CMA Dishmachines EST-FL Installation & Operation Manual - User Manual

than 65 PSIG are present, a pressure regulating valve must be installed in the water line to the
dishmachine (by others). If flowing pressure is lower than 15 psi, improper machine operation
may result.

METRIC

USA

Getting Started

MODEL EST-FL Front Loader INSTALLATION & OPERATION MANUAL Rev. 1.00 10/26/15

Page

2. Getting Started

2.1.

Introduction to the EST-FL Front Loader

The EST-FL Front Loader Dishmachine is safe, economical and easy to operate with its “Auto Start/Stop”,
and it uses only 1.09 gallons of water per cycle. The EST-FL Front Loader Dishmachines top mounted
controls houses built-in chemical pumps and a deliming system that assures proper chemical usage. Its
integrated scrap tray prevents food soil from entering the drain system. The EST-FL can be run at a rate of
40 racks/160 covers per hour and its all stainless steel construction assures longevity.

The EST-FL Front Loader; features an optional fully intergraded hot-water assurance storage tank, to insure
consistent water temperature is always being supplied to the dishmachine.

The attributes of this

dishmachine are always taken into consideration by our well-trained sales representatives prior to the order
being placed

This manual is structured to provide a complete reference guide to the EST-FL Front Loader Dishmachine.
It is presented in a manner that all levels of users will be able to comprehend and use as an effective tool in
supporting the operation and maintenance of the dishmachine.  The function of the dishmachine itself is
mostly automatic and takes little training to put into operation. The Operation section also includes
diagnostic considerations (troubleshooting) for the dishmachine when problems occur.

The first section explains how the dishmachine is packaged and what to look for when receiving the
machine. After unpacking the dishmachine, this manual explains how to install and set up the dishmachine
for use. Requirements are given for plumbing, wiring, and space considerations.

Guidance is also given for installation to ensure that the machine will be able to run at optimum efficiency.
The Operation section of the manual may be used for instruction and procedures when required. Parts
Manual and Electrical Diagram-have the parts lists with exploded view drawings and the wiring diagram for
the dishmachine.

CMA Dishmachines warrants the workmanship of the dishmachine. We are committed to providing the best
dishmachines and customer service in the warewashing industry and your feedback is welcome.

DISCLAIMERS
CMA Dishmachines expressly disclaims any and all warranties, express or implied, relating to the installation of any and all CMA
equipment that is installed by chemical dealers, contracted servicers or third party servicers to CMA equipment. If the installation
instructions are not followed exactly (to the letter), or, if any person or company conducting the installation of the CMA
equipment, revise the installation procedures or alter the instructions in any manner, the CMA warranty becomes void. If, due to
the improper installation of CMA equipment, this equipment ceases to operate properly or affects other parts of the CMA
dishwashing equipment, in that the other parts become defective, the CMA warranty becomes void. CMA will not be liable or
responsible or warrant CMA equipment, due to improper installation of any CMA model dishwasher.

CMA Dishmachines does

not

endorse “Tankless On-Demand” water heaters for use on CMA Dishmachine products. On most

applications, the volume of hot water required for commercial dishmachines exceeds the capacity of these types of heating
sources. You will find that most, if not all, commercial dishmachines have been programmed with auto-filling features that
require quick filling, with a designated limited time.

CMA Dishmachines

does

endorse, and highly recommends, the standard “tank” style hot-water heaters, sized properly to

handle each particular facility with their water heating requirements.  A “tank” style water heater stores and supplies a large
capacity of preheated water before providing hot water to the dishmachine.  To meet required health codes, there must be a
reliable and consistent flow of adequate hot water supplied to the dishmachine.  If the facilities’ “tank” style water heater is
marginal in size, the option on-board hot-water assurance storage tank can be used, which can be fully intergraded into the
footprint of the dishwasher

Getting Started

MODEL EST Front Loader INSTALLATION & OPERATION MANUAL Rev. Draft

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2.2.

Receiving and Installation

The dishmachine 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 dishmachine from the box, and remove all the packaging materials.
Unwrap the machine, and check for the following components:



Inside the wash tank is a plastic bag with one control box key and a cam timer

wrench.



Tube stiffeners must be used to prevent the feed tubes from curling inside the

chemical pail and sucking air. These are located on the outside of the machine with
the chemical tubing already installed into the stiffeners. The ends of the chemical
tubing have been flared so that the tubing will not pull out of the stiffener. Red is for
detergent, white for sanitizer, and blue for rinse aid.

