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TECHNICAL MANUAL
Counter Type Dishwasher
Ensign 40-2
Installation, Operation and Maintenance Instructions
Insinger Machine Company
6245 State Road
Philadelphia, PA 19135-2996
800-344-4802
Fax 215-624-6966 www.insingermachine.com
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Thank you for purchasing this quality |
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Insinger product. |
TABLE OF CONTENTS |
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On the space provided below please record the |
Part 1 |
1-6 |
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model, serial number and start-up date of this unit: |
Technical Information |
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Model:__________________________________ |
• Catalog Cut-sheet |
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• Introduction |
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Serial Number:___________________________ |
• Warranty |
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Part 2 |
7-8 |
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Start-Up Date:____________________________ |
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Installation Instructions |
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When referring to this equipment please have this |
• Installation Drawing |
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information available. |
Part 3 |
9-14 |
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Each piece of equipment at Insinger is carefully |
Operating Instructions |
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• Operation and Cleaning Instructions |
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tested before shipment for proper operation. If the |
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• Maintenance and Repair Procedures |
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need for service should arise please contact your |
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• Basic Service Guide |
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local Authorized Insinger Service Company. |
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A Service Network Listing is provided on our web |
Part 4 |
15-35 |
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site, www.insingermachine.com or call Insinger at |
Electrical Schematics & Replacement Parts |
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800-344-4802 for your local authorized servicer. |
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For proper activation of the Insinger Limited |
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Warranty a SureFire™ Start-Up & Check-Out Service |
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should be completed on your machine. Refer to the |
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Introduction section in this manual for an explanation |
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of Insinger SureFire™ Start-Up & Check-Out |
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Program. |
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Please read the Insinger Limited Warranty and all |
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installation and operation instructions carefully before |
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attempting to install or operate your new Insinger |
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product. |
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To register your machine for warranty by phone, fax |
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or the internet or for answers to question concerning |
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installation, operation, or service contact our |
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Technical Services Department: |
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TECHNICAL SERVICE CONTACTS
Toll-Free |
800-344-4802 |
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Fax |
215-624-6966 |
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service@insingermachine.com |
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Web site |
www.insingermachine.com |
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Ensign_40-2_TM2009 |
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PART 1 TECHNICAL INFORMATION
Item #_____________
ENSIGN 40-2
AUTOMATIC SINGLE TANK
COUNTER TYPE DISHWASHER
DESIGN
Automatic counter type single tank dishwasher with telescoping hood and timed wash and rinse cycle. Capacity is 43 racks per hour or 720 dishes. Fully automatic operation with power on/off button. Cycle starts when door is closed. Designed for straight through operation.
STANDARD EQUIPMENT
●Tank heat: electric immersion heater or steam injector
●Thermometer for wash
●Thermometer for final rinse
●Vacuum breaker
●Manifold cleanout brush
●Automatic tank fill
●Low water protection
●Detergent connection provision
●SureFireTM Start-Up and Check-Out Service
●Space saving compact design
●Single point electrical connection: motor, controls, heater
●Fully automatic operation
●Side mounted control panel (NEMA 12)
●Simplified scrap screen design
●Standard frame drip proof motor
●Door safety switch
OPTIONAL ACCESSORY EQUIPMENT
Stainless steel steam coil tank heat
Pressure reduction valve and line strainer
S/S frame
Steam booster
Remote electric booster
Totally enclosed motor
Plastic 16” x 16” racks (2 plate racks, 2 silver racks)
11400 - CSI
6245 State Road Philadelphia, PA 19135-2996 215-624-4800
215-624-6966 FAX
800-344-4802
www.insingermachine.com
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PART 1 TECHNICAL INFORMATION
ENSIGN 40-2
CSI - 11400
Note: For all rough in connections see Installation and Layout Detail Drawing.
SPECIFICATIONS
CONSTRUCTION - Hood and tank constructed of 16 gauge 18-8 type 304 S/S. Hood unit of all welded seamless construction. All internal castings are non-corrosive lead free nickel alloy or bronze.
