® TECHNICAL MANUAL UNDERCOUNTER DISHMACHINE GS 302 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 Undercounter DOC GS 302 1.0 05 www.insingermachine.
® Thank you for purchasing this quality Insinger product. On the space provided below please record the model, serial number and start-up date of this unit: Model:__________________________________ Serial Number:___________________________ Start-Up Date:____________________________ When referring to this equipment please have this information available. Each piece of equipment at Insinger is carefully tested before shipment for proper operation.
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PART 1 ® TECHNICAL INFORMATION GS 302 UNDERCOUNTER DISHWASHER INTRODUCTION Purpose The purpose of this technical manual is to provide installation, operation, cleaning and maintenance directions. Intended use The Insinger dishwasher GS 302 may only be used for cleaning plates, cups, dishes, cutlery and similar restaurant ware and commercial catering. A section is provided for replacement parts.
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.
PART 1 ® TECHNICAL INFORMATION INSINGER MACHINE COMPANY LIMITED WARRANTY COMMERCIAL MARINE USE 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. Insinger Machine Company, Inc. (Insinger) hereby warrants to the original retail purchaser of this Insinger Machine Company, Inc.
® PART 2 INSTALLATION INSTRUCTIONS INSTALLATION AND CONNECTION ! Connection to the Power Supply: Before using the washer, check that all electrical protection systems are working correctly. Attention: The machine should not be regarded as isolated from the power supply unless switched off at the customer’s main switch.
PART 3 ® OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Operating Panel The operating panel is situated in the upper part of the machine.
PART 3 ® HOW THE DISHWASHER WORKS OPERATING INSTRUCTIONS As soon as the target temperatures are reached, (wash water approximately 150°F; final rinse water approximately 180° F) the washer is ready for operation. The program button (6) then lights up green. When the machine is switched on, the booster and wash tank fill and are heated to operating temperature. The program button (6) is lit red during heating. The booster preheats the wash water before pumping to the wash tank.
PART 3 ® OPERATING INSTRUCTIONS WASH PROGRAMS The dishwasher can operate in a normal time cycle or an extended time cycle (additional 80 seconds added to the wash cycle.) The individual programs are selected by means of the control panel. Program (button) Description Normal Program (3) For normal soiling. Medium drying time. Extended Program (4) For heavy soiling. Long drying time.
PART 3 ® Changing the Detergent Type. If changing to a different detergent type (even one by the same manufacturer), you must rinse the suction and pressure hoses with fresh water before connecting the new detergent container. Otherwise, the mixing of different types of detergent will cause crystallization, which may result in a breakdown of the dosing pump. OPERATING INSTRUCTIONS Washing with the Normal Program Push the full wash rack into the machine and close the door. Press program button (3).
PART 3 ® OPERATING INSTRUCTIONS WASHING (CONTINUED) Extensive Program Use: Depending on the level of soiling on the wash items, select the button indicating extended wash time. Press the button to select the extended wash program. ; NOTE: The short cycle is not available with this machine. Press the button to start the program. Draining the Tank; Rinsing the Chamber Remove the rack. Close the door. Hold down the function button for three seconds to start the rinsing program.
PART 4 GENERAL MAINTENANCE ® GENERAL MAINTENANCE The washer should be regularly cleaned to ensure that it remains reliable and in good working order for many years to come. Reinsert the bottom wash trays. CAUTION: Clean the outer walls of the washer with cleaning products for high grade stainless steel. Do not spray the outside of the washer with a high pressure or steam jet cleaner. Every Day After Washing Open the door slightly using the to the vent position.
PART 4 GENERAL MAINTENANCE ® DELIMING PROCEDURES FOR THE GS 302 (CONTINUED) C 1 1. 2 3 A Note and record detergent dose setting.Turn off unit (Button 1) Press and hold Buttons 2 & 3 simultaneously, while holding these buttons press button 1. P11 in visible display A. Note value in display B. 2. Press Button 7 (to decrease detergent dosage) until display B display reads “10”. 3. Press button 4 to store value. 4. Drain Machine.
PART 5 MAINTENANCE AND REPAIR PROCEDURES ® Combination of Buttons C 1 2 Button 3 Function A B 4 Remark 5 7 8 Button 6 Function 1. Set Up Parameter Mode 3. Quit parameter mode or test mode 1 Switch off machine 1 Switch off machine ON Set service switch to ON OFF Set service switch to OFF 1 Switch on machine 1 Switch on machine 5 Parameter backwards 6 Parameter forwards 7 Parameter value backwards Display A: P00=parameter set P01-P050= parameters 4.