2.2.1. Electrical

Prior to installation make sure the electrical supply is compatible with the specifications on the
machines data plate.

The EST-FL Dishmachine must be hard wired directly to a dedicated 115 VAC, 60Hz circuit
equipped with proper circuit protection. The main power switch is at the top-right side of the
control box.

WARNING: Electrical and grounding connections must comply with the applicable portions of the
National Electrical Code and/or other local electrical codes.
Note: For supply connections, use copper wire only rated at 90 degree C minimum.

2.2.2. Plumbing

The water supply connection is made with a ½” hot water line to the water supply inlet on the top
of the dishmachine. The water supplied to the machine is recommended to be 140° F. The time
necessary to deliver water to the machine is controlled by the number four cam.

The EST-FL Front Loader Dishmachine has a 2” drain. The following section explains how to
connect the drain.

Electrical and plumbing connections must be made by a qualified person who will comply with all

available Federal, State, and Local Health, Electrical, Plumbing and Safety codes

Getting Started

MODEL EST Front Loader INSTALLATION & OPERATION MANUAL Rev. Draft

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Notice to Plumber:

The plumber

connecting this machine is responsible for making certain that

the water lines are THOROUGHLY FLUSHED OUT BEFORE connecting to the dishmachine

Ask your municipal water supplier for details about your local water conditions prior to installation.
Recommended water hardness is, 3 grains per gallon or less.

Note:

high iron levels in the water supply can cause staining and may require an iron filter. High

chlorine levels in the water supply can cause pitting and may require a chloride removal system.
If an inspection of the dishwasher or booster heater reveals lime buildup after the equipment has
been in service, water treatment is recommended. If water softener is already in place, ensure
there is a sufficient level of salt.

∗

2.2.3. Connecting the Scrap Accumulator and Drain

The scrap accumulator is designed to perform two basic functions:

1. It allows a method to discharge all the heavy solids out of the machine with each

wash cycle.

2. It provides accumulation capacity to allow draining the contents of one cycle

regardless of the discharge rate of the existing drain.

The drainpipe is connected to the scrap accumulator drain using a 2” no-hub connector as shown
in

Figure 2.1.3

below.

2" DRAIN

SLEEVE

NO-HUB

2" DRAINPIPE

SCRAP ACCUMULATOR

HOSE

CLAMPS

Figure 2.1.3

∗

The de-liming agents used to de-scale a commercial dishwasher, are highly caustic and de-liming

should be done by a qualified chemical specialist.

Operation

MODEL EST-FL Front Loader INSTALLATION & OPERATION MANUAL Rev. 1.00 10/26/15

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3. Operation

3.1.

Initial Setup

∗

The CMA EST-FL Front Loader is equipped with switches to prime the peristaltic pumps at
anytime when the master power switch on the back of the control box is "ON".

Following completion of the installation, always fill the machine with water before starting the
machine.

1. With the power switch “ON” press and hold the Fill

2. Check the chemical lines to the chemical containers.

switch until the water overflows

into the wash scrap accumulator.

a. Red: Detergent line.

b. Blue: Rinse Aid line.

c. Clear/White: Sanitizer line.

3. Individually activating the prime switches for the three chemical pumps until each

product is discharging into the dishwasher.

(The chemicals must

be programmed by a qualified chemical specialist)

Note:

Low Temperatures chemical-sanitizing dishmachines must not exceed 6% sodium
hypochlorite solution (bleach) as the sanitizing agent. Higher levels may damage
stainless or components.

Use only commercial-grade detergents and rinse aids recommended by your

chemical professional. Do not use detergents and rinse aids formulated for residential
dishwashers.

Follow the directions precisely that are on the litmus paper vial and test the water on the
surface of the bottom of the glasses. Concentration should be 50 p.p.m. minimum to 100
p.p.m. maximum. If concentration is incorrect contact your chemical supplier.

4. To start the dishmachine, close the door press and hold the start-switch for 2 to 3

seconds or until the cycle begins. The machine will run through its cycle.