DOORS - Two opening operating doors. Operating doors have fingertip control, rotating on S/S bracket. Doors formed of 18 gauge 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, extension or sleeve. All working parts mounted as an assembly and removable as a unit without disturbing pump housing. One 1/2 HP motor, standard horizontal C-face frame, drip proof, internally cooled with ball-bearing construction.
CONTROLS - Side-mounted control cabinet, 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 pipe.
WASH - Power wash arm above with 14 high pressure action cleansing slots and 6 power wash arms below, each designed with 5 high pressure action cleansing slots. The slots are precision milled for water control producing a fan spray. Wash arms are removable without the use of tools.
FINAL RINSE - 1 spray body above designed with 4 power rinse nozzles and 1 power rinse coil below designed with 6 nozzles.
DRAIN - Overflow assembly with skimmer is removable without use of tools for drain line inspection. Heater protected by low water level controls.
Capacity |
Tank capacity |
Motor size |
Electric usage |
Steam consumption |
Final rinse |
per hour |
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at 20 psi min. |
peak flow |
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1.5 kw wash tank |
6 lbs./hr tank |
at 20 psi min. |
43 racks |
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8.1 gals. |
1/2 hp (wash) |
6 kw booster 40° rise |
22 lbs./hr rem. booster 40° rise |
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720 dishes |
12 kw booster 70° rise |
43 lbs./hr rem. booster 70° rise |
4.1 gals./min. |
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Peak rate |
Shipping |
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Final rinse |
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Exhaust hood |
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Current draw |
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Steam |
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Electric |
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consumption |
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requirement |
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drain flow |
weight |
amps |
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w/o booster |
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at 20 psi min. |
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115/1/60 |
10.7 |
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24.0 |
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.....................208/3/60 |
......................2.9 |
7.1 |
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240/1/60 ..................... |
5.6 ..................... |
11.3 |
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34 gals./hr. |
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N/A |
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240/3/60 ..................... |
2.6 ...................... |
6.2 |
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380/3/50 ..................... |
1.6 ...................... |
3.9 |
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0.75 gals./rack |
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9 gals./min. |
400 lbs. |
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480/3/60 ..................... |
1.4 ...................... |
3.1 |
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3M 0808 PRINTED IN USA
Information and specifications subject to change without notice
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PART 1 TECHNICAL INFORMATION
ENSIGN 40-2
INTRODUCTION
Purpose
The purpose of this technical manual is to provide installation, operation, cleaning and maintenance directions.
A section is provided for replacement parts.
Scope
This manual contains all pertinent information to assist in the proper installation, operation, cleaning, maintenance, and parts ordering for the Insinger Ensign 40-2.
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. You can speak to the
Insinger Technical Services Department, 800/344-
4802, or e-mail us at service@insingermachine.com. 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.
Surefire™ Start-up & Check-out 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 at optimum levels from the very first pass. Please call the factory or your local
Insinger Sales Representative to schedule this service.
NSF 3-2008 requirements for detergent and chemical sanitizer dispensers.
This machine must be operated with an automatic detergent dispenser and, if applicable, an automatic chemical sanitizer feeder, including a visual means to verify that detergents and sanitizers are delivered or a visual or audible alarm to signal if detergents and sanitizers are not available for delivery to
the respective washing and sanitizing systems. Please see instructions for electrical and plumbing connections located in this manual and in the feeder equipment manual.
Definitions
Throughout this guide you will find the following terms: WARNING, CAUTION, & NOTE.
WARNING indicates potential physical danger. CAUTION indicates potential equipment damage. NOTE indicates helpful operating hints or tips.
You will visually be able to identify each as shown below:
NOTE:
Indicates helpful operating hints or tips.
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WARNING: |
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Indicates potential physical danger. |
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CAUTION: |
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Indicates potential equipment damage.
