DP-812-DL-1T DP-813-DLL-1T DP-812-LL-1T DP-813-LLL-1T Introduction The PINNACLE warewash control is a single control board design. This controls all of the system functions. The system requires a single transformer. The PINNACLE responds to detergent and rinse triggers in the range of 50V through 500V 50/60Hz. System Features Probeless detergent control Detergent control without need for a conductivity cell Precise chemical dosing for cost sensitive accounts Eliminates nuisance service calls Door and conveyor options Liquid or dry chemical capability Low chemical alarms Concentration Control High/Low range concentration settings Patent Pending on control software Feed rate adjustment for chemical strength & tank size compensation Liquid or dry chemical capability Probe fault alarm Rinse control Rinse pump speed adjustment Rinse delay adjustment Rinse limit function or override Sanitizer control Sanitizer pump speed function Sanitizer pump may run with rinse or detergent Independent low chemical alarms Low level alarm for each chemical Liquid or dry chemical capability Audible and visual alarm I778 Pg. 1 of 10
Dish Room Survey PINNACLE WAREWASH CONTROL DP-812-DL-1T DP-813-DLL-1T DP-812-LL-1T DP-813-LLL-1T PINNACLE System Installation Prior to installation, take a complete survey of the dish room. Determine the desired placement of the PINNACLE and chemicals. Also determine how the electrical connections will be made. 1. Locate the electrical connection point. The input power may be 120V, 208V, or 240V 50/60Hz standard. A 460V 50/60Hz option is available. Check with the manufacturer of the machine to determine if there are dedicated terminals available for this installation. 2. Mount the DEMAMASTER unit on a flat vertical surface, away from splashing and steam originating from the machine. The unit must be placed so that it can be easily observed and serviced. 3. If the DEMAMASTER will be operating in the concentration mode locate the proper position for the probe in the wash tank. The probe must be installed below the water level, normally 1-2 (30-50 mm) from the bottom of the tank. Probe must be kept away from heating elements, pump intake, drains and incoming water supply. 4. Install the detergent injection fitting above the probe (if a probe is used) to obtain a rapid reading of all chemicals entering the wash tank. 5. Install the rinse line injection fitting into the rinse line tap provided by the manufacturer of the machine. If a tap is not provide follow the manufacturers recommendations for installing this fitting. 6. Install the santitizer injection fitting (if santitizer is being used) into the rinse line tap provided by the manufacturer of the machine. If a tap is not provided follow the manufacturers recommendations for installing this fitting. Electrical Installation Note: All European installations must be carried out by a certified electrical engineer. All other installations must be installed according to local country, city, state, or provincial electrical codes. For questions please contact a local contractor. 1. ALL ELECTRICAL POWER MUST BE TURNED OFF TO THE HEATING ELEMENTS AND DISH MACHINE PRIOR TO BEGINNING INSTALLATION. 2. Connect power to the DEMAMASTER per the dish machine manufacturer s recommendations. Power should be supplied to the DEMAMASTER anytime the dish machine power is on. 3. Connect the detergent trigger to the dish machine per the dish machine manufacturer s recommendations. The DEMAMASTER should receive a detergent trigger any time the wash motor is running. 4. Connect the rinse trigger to the dish machine per the dish machine manufacturer s recommendations. The DEMAMASTER should receive a rinse trigger any time the rinse solenoid is powered. I778 Pg. 2 of 10
Tubing Connections PINNACLE WAREWASH CONTROL DP-812-DL-1T DP-812-LL-1T DP-813-DLL-1T DP-813-LLL-1T DEMA model 82.3 low-level sensors may be used with this control. Connections are provided for three sensors when operating in Feed Forward mode or two sensors when operating in Concentration mode. When operating in Concentration mode make sure S1 position 1 is ON. Unused rinse and santitizer inputs on the control board must have a jumper installed between the terminals. 1. Insert one end of the sensor into the 3 EPDM tube provided with the sensor. Secure with a tie wrap over the tube. See figure 1. 2. Insert the other end of the sensor into the squeeze tube at the inlet of the peristaltic pump. Secure with a tie wrap over the squeeze tube, between the beads. 3. Insert the inlet tubing into the 3 EPDM tube. Secure with a tie wrap. 4. Route the sensor cable into the enclosure and to the control board. 5. Connect the two leads in the sensor cable to the appropriate input on the board. In Feed Forward mode the detergent sensor is connected to the probe inputs and S1 position 1 is set to OFF. See figure 2. 82.4 81.16.1 25.65CE.3 FIGURE 1 Connect the chemical container, via the pump, to the fittings on the machine with LDPE tubing. Install the tubing to the pickup tubes (Grey PVC) through the compression nut, and tighten the nut. Route the tubing to the suction side of the pump. An arrow on the faceplate indicates the flow direction. Push the tubing into the pump squeeze tube approximately 1/2-3/4 (15-20mm). Secure the tubing with a tie wrap around the squeeze tube. Use the same procedure on the outlet of the squeeze tubing to route the LDPE tubing to the injection points of the machine. Cut off all excess tubing. Keep tubing away from hot surfaces and sharp edges to prevent damage or leakage. At this point the installation is complete. I778 Pg. 3 of 10