5. Operate the machine one cycle and watch to ensure that the chemicals are

delivered and stop during the cycle. Remember: red tube - detergent: blue tube -
rinse aid: and clear/white tube - sanitizer. Check temperature at the end of the
cycle for 140

F, 60

The amount of product delivered by each cam is controlled by adjusting the cam’s
opening.  When the micro switch rides down into the cam the peristaltic pump motor
begins to rotate. It will continue to rotate until it rides up out of the groove.
Therefore, to extend the amount of product delivered to the machine, open the
grove; to reduce the amount of product delivered to the machine, close the groove.
The cams are slip fit and a cam adjustment wrench is provided.

CAUTION:

The motors on the new peristaltic pumps may be stalled by excessive tightening

of the cover plate screws. If a peristaltic pump does not turn when the micro switch is
activated, loosen the screws on the cover plate

Technical personnel are available during normal business hours at CMA Headquarters should you, as an
installer, have any questions please call CMA Tech Support at:

800-854-6417

for assistance.

Operation

MODEL EST Front Loader INSTALLATION & OPERATION MANUAL Rev. Draft

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3.2.

EST-FL Front Loader Operational Cycle

The EST-FL Operational Cycle has a total cycle time of 90 seconds. The Timing
Diagram and the steps listed below detail the individual functions that are executed
during each Operational Cycle.

Seconds:

With the machine powered up, the door closed the dishwasher will begin a cycle.

When the Start switch is pressed the timer assembly motor is energized through
the normally closed contact of the Start/Stop Relay.

Within a couple of seconds cams 1 and 2 close their respective switches. Cam
switch 1 (Start/Stop) maintains power to the timer assembly motor throughout the
90-second cycle. Cam switch 2 (Cycle Reset) energizes the Start/Stop Relay.

The Start/Stop Relay, once it is energized by cam switch 2, is held in by its own
normally open contact for as long as the doors remain closed.

“S” series same otherwise noted

Start/Stop

Cycle Reset

Drain/Rack

Counter

Flush/Fill

Detergent

Sanitizer

Rinse Aid

Pump Motor

WASH

DRAIN

Cam 1

Cam 2

Cam 3

Cam 4

Cam 5

Cam 6

Cam 7

Cam 8

RINSE

4sec. delay to prevent
chemical damage

Operation

MODEL EST Front Loader INSTALLATION & OPERATION MANUAL Rev. Draft

Page

Cam switch 8 controls the pump motor. The pump motor comes ON at the beginning
of the operational cycle and continues to run until the end of the drain function
(controlled by cam switch 3), at which time it turns off for about eight seconds
allowing time for the machine to refill enough to avoid running the pump dry before
the pump motor restarts and runs to the completion of the operational cycle.

The pump motor runs the pump for the 45-second wash cycle, then pumps the water
out through the drain, turns off for about 8 seconds (allowing the machine to refill
with clean rinse water) and then runs the pump for the 30-second rinse cycle.

Cam switch 3 controls the drain function. At the end of the 45-second wash cycle,
cam switch 3 energizes the drain solenoid allowing the wash water out of the
machine. Cam switch 3 also increments the rack counter by one each cycle.

Cam switch 4 controls the water solenoid valve on the water supply to flush and fill
the machine. At the end of the wash cycle the drain solenoid valve is open and drain
begins, the pump motor continues to run. About the middle of the drain cycle, Cam 4
opens the fill solenoid valve and the flush function begins flushing residual detergent.
At the end of drain cycle, drain solenoid valve closes and the pump motor is
stopped- the machine begins to fill for the rinse cycle. Once the machine has
refilled sufficiently, the pump motor restarts carrying out the rinse portion of the
cycle as the filling of the wash tank completes. This can be adjusted as necessary for
water pressure situation.

Cam switch 5 controls the detergent pump and turns ON about 5 seconds after the
operational cycle is started and runs for a few seconds to provide sufficient detergent
for the wash cycle. This cam can be adjusted as necessary for proper detergent
dosage.

Cam switches 6 and 7 control the sanitizer and rinse pumps respectively. They turn
ON at the beginning of the rinse cycle and run for a few seconds to provide sufficient
sanitizer and rinse aid for the rinse cycle. These cams can be adjusted as necessary
for proper chemical dosage.

At the end of the cycle cam switches 1 and 2 open (de-energize) stopping the cycle.
The Start/Stop relay is held energized by its normally open contact until the doors are
opened. Opening the doors de-energizes the Start/Stop Relay, which will then cause
a new cycle to start when the doors are once again closed.

Note:

Press and holding the START switch on for a couple of seconds will start a cycle.