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PART 1 TECHNICAL INFORMATION
Ensign 40-2 Counter Type Dishwasher Safety Summary
The following are general safety precautions that are not related to any specific procedures. These are recommended precautions that personnel must understand and apply during many phases of operation and maintenance.
Keep Away From Live Circuits
Operating personnel must at all times observe all safety regulations. Do not replace components or make adjustments inside the equipment with the high voltage supply turned on. Under certain conditions, dangerous potentials may exist when the power control is in the off position. To avoid casualties, always remove power, red tag machine and ground a circuit before touching it.
Do Not Service or Adjust Alone
Under no circumstances should any person reach into or enter the enclosure for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable of rendering aid.
Resuscitation
Personnel working with or near high voltages should be familiar with modern methods of resuscitation. Such information may be obtained from the Bureau of Medicine and Surgery.
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PART 1 TECHNICAL INFORMATION
INSINGER MACHINE COMPANY LIMITED WARRANTY
Insinger Machine Company, Inc. (Insinger) hereby warrants to the original retail purchaser of this Insinger Machine Company, Inc. product, that if it is assembled and operated in accordance with the printed instructions accompanying it, then for a period of either 15 months from the date of shipment from Insinger or 1 year (12 months) from the date of installation or start-up that said Insinger product shall be free from defects in material and workmanship. Whichever one of the two aforestated limited warranty time periods is the shortest shall be the applicable limited warranty coverage time period.
Insinger may require reasonable proof of your date of purchase; therefore, you should retain your copy of invoice or shipping document.
This limited warranty shall be limited to the repair or replacement of parts which prove defective under normal use and service and which on examination shall indicate, to Insinger’s satisfaction, they are defective. Any part that is claimed to be defective and covered by this limited warranty must be returned to Insinger. An RMA# must be obtained from the Insinger Warranty Department before returning any material. Return may be done through an Authorized Service Agency. Furnish serial number of machine and RMA # with shipment and send to:
Insinger Machine Company 6245 State Road Philadelphia, PA 19135-2996
If Insinger’s inspection confirms the defect and the claim, Insinger will repair or replace such part without charge and return it to you freight or postage prepaid.
This limited warranty does not cover any failure or accident, abuse, misuse, alteration, misapplication, improper installation, fire, flood, acts of God or improper maintenance or service,
or failure to perform normal and routine maintenance as set out in the instruction booklet (operating instructions) or for improper operation or failure to follow normal operating instructions (as set out in the instruction booklet). Insinger is not responsible nor liable for any conditions of erosion or corrosion caused by corrosive detergents, acids, lye or other chemicals used in the washing and or cleaning process.
Service must be done by either Insinger Appointed Service Agencies or agencies receiving prior authorization from Insinger.
All warranty work must be done during normal working hours, unless purchaser receives prior authorization from Insinger.
There are no other express warrants except as set forth herein and any applicable implied warranties of merchantability and fitness are limited in duration to the period of coverage of this express written limited warranty. This limited warranty supersedes all other express warranties, implied warranties of merchant-ability and fitness or limited warranties as of this date, January 1, 1998. Some states do not allow limitation on how long an implied warranty lasts so this limitation may not apply to you.
Insinger is not liable for any special, indirect or consequential damages. Some states do not allow the exclusion or limitation of incidental or consequential damages, so this limitation nor exclusion may not apply to you.
Insinger does not authorize any person or company to assume for it any other obligation or liability in connection with the sale, installation, use, removal, return or replacement of its equipment: and no such representations are binding on Insinger.
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PART 1 TECHNICAL INFORMATION
INSINGER MACHINE COMPANY LIMITED WARRANTYCOMMERCIAL MARINE USE
Insinger Machine Company, Inc. (Insinger) hereby warrants to the original retail purchaser of this Insinger Machine Company, Inc. product, that if it is assembled and operated in accordance with the printed instructions accompanying it (installation manual), then for a period of 15 months from the date of installation on board the vessel, that said Insinger product shall be free from defects in material and workmanship.