DP-812-DL-1T DP-812-LL-1T System Set Up DP-813-DLL-1T DP-813-LLL-1T 24VAC 50/60Hz POWER IN TO CONTROL BOARD 24VDC TO DETERGENT MOTOR/VALVE 24VDC TO RINSE MOTOR/VALVE 24VDC TO SANITIZER MOTOR/VALVE RINSE TRIGGER INPUT 80-500VAC 50/60Hz J5 SANITIZER DISPENSE SETTING WITH DETERGENT OR WITH RINSE DETERGENT TRIGGER INPUT 80-500VAC 50/60Hz SANITIZER SPEED RINSE SPEED S2 SWITCH CONCENTRATION OR PROBELESS SANITIZER ALARM PROBE S1 SWITCHES SWITCH 1 STARTS ON FAR LEFT RINSE DELAY TOP OFF RINSE ALARM PROBE DWELL/FEED RATE Figure 2 CONCENTRATION CONTROL PROBE DETERGENT LEVEL SENSITIVITY RINSE LEVEL Figure 1 SENSITIVITY CHARGE/SET POINT MEMBRANE SWITCH/LABEL CONNECTION I778 Pg. 4 of 10
DP-812-DL-1T DP-813-DLL-1T DP-812-LL-1T DP-813-LLL-1T Switch settings Refer to figure 2 to determine the location of the switches described in this section. S2 Move switch up for concentration control with a DEMA C.12B conductivity cell. Move the switch down for Probeless operation. S1 Switch One Probeless detergent alarm defeat On = Detergent level alarm is inactive in Probeless mode Off = Detergent level alarm is active in Probeless mode Always set this switch to ON when using concentration mode. This will prevent false alarms if the control must be switched to Probeless in probe fault situations. Switch Two Conductivity Range for Concentration Mode On = High range Off = Low range This switch has no affect in Probeless mode Switch Three Machine type for Probeless operation On = Door Off = Conveyor This switch has no affect in Concentration mode but should be set to provide proper operation if the control must be switched Probeless in probe fault situations. Switch Four Rinse Limit On = 18 second rinse limit for machines that fill through the rinse solenoid Off = No limit for most conveyor machines Initial Charge Clock Switch Five Switch Six 15 minutes Off Off 2 hours On Off 3 hours Off On 4 hours On On Indicating lights The Detergent, Rinse, and Sanitizer lights will be red when no trigger is present. They will be green when there is a trigger and the pump or valve is running. They will be yellow when there is a trigger and the pump or valve is not running. They will flash when an alarm condition exists. The Probe Fault light will flash red when the probe is shorted or open in the concentration mode. An audible alarm will sound when a light is flashing and a trigger is present. I778 Pg. 5 of 10
Detergent and Rinse Calibration DP-812-DL-1T DP-812-LL-1T DP-813-DLL-1T DP-813-LLL-1T Refer to Figure 2 to locate the various control features that are described in this section. Probeless Mode Detergent Calibration Prior to calibration the system must be primed when using a pump to dispense detergent. The system is primed when the chemical is dispensing from the injection point into the dish machine tank. By pressing the button on the front cover labeled DETERGENT PRIME the pump will run. Simply press and hold until the pump and tubing has been primed. Skip this step when using a solenoid valve to dissolve detergent into the wash tank. The detergent concentration should be set so that the desired level of concentration is maintained while the dish machine is being used. The concentration can be tested by use of a titration test kit (DEMA P/N 81-53), not included. 1. Set the Door or Conveyor mode on S1 (figure 2). 2. Initial Charge Time: This adjustment sets the amount of Initial Charge based on time. This time should be set to dispense the amount of detergent needed for a wash tank of fresh water. When the wash tank is first filled with fresh water and the initial charge is triggered the titration should be at the desired level. An initial charge will be dispensed on the next trigger 1) any time main power is interrupted to the dispenser, 2) any time the rinse limit is reached, 3) any time the initial charge clock expires. 3. 3A. Dead Cycle Count Door Mode Only This adjustment sets the number of wash cycles (door operations) that will take place before a top-off charge will occur. Example: If the Dead Cycle Count is set to 3, there will be three wash cycles where no detergent will be added. On the 4 th cycle a top-off charge will occur. 3B. Dwell Time Setting Conveyor Mode Only Sets the amount of time between top-off charges. Example: Dwell Time is set for 1 min 30 sec. After the control supplies an initial charge or a top-off charge, 1 minute and 30 seconds must expire before the next top-off charge will occur. 