® PART 5 MAINTENANCE AND REPAIR PROCEDURES Combination of Buttons C 1 2 Button 3 Function A B 4 5 7 8 6 Remark 6. Prime the detergent unit, set concentration Direct to P11 1 Switch off machine 2+3 Keep pressed 1 Switch on machine 2 Keep pressed to ventilate unit 7 Decrease dosage of detergent 8 Increase dosage of detergent 4 To store altered value P11 in display A Value x 0,1 ml/ L Button 3 glows red 7.
PART 5 MAINTENANCE AND REPAIR PROCEDURES ® Parameter Set C 1 2 3 SET A B 4 5 7 8 6 Specification Factory Setting Multiplicator P00 Parameter set 121 Standard 120 w/water softener P01 Tank target temperature Tank filling temperature: Min. temperature 169°F (P01+15) Max. temperature 185°F (P01+31) 154 °F P02 Boiler target temp. 1 182 °F P03 Boiler target temp. 2 (149) Option 149 °F P06 Time of wash pump, normal program (135sec) 27 5 sec.
PART 5 MAINTENANCE AND REPAIR PROCEDURES ® Parameter Set C 1 SET 2 3 A B Specification 4 5 7 Factory Setting P24 Simple door start (0:no/1:yes) P25 Error management (1: activated/0: not activated, however the 1 safety criterias are activated) P26 Automatic tank draining and refilling 2: yes if tank temp.
PART 5 MAINTENANCE AND REPAIR PROCEDURES ® Inputs and Outputs C 1 2 3 A B 4 5 7 8 6 Test Mode (table for output/input) Display A Specification Safety Criteria Display B 101 Tank heating 1 Min. tank level present Temp. below 182°F A02 Boiler heating Min. boiler level present Boiler temp. in °F Temp. below 182°F A03 Soft starter for wash pump Door closed A08 Relay soft start A09 Rinse pump M3 Door closed Tank level in mm A10 Dos. Rinse Aid Door closed 1 or 0 A11 Dos.
® PART 5 MAINTENANCE & REPAIR PROCEDURES TROUBLESHOOTING Work on the electrical equipment should only be performed by service personnel. First disconnect the washer from the main power switch. Do not switch the washer on again until the cause of the fault has been identified. Faults where it is not necessary to call Insinger. You can rectify minor faults yourself following the steps described in the table below. If you are unable to rectify the fault, contact Insinger service (1-800-344-4802.
PART 5 ® MAINTENANCE & REPAIR PROCEDURES TROUBLESHOOTING (CONTINUED) Faults where it is necessary to call Insinger Service. Display Possible Cause Flashing light: Temperature in booster or tank is greater than 203°F. Caution: Surface is very hot. The fault (3) symbol appears together with the fault code Err 2 or Err 3. Switch off main switch. Notify the Insinger service team immediately.
® PART 5 MAINTENANCE AND REPAIR PROCEDURES Error Management Error Code Fault Description Machine/Fault Reaction Cause Panel Input Acuator Actuator Display Short circuit Broken cable 1 Wash tank level sensor E3 Shuts down No connection to WPS board Short circuit Tank heater shuts down 2 Wash tank temp sensor Wash button flashes red Broken cable No connection to WPS board E1 A01 Tank Temp A12 Shows tank level in mm, level will drop if pump is operating Tank temp exceeds 203F Short circuit
® PART 5 MAINTENANCE AND REPAIR PROCEDURES Error Management (CONTINUED) Error Code Fault Description Machine/Fault Reaction Panel Input Cause Acuator Actuator Display Defective 7 Booster heater Blown Fuse No temp increase within 5 minutes Improper connecof turning on mation chine K2 Defective contactor Blown Fuse 8 Wash tank heater 9 Machine losing water No temp increase Improper connecwithin 30 minutes tion of turning on Defective contactor Water level drop greater than 3/4” K3 Leak C
® PART 5 MAINTENANCE AND REPAIR PROCEDURES Error Management (CONTINUED) Error Code Fault Description Machine/Fault Reaction Panel Input Cause Acuator Actuator Display Incoming water line blocked 15 Fill time fault-booster No water in booster detected within 6 minutes Y3 Defective level sensor booster E12 Short circuit E4 17 Final rinse temp sensor 18 Parameter 00 not set @ 121 Changed WPS board 19 Water level inc of 10mm/ Water pumped min detected w/closed so- out by drain pump lenoi