Insinger may require reasonable proof of your date of equipment install, therefore, you should retain your copy of invoice or shipping document.
This limited warranty shall be limited to the replacement of parts which prove defective under normal use and service and which on examination shall indicate, to Insinger’s satisfaction, they are defective. Any part that is claimed to be defective and covered by this limited warranty must be returned to Insinger. Furnish serial number of machine with shipment and send to:
Insinger Machine Company, Inc.
6245 State Road
Philadelphia, PA 19135-2996
If Insinger’s inspection confirms the defect and the claim, Insinger will repair or replace such part without charge and return it to you freight or postage prepaid. If part damages are not covered, Insinger will contact the customer and advise.
If a factory trained authorized technician is required to repair or replace defective parts or material during the 18 month warranty period, the cruise line will be responsible for the payment of travel expense and a minimum of four hours labor.
Labor will be billed to the customer at a reduced rate of $40.00 per hour. If sailing with a vessel is required, then an eight hour per day minimum will apply.
This limited warranty does not cover accident, abuse, misuse, alteration, misapplication, improper installation, fire, flood, or improper maintenance or service, or failure to perform normal and routine maintenance as set out in the instruction booklet (operating instructions) or for improper operation or failure to follow normal operating instructions (as set out in the instruction booklet).
Insinger is not responsible nor liable for any conditions of erosion or corrosion caused by corrosive detergents, acids, lye or other chemicals used in the washing, caring and or cleaning process.
Warranty service must be done by either Insinger Appointed Service Agencies or agencies, customers galley engineers receiving prior authorization from Insinger.
There are no other express warrants except as set forth herein and any applicable implied warranties of merchantability and fitness are limited in duration to the period of coverage of this express written limited warranty. This limited warranty supersedes all other express warranties, implied warranties of merchantability and fitness or limited warranties as the above date.
Insinger does not authorize any person or
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locally or overseas to assume for it |
any other |
obligation or liability in connection |
with the sale, installation, use, removal, return or replacement of its equipment; and no such representations are binding on Insinger.
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PART 2 INSTALLATION INSTRUCTIONS
INSTALLATION INSTRUCTIONS
Ensign 40-2 Counter Type Dishwasher
Machine Specifications
Insinger model Ensign 40_2 stainless steel counter type dishwasher with automatic timing of the wash and rinse cycle with either electric immersion heater for tank heat and electric heat exchange booster for rinse or steam coils for tank heat and steam heat exchange booster for rinse.
ELECTRICAL REQUIREMENTS
(specified by end-user):
1/2 HP, 110-120/240 single phase or 208-220/460VAC three phase, 60 cycle. Motor operates through a timed cycle controller. Rinse operates through a 24VAC solenoid valve actuated by the timed cycle controller.
Feed:
Side door loading, counter top installation. Direction of feed specified by end-user.
Tools:
No special tools required for cleaning or maintenance. Cleanout brush provided for the spray pipes. Machine must be welded into the tabletop (unless provided with a stand).
Dishbaskets:
16” square plastic inserts.
Placement
Carefully uncrate machine. Take caution not to damage components which may be mounted on the top or sides of the machine. Set unit in the table cutout. Refer to installation drawing in this section for table cut-out dimensions. Weld the dish machine into the table. Install temp gauges.
Electrical Connections
Connect electrical lines sized for the correct voltage, current and phase of the machine. These should agree with the machine requirements indicated on the nameplate and labels on the control panel. A singlepoint electrical connection is provided for the pumps, control circuit, and wash tank heater. If an electric booster is provided, connect power directly to the booster.
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.
Chemicals
Upon the completed installation of the dishwasher, contact a local detergent/chemical supplier for the correct chemicals for your soil load and geographical area.
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
CAUTION:
When connecting on the 24VAC control voltage side of the transformer, total VA must not exceed 50VA.