4. Top-Off Charge Time: This adjustment is used to set the top-off charge time. This time should be set to add detergent to maintain the desired titration. The top-off and dead cycle or dwell time settings should be made as short as practical to maintain titration and minimize detergent use. If the titration climbs after several racks of dishes decrease the top-off time. If the top-off time is at the minimum increase the dead cycle count or dwell time. 5. Initial Charge Clock: This feature is used to provide an initial charge after a set amount of time expired without providing a detergent trigger to the PINNACLE. Example: Initial Charge Clock is set for 2 hours. If no detergent trigger has been applied to the control for at least 2 hours, the control will provide an initial charge the next time a detergent trigger is applied. I778 Pg. 6 of 10
DP-812-DL-1T DP-812-LL-1T Concentration Mode Detergent Calibration DP-813-DLL-1T DP-813-LLL-1T Setting Feed Rate This potentiometer lets the operator set how fast chemical is put into the dish machine. Turning this adjustment counterclockwise slows the introduction of chemical and reduces overshoot of the set point. Turning this adjustment clockwise gets chemical to the dish machine faster but may cause objectionable overshoot. For most dish machines you will use the lower 1/3 of the range. When in doubt turn it all of the way COUNTERCLOCKWISE. Setting Concentration 1. Make all necessary DIP switch selections. Refer back to the DIP switch definitions and function section to aid in the selection process. 2. Turn the SET POINT and FEED RATE potentiometers on the PINNACLE fully counterclockwise. 3. Remove the pickup tube from the liquid container of chemical during setup. If Dry or Powder dispensers are being used remove dry or powder canister from the Universal Bowl. This prevents chemical from being injected during the setup operation. 4. Now determine degree of water hardness and the capacity of the wash tank. Fill wash tank with water to the proper water level from machine operational manual. Select the predetermined amount of chemical into wash tank to give proper solution strength for tank capacity, water hardness, soil load and miscellaneous items. This will determine the concentration set point. Check chemical concentration with a water titration test kit for proper concentration required. Manually add chemical as needed to meet concentration level. 5. Start the dish machine. The DETERGENT FEED light on front face of PINNACLE unit will turn red. This indicates there is power to the control. 6. Slowly rotate the SET POINT adjustment knob clockwise until the DETERGENT FEED light turns yellow. Wait five seconds and then slowly turn the adjustment knob counterclockwise until the light turns red. 7. Insert chemical pickup tubes in the appropriate liquid container. The PINNACLE is now ready to feed chemical to the dish machine. As the control adds detergent to the dish machine the DETERGENT FEED light will periodically turn yellow. This indicates the control is calculating the amount of detergent needed to reach the proper concentration level. 8. Allow the dish machine to run through several cycles. Adjust the concentration adjustment knob as needed to achieve desired concentration. Rinse Pump Calibration Prior to calibration the system must be primed. The system is primed when the chemical is dispensing from the injection point into the rinse manifold. By pressing the button on the front cover labeled RINSE PRIME the pump will run. Simply press and hold until the pump and tubing has been primed. 1. When a rinse trigger is received the rinse pump will run following the rinse delay. This delay is set with the rinse delay potentiometer. It may be set in the range of 0 (fully counterclockwise) through 12 (fully clockwise) seconds. 2. Set the pump speed to deliver the chemical manufacturer s recommended amount. This amount must be delivered between the end of the rinse delay and the end of the rinse cycle of the machine. 3. An 18-second rinse limit is available. This is primarily used for dish machines that fill the wash tank through the rinse manifold. When switch 4 of S1 is on the rinse pump will stop 18 seconds after the rinse trigger is I778 Pg. 7 of 10
