpipe, and optional chemical dispensers. The machine uses re-circulated wash water and fresh water final-rinse.

Operation of the CMA-180UC is extremely user friendly. To initially fill the machine each day, push the switch marked “FILL”. The machine is full when water begins to flow into the scrap tray. The booster tank heater will maintain the wash water temperature at 155°F. The booster heater will produce a minimum of 180°F final rinse water each cycle.

The supply water to the CMA-180UC must be a minimum of 140°F at 24 PSI (Pounds per Square Inch) with a 6 GPM (Gallons Per Minute) flow rate and 60 GPH (Gallons Per Hour) recovery rate. The pipe supplying the water must be ½” minimum. The plumbing connection is located at the back of the machine. (See specification sheet on page

The drain is a 1" barbed fitting on the back of the machine for easy attachment of your drain hose.

The machine retains the features of the standard CMA-180 Series in that it has a scrap tray and the manner in which the tank is filled ensures that the dishes are always rinsed with fresh water instead of re-circulated water. The CMA-180UC is the first under-counter dishmachine of its kind to discharge soil from the wash tank into a scrap tray outside of the wash chamber. This feature keeps the wash water much cleaner over long periods of time. The scrap tray may be emptied on a periodic basis without interruption of the flow of work, thereby providing a much cleaner environment for the wash and rinse cycle. There are also enhancements that can be chosen when required such as drain pump kits and other accessories. Refer to Section for the parts list and accessories available for the machine.

This manual is structured to provide a complete reference guide to the CMA-180UC. It is presented in a manner that all users will be able to comprehend and use as an effective tool in supporting the operation and maintenance of the dishmachine. The first section explains how the machine is packaged and what to look for when receiving the machine.

After unpacking the machine, this manual explains how to install and set up the machine for use. Requirements are given for plumbing, wiring, and space considerations. These attributes of the

machine are always taken into consideration by our well-trained sales representatives prior to the order being placed. In the manual, guidance is also given for installation to ensure that the

machine will be able to run at optimum conditions. The

Operation Section of the manual may be used for instruction and procedures when required. We make this portion of the manual easy to understand so that all levels of operators may be able to read and comprehend the operation of the machine. The function of the machine itself is mostly automatic and takes little training to put into full operation. The includes diagnostic considerations for the machine when problems occur.

The next section of the manual is the diagram for the machine. CMA warranties the workmanship of the machine.

We are committed to providing the best machines and customer service in the food industry and your feedback is welcome.

Parts Manual. This section has the parts lists and wiring

2).

4 “Parts Manual”

Operation Section also

MODEL CMA-180UC SERVICE & PARTS MANUAL Rev. 1.10 Page

Getting Started

2.2. Receiving and Installation

The dishwasher is shipped from the factory in a corrugated box on a wooden pallet. The installation guidelines give a systematic procedure for setting up the machine.

Start by removing the packaging material. Unwrap the machine and check for the following component parts:

The Wash Tank Scrap Screen is shipped inside the wash cavity of the machine. This screen must be in place during operation. It has been designed to perform two basic functions:

1. Strain water that is circulating through the spray arms and pump assembly.

2. A basket to catch broken glass, or heavy solids that may plug the impeller.

Set the machine in place, and level from side-to-side and front-to-back.

2.2.1. Electrical

A 50-amp, single-phase 230 volt, 60 Hz dedicated circuit should be used to supply electrical energy to the CMA-180UC dishwasher (see specification sheet page three power wires, which include a current carrying neutral. An additional fourth wire must be provided for ground. CMA and local codes require the CMA-180UC to be hardwired using #8 AWG (90°C) copper wire (minimum). Approximately 4-feet of ¾” flexible conduit with power leads (L-1, L-2, Neutral and Ground) extending out of the conduit are provided for easily connecting the power at installation. The power connection must be located such that there is sufficient length of the flexible conduit remaining to permit the machine to be moved for cleaning.