Tabling
Load and unload tables should be pitched towards the machine to return excess water into the machine.
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PART 2 INSTALLATION INSTRUCTIONS
Initial Start-Up Adjustments
Tank Overfill Adjustment
1.Locate tank overfill timer in the control panel.
See the control panel layout drawing located in Section 4, Electrical Schematic and Replacement Parts.
2.The overfill timer starts timing when the upper level float is actuated. Adjust the overfill timer potentiometer to turn the tank fill solenoid off when the water level is 1/4” below the lip of the overflow tube.
3.The timer has a built in dwell timing delay of 5 seconds (nominal to dampen float bounce caused by tank water motion).
Final Rinse Pressure Adjustment
1.The final rinse pressure must be adjusted to
20PSI. This is done by adjusting the pressure regulator.
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PART 3 OPERATION & CLEANING INSTRUCTIONS
Insinger dishmachines are user-friendly, making them the easiest dishmachines on the market to operate and maintain. By following these operating procedures your Insinger dishwasher will give you years of trouble free service.
OPERATION INSTRUCTIONS
1.Ensure drain overflow tube is in place. Close all tank drain valve. One drain is provided for each tank of the dishmachine.
2.Check for proper installation and cleanliness of all internal, removable components such as suction strainers, scrap screens, and spray manifolds.
3.Ensure all water & steam lines are open. Ensure electrical circuits are on.
4.Close machine doors.
NOTE:
An interlock is provided to shut the machine down if the doors are open, therefore the machine will not run if the doors are opened.
5.Press the power switch to the ON position. The switch will light up red when on. The machine will fill the tank, run through a complete wash/rinse cycle and shut-off.
6.When the tank is full the tank heat will operate automatically. Proper wash tank temperature is
160º F minimum. Proper final rinse temperature is 180º F minimum at 20 PSI ± SPSI, while in the final rinse cycle.
CAUTION:
To ensure proper operation of the auto tank fill feature and the tank heaters,
the tank level floats MUST be cleaned daily.
7.Open doors.
8.Insert a rack of soiled dishware in machine and lower doors. Depress the cycle start button, machine will wash and rinse automatically. When the rinse indicator light goes off the machine cycle is complete.
CAUTION:
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 hot water may spray out if doors are opened too quickly.
9.Open doors and remove rack of clean ware. For continuous operation repeat steps 7-9.
10.Upon completion of ware cleaning press the power switch to the “OFF” position. The switch light will go off.
11.Refer to the cleaning procedures for proper clean-up of the dishmachine.
12.A switch on the control panel labeled “De-lime” is provided for use when de-liming the machine.
When activated, this switch will keep the machine in an indefinite wash cycle.
13.A switch on the control panel labeled “Heavy
Cycle” will activate the extended wash cycle for heavily soiled ware.
14.Report any unusual occurrences to qualified service personnel.
The following cleaning procedures should be done daily, at the end of the shift.
Cleaning Procedures, Daily
1.Turn the power switch to off.
2.Drain unit by removing overflow tube.
3.Metal surfaces may be hotuse caution.
4.Remove all internal removable parts including spray manifolds, scrap screens, drain overflow tube and suction strainer.
5.Remove the end caps from the spray manifolds and clean with the brush provided. Flush the manifolds.
6.Flush scrap screens
7.Clean drain overflow tube.
8.Clean suction strainer of build-up
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®PART 3 OPERATION & CLEANING INSTRUCTIONS
CLEANING PROCEDURES (continued)
9.Clean the tank level float with a plastic abrasive pad
(do not use steel wool).
10.Final rinse nozzles should be cleaned of matter clogging the jet spray.
11.The doors should be left open to allow drying of interior surfaces.
NOTE:
Improper cleaning of the suction strainers will cause the pumps to cavitate. This will cause poor washing results.
CAUTION:
Level floats must be cleaned daily.
Build-up of grease and dirt will cause faulty operation of the tank fill heating system.
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