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Water Inlet Item Description Parts No. Pc. 1 WSE with impeller counter kit GS6000312 1.1 O-ring; 24 x 3 GS2707066 1.2 Hose clip; D14-24 x 9 GS2802108 3 Shaped hose; DN10 x DN12; 549 GS60003154 4 Shaped hose; DN12, 5 x 3, 5; 780 GS60003163 5 Dirt catcher coupling GS80002153 5.1 Gasket; D16 x D24 x 3.0 GS80002241 5.2 Double nipple; G 3/4” x 40; SW30 GS80002167 5.3 Strainer cpl.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Water Drainage, Mediamat Cyclo Item Description Parts No. 1 Filter cartridge (scrap screen basket) GS60003039 2 Flat filter; 32, 5 x 238 x 547 scrap screen GS60003414 3 Mediamat Cyclo kit GS60003513 3.1 O-ring; 17 x 3 GS2707068 3.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Wash Pump Item Description Parts No. Pc. Notes Pump motor kit; 240V/1 PH/60HZ GS60003595 We recommend ordering the set of pump running wheels, as well, when the motor is replaced. Pump motor kit; 208V/1 PH/60HZ GS60003596 We recommend ordering the set of pump running wheels, as well, when the motor is replaced. 1.1 Sealing for pump system kit GS60003591 1.2 Capacitor; 10YF 400V;D35 X 80 GS3113120 1.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Bottom Washing/Rinsing System Item Description Parts No. Pc. 1 Wash unit support; 70,70 LG GS60003435 2 Self-locking nut with serrated surface; M5 GS2101310 2 3 Wash unit cpl GS60002994 2 4 Revolving rinse arm kit GS60003515 4.1 Revolving arm screw; M12 X 30; SW20 GS60003045 4.2 Washer; D12,5 X D24 X 2,5 GS60003386 4.3 O-ring; 10 X 2,5 GS2707030 5 Wash unit support; 58,04 LG GS60002999 6 Distributor top kit GS60003516 6.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Top Washing/Rinsing System Item Description Parts No. 1 Shaped hose; DN12,5 X DN14 X 3,5 GS60003160 2 Revolving rinse arm kit GS60003515 2.1 Washer; D14,10 X D20 X 1,0 GS60003487 2.2 Locking ring; D12 X 0,8 GS60003023 2.3 Washer; D16,1 X D22 X 1,0 GS60003264 2.4 Sliding ring; D22 X D16,30 X 1 GS60003173 2.5 Revolving arm screw; M12 X 31,3; D20 GS60003022 3 Set of rotary arms washing GS60003520 3.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Pressure Independent Boiler Item Description Parts No. Pc. 1 Hose clip; D14-24 X 9 GS2802108 2 Shaped hose; DN12,5 X DN25; 582 GS60003159 3 Hose clip; D24-36 X 12 GS2802111 4 Countersunk screw; M6 X 16 GS2012319 5 Pump 0.27kW 3/3; 220V/240V/1/60HZ GS3102461 5 Pump 0.27kW 3/3; 200V/1/60HZ GS3102463 5.1 Capacitor; 5 mikro F GS3113099 5.2 Spring washer; B8 GS2303301 5.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Dosage Item Description Parts No. Pc. Notes 1 Dispenser nipple kit; M10 X 29; SW5 GS61005883 1.1 O-ring; 10 x 2,5 GS2707030 1.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Chassis, Container and Paneling Item Description Parts No. Pc. 1 Cover plate cpl.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Door Item Description Parts No. Pc. 1 Door seal GS60003066 2 Washer; D5,3 X D15 X 1,2 GS2205301 3 Right stop GS60003411 4 Hexagonal nut M5 GS2105302 5 Leaf spring kit GS60003744 6 Brace right, offset, cpl. GS60003231 7 Cylinder head screw; M5 X 12 GS2003307 2 8 Door bearing bolt; D9,5 X D7,0 X M5; SW4 GS60003147 2 9 Door cpl. GS80002919 10 Door handle kit GS60003522 10.1 O-ring; 5 X 1,2 GS2707070 2 10.
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PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Electrical Parts Item Description Parts No. Pc. Notes 1 Protective cover UL/CSA; white; WEISS GS60003730 2 Self-locking nut with serrated surface; M5 GS2101310 3 Soft start WSA4 GS3113180 4 Cover UL/SCA; white; WEISS GS60003729 5 Pressure transmitter sensor; 0-30MBAR; 5VDC/0, 5-3.
PART 6 ® ELECTRICAL SCHEMATICS & REPLACEMENT PARTS Electrical Parts (CONTINUED) Item Description Parts No. 27 Magnetic switch; 32 X 14, 9 X 6, 9; 400LG GS3124229 28 Operating panel; 25 X 55 X 210 GS3124222 29 Hexagonal nut; M5 GS2101203 30 O-ring; 46 X 6,0 GS2707015 31 Heater with fuse; 2.5kW; 1 X 220-240V GS3103214 31 Heating element 2.6kW plus fuse; 1 X 200-208V GS3103215 O.P. Cable buse; 5 X 0,34QMM GS60003174 Undercounter DOC GS 302 1.0 05 45 Pc. Notes www.