2.2.2. Plumbing

The machine is equipped with a ½” NPT connection located at the lower left-hand corner (facing the back) of the machine. A 140°F water line should be plumbed to this point (see specification sheet page

2). The water line used must be of sufficient length and flexibility to permit the

machine to be moved for cleaning. The supply water to the CMA-180UC must be a minimum of 140°F at 24 PSI (Pounds per Square

Inch) with a 6 GPM (Gallons Per Minute) flow rate and 60 GPH (Gallons Per Hour) recovery rate. The pipe supplying the water must be ½” minimum. The plumbing connection is located at the back of the machine. (See specification sheet on page

The CMA-180UC may be supplied with an optional drain pump for elevated drains. For floor gravity drain applications the drain pump should not be used and a good commercial grade hose needs to be connected to the discharge side of the diverter valve (drain valve) and run to the floor drain. If removing a drain pump, safe-end (insulate electrically) the white and purple wires and secure them out of the way. If a drain pump is used with a floor drain, the drain hose must rise 12 to 16” before dropping to the floor drain (to reduce any chance of the pump cavitating).

2.2.3. Detergent And Rinse Dispenser

Note: If you are installing the optional CMA Supplied Detergent and Rinse

Dispenser follow the instructions in Section Rinse Dispenser

1. A mounting plate for ½” conduit is provided on the top right-hand corner (facing the back) of the machine. (See section Assembly

All electrical connections must be made by a qualified electrician

All plumbing connections must comply with all safety and plumbing codes

2). This system requires

2).

2.2.4 CMA Supplied Detergent and

4.4 Mechanical Drawings; Cabinet

, item A).

MODEL CMA-180UC SERVICE & PARTS MANUAL Rev. 1.10 Page

Getting Started

i. Run an appropriate length of ½” conduit from your dispenser to the mounting

plate where it will be secured. The conduit needs to be of sufficient length and flexibility to permit the machine to be moved for cleaning without having to disconnect any wiring.

ii. Run your dispenser wires from the conduit through the enclosed area across

the top of the machine and feed them through the access hole provided in the back of the control panel drawer.

2. With the machine’s power “OFF”, connect your detergent and rinse dispenser wires to the power block supplied and labeled (“DISPENSER 110V - 3 AMPS MAX”) inside the control panel drawer. See Figures

Connect dispenser ground (if present) to the ground lug located next to the power block. See Figure

2.2.3d.

3. Remove the plug from the mixing chamber located by the vacuum breaker on the back of machine and install the rinse injection fitting (supplied with your dispenser). See Figure

2.2.3b.

4. A 7/8" detergent injection hole is provided in the back of the wash tank. Remove the S.S. plug and install the detergent fitting. See Section Assembly

, item #17.

2.2.3a, and Figure 2.2.3c.

4.4.1 Cabinet

Figure 2.2.3a Figure 2.2.3b

(Dispenser wire connections) (Ground lug)

Figure

2.2.3c Figure 2.2.3d

MODEL CMA-180UC SERVICE & PARTS MANUAL Rev. 1.10 Page

Getting Started

2.2.4. CMA Supplied Detergent and Rinse Dispenser (Optional)

The CMA supplied Detergent and Rinse Dispenser has its own reference manual. Familiarize yourself with the dispenser’s reference manual before proceeding with installation.

1. The CMA supplied dispenser is pre-wired with a multi-conductor electrical cable that is to be run through a conduit to the power block inside the control panel drawer. Use a ½” watertight conduit meeting all local and national codes. A conduit fitting is present on the bottom of the dispenser where the power cable exits. A mounting plate to receive the ½” conduit is provided on the top righthand corner (facing the back) of the machine. (See section Drawings

; Cabinet Assembly, item A).

4.4 Mechanical

i. Run an appropriate length of ½” conduit from your dispenser to the mounting

plate where it will be secured. The conduit needs to be of sufficient length and flexibility to permit the machine to be moved for cleaning without having to disconnect any wiring.

ii. Run your dispenser wires through the conduit and through the enclosed area

across the top of the machine and then feed them through the access hole provided in the back of the control panel drawer.

iii. With the machine’s power “OFF”, connect your deterg ent and rinse dispenser

wires to the power block supplied and labeled (“DISPENSER 110V - 3 AMPS MAX”) inside the control panel drawer. The table that follows lists the function of each conductor of the multi-conductor electrical cable.