DP-812-DL-1T DP-813-DLL-1T DP-812-LL-1T DP-813-LLL-1T applied. When probeless control is being used for detergent delivery the next detergent trigger (after the rinse limit is reached) will yield an initial charge. Sanitizer Calibration Prior to calibration the system must be primed. The system is primed when the chemical is dispensing from the injection point into the rinse manifold. By pressing the button on the front cover labeled SANITIZER PRIME the pump will run. Simply press and hold until the pump and tubing has been primed. 1. The sanitizer pump may run either with the rinse pump or detergent dispenser. Placing the shunt on the bottom and middle pins of J5 causes the sanitizer pump to run with the rinse pump. Placing the shunt on the middle and top pins of J5 causes the sanitizer pump to run with the detergent dispenser. 2. Apply the appropriate trigger signal and set the pump speed to deliver the chemical manufacturer s recommended amount. Probeless Alarm Set Up This alarm requires a DEMA 82.3 probe for liquid detergents or a DEMA 581E Universal Bowl with conductivity probes for dry detergents. For liquid detergent, turn the detergent sensitivity potentiometer fully clockwise (maximum setting). Set switch 1 on S1 off. For dry detergent, turn the detergent sensitivity potentiometer fully counterclockwise (minimum setting). Set switch 1 on S1 off. Run the dish machine through one cycle with an empty capsule in the DEMA Universal Bowl. The alarm should start. Place a full capsule in the DEMA Universal Bowl. Press the detergent prime button and hold for at least 10 seconds. The alarm should clear. If the alarm does not clear press and hold the detergent prime button. While holding the detergent prime button slowly turn the detergent sensitivity potentiometer clockwise until the alarm clears. If no detergent alarm is connected set switch 1 on S1 on. Concentration Alarm Set Up Set switch 1 on S1 on. No further set up is required. Rinse Alarm Set Up This alarm requires a DEMA 82.8 sensor. For liquid rinse additive, turn the rinse sensitivity potentiometer fully clockwise (maximum setting). CAUTION Many dry rinse additives reduce or have no affect on the conductivity of water. The rinse alarm will not work with these rinse additives. I778 Pg. 8 of 10
DP-812-DL-1T DP-813-DLL-1T DP-812-LL-1T DP-813-LLL-1T For dry rinse additive, turn the rinse sensitivity potentiometer fully counterclockwise (minimum setting). Run the dish machine through one cycle with an empty capsule in the DEMA 581RB Rinse Bowl. The alarm should start. Place a full capsule in the DEMA 581RB Rinse Bowl. Press the rinse prime button and hold until the clear water is flushed from the tubing and rinse additive enters the rinse manifold. The alarm should clear. If the alarm does not clear press and hold the rinse prime button. While holding the rinse prime button slowly turn the rinse sensitivity potentiometer clockwise until the alarm clears. If the alarm does not clear the problem is as described above. Sanitizer Alarm Set Up This alarm requires a DEMA 82.8 sensor. No further set up is required. Technical Specifications Main Power 120/208/240V 50/60 Hz 0.5A Trigger Inputs 80-500V 50/60Hz <20mA Motor/Solenoid Rating 24 VDC Case 300 series stainless steel Size W x H x D 16 x 7 x 8 (41cm x 18cm x 20cm) Shipping Weight 19lb (8.6Kgm) Initial Charge Range 0.6 seconds - 153 seconds Dwell Time Range 0.8 seconds - 204 seconds Door Count Range 0-3 Recharge Time Range 1 second - 13.75 seconds Initial Charge Clock 15 minutes, 2 hours, 3 hours, or 4 hours Detergent Trigger Qualifying Time 3.2 seconds Concentration Range Low Concentration Range High 100µS 9,524µS 8,333µS 26,316µS Rinse Delay Range 0 seconds - 12.75 seconds Rinse Limit 18 seconds Adjustment Range 0-100% I778 Pg. 9 of 10
DP-812-DL-1T DP-812-LL-1T DP-813-DLL-1T DP-813-LLL-1T Installation Kit Parts 81.21.9 Installation Kit for DM-813-LLL Part No. Description 25.68.20 LDPE Tubing ¼ OD x 20 (3 in kit) 80.66 10 Pick Up Tube ¼ ID(3 in kit) C.12B Conductivity Cell 904.8P Check Valve/Sanitizer Line 904.8T Check Valve/Rinse Line 81.16.1 8 Tie Wraps (5 in kit) 80.55 Liquid Feeding Elbow ¼ 81.16 Liquid Tight Feed Through 81.21.10 Installation Kit for DM-813-DLL Part No. Description 25.68.20 LDPE Tubing ¼ OD x 20 (2 in kit) 80.66 10 Pick Up Tube ¼ ID(2 in kit) C.12B Conductivity Cell 904.8P Check Valve/Sanitizer Line 904.8T Check Valve/Rinse Line 81.16.1 8 Tie Wraps (5 in kit) 58.5 Overflow Elbow 81.16 Liquid Tight Feed Through Return Policy No merchandise may be returned for credit without DEMA Engineering Company s written permission. Return Merchandise Authorization (RMA) number required in advance of return. Warranty DEMA products are warranted against defective material and workmanship under normal use and service for one year from the date of manufacture. This limited warranty does not apply to products that have a normal life shorter than one year or failure and damage caused by chemicals, corrosion, improper voltage supply, physical abuse or misapplication. Rubber and synthetic parts such as O -rings, diaphragms, squeeze-tubes and gaskets are considered expendable and are not covered under warranty. This warranty is extended only to the original buyer of DEMA products. If products are altered or repaired without prior approval of DEMA, this warranty will be void. Defective units or parts should be returned to the factory with transportation prepaid. If inspection shows them to be defective, they will be repaired or replaced without charge. F.O.B. factory DEMA assumes no liability for damages. Return merchandise authorization number to return units for repair or replacement must be granted in advance of return. I778 Pg. 10 of 10