Wire Colors Circuit Voltage Function

Gray/Violet 90 VAC-130 VAC 50/60 Hz Main AC Power Black 90 VAC-130 VAC 50/60 Hz Main AC Power Brown This wire is LIVE!

Yellow 90 VAC-130 VAC 50/60 Hz Detergent Signal White/Yellow 90 VAC-130 VAC 50/60 Hz Detergent Signal

Violet 90 VAC -130 VAC 50/60 Hz Rinse Signal White/Violet 90 VAC -130 VAC 50/60 Hz Rinse Signal

No Connection. Insulate this wire!

The individual conductors need to be connected as shown in Figure and as described on next page.

2.2.4

All electrical connections must be made by a qualified electrician

MODEL CMA-180UC SERVICE & PARTS MANUAL Rev. 1.10 Page

Getting Started

(

)

Brown (LIVE) wire

Multi-conductor cable

Rinse Signal wires

Detergent Signal wires

(Red terminals)

Black (Main Power)

Figure 2.2.4

Note: In Figure 2.2.4 the machine’s wire harness was left out of the back of the power block to more clearly show the dispenser wires.

2. Remove the plug from the mixing chamber located by the vacuum breaker on the back of machine; and install the rinse injection fitting (supplied with your dispenser). See Figure

2.2.3b.

3. A 7/8" detergent injection hole is provided in the back of the wash tank. Remove the S.S. plug and install the detergent fitting (supplied with your dispenser). See Section

4.4.1 Cabinet Assembly, item #17.

4. The final step of installing the CMA supplied Detergent and Rinse Dispenser is programming it to your specific application. The reference manual supplied with the dispenser shows you how to program it.

 Keep in mind while reading the reference manual that the CMA-180UC

operates in “probe-less” mode. (This mode is selected by setting a value of “2” in screen 21).

 Screen 22 must be set to “1” (Door).

There are four user functions with this dispenser. Their operation is described in the reference manual. The four user functions are:

(Blue terminals)

Gray/Violet

(Main Power Neutral)

Same terminal as rinse neutral

Note: Machine Neutral

(White wires)

 Rack Counter  Detergent Prime  Rinse Prime  De-Lime

MODEL CMA-180UC SERVICE & PARTS MANUAL Rev. 1.10 Page

Getting Started

2.2.5. Booster Heater Setup

The booster tank must be filled with water before the heating element is energized. For this reason the “High Limit Switch” has intentionally been activated at the factory and will require resetting before the heating element will turn on.

Follow the procedure below to complete the initial installation:

1. Close the door on the machine.

2. Turn the Power switch to the "ON" position.

3. Hold the “FILL” switch in until water overflows into the scrap tray.

4. Turn the Power switch to the "OFF" position.

5. Reset the High Limit Switch by pressing its reset button (the High Limit Switch is located behind the thermostat, which is behind the front kick panel). See section

2.2.6. Installers Checklist

 Dishmachine checked for concealed damage  Hot water supply is 140° F (60 C) — minimum  Incoming water supply line is ½” — minimum  Incoming water supply is 6 GPM minimum at 24 PSI  Supply circuit breaker for machine is properly sized (50 amp)  Service voltage and phase type are correct to machine data plate  If drain pump is used, drain hose rises 12 to 16” before dropping to drain  Drain hose is installed with air gap (discharge 1” above drain)  Optional detergent and rinse dispenser (if present) is properly installed  Dishmachine is properly grounded  Dishmachine is properly leveled  Machine circuit breaker is labeled “DISHWASHER”  Machine has been “hard-wired” with correctly sized wire  Booster tank has been filled with water (before High Limit Switch is reset)  High Limit Switch for heater has been reset (after Booster Tank has been filled)

4.4.10 Heater Assembly, item #3.

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