The Water and Chemicals to the dishmachine must be programmed by a qualified

chemical specialist. Contact your local Chemical Supplier or Equipment Dealer for
assistance.

Operation

MODEL EST Front Loader INSTALLATION & OPERATION MANUAL Rev. Draft

Page

3.3.

(Optional) Hot-Water Assurance Storage Tank

The Optional Fully Integrated Hot-Water Assurance Storage Tank will

not

require

its’ own power supply. The unit has been designed with a 115 volt, 1500 watt
element which will only be active when the dishwasher is not in operation.

This will assure consistent and continuous water temperature is being supplied to
the dishmachine at all times. This unit can be ordered to be fully installed, from
the factory, if necessary it can be field installed by a qualified field service
technician.

Note: The storage-Tank is shipped on the dishmachine empty to prevent damage from
freezing. When the dishmachine is powered up for the first time, the storage tank must be
filled with water by pressing and holding fill switch; this will prevent heating element from
being damaged.

Note:

Plumbing connections must be made by a qualified service company who will comply with all available

Federal, State, and Local Health, Plumbing and Safety codes.

Operation

MODEL EST Front Loader INSTALLATION & OPERATION MANUAL Rev. Draft

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3.4.

Startup Procedures

Please follow the instructions given here before each shift to assure trouble free operation.

2. Drain the water if it is cold, by pressing and holding the drain switch until all

the water is completely drained from the dishwasher.

3. Check the internal drain screen if necessary, remove it from the machine and

clean it out. After cleaning, reinstall it properly back into the sump.

4. Check the wash arm spray tips. If they are clogged, clean with soft bristle

brush and a toothpick, and rinse well in sink. Reinstall the wash arms.

5. Press and hold the Fill

switch until the water overflows into the wash scrap

accumulator.

6. Once a proper water level is established, check the temperature of the water

(it should be between 120

F 66

C and 140

F, 77

C).

7. Insert the tray of dishes into the machine and close the doors. The press

and hold the start-switch for 2 to 3 seconds while the wash-cycle is started.

8. After the machine stops, lower the door, slide the dish-rack out onto the door

and allow the contents to dry, before stacking.

When the door is lowered during a cycle, the machine will automatically stop running.

The EST-FL Front Loader will run through the wash and rinse cycles automatically feeding the proper
chemicals and then turn itself off.

(

The Water and Chemicals to the dishwasher must be programmed by a qualified chemical specialist)

In an emergency you can turn off the machine by turning off the master switch located on the back of the
control box.

Operation

MODEL EST Front Loader INSTALLATION & OPERATION MANUAL Rev. Draft

Page

3.5.

Quick service trouble shooting guide

MODELS: EST-FL Front Loader

TECHNICAL ISSUE

Cause

Solution

Machine starts while doors are

open

Faulty magnetic door switch

Replace the switch, P/N 00556.10

Faulty start/fill switch

Replace the switch, P/N 03470.01

Faulty #1 micro switch (start/stop) Replace micro switch, P/N 00411.00

Continuous cycles

Faulty start/fill switch

Replace micro switch, P/N 00411.00

Faulty door switch

Replace the switch, P/N 00556.10

Delimer switch in wrong position Switch to

NORMAL

position

Wash motor runs continuously

Faulty delime switch

Replace the switch, P/N 00475.00

Faulty motor contactor

Replace contactor, P/N 00404.82

Delimer switch on wrong position Switch to

NORMAL

position

Sanitizer pump does not run

Faulty delimer switch

Replace the switch, P/N 00475.00

Faulty # 6 micro switch

Replace micro switch, P/N 411.00

Faulty sanitizer pump motor

Replace the motor, P/N 00416.00

Broken Spring

Replace spring, P/N 00105.82

Drain valve does not operate

Faulty #3 Micro switch

Replace micro switch, P/N 00411.00

Faulty drain motor

Replace drain motor, P/N 00104.82

Faulty #4 micro switch (Fill)

Replace micro switch, P/N 00411.00

Debris inside water solenoid valve Clean valve replace diaphragm kit,

P/N 00707.00

Machine does not fill

Faulty start/fill switch

Replace the switch, P/N 03470.01

Drain not closing

check function of drain sys.

Faulty water solenoid coil/valve

Replace coil/valve, P/N 00738.10 or

03603.10

Faulty check valve

Replace valve, P/N 00718.00

Water leaks out of vacuum breaker Low incoming water pressure

Increase water pressure to 20 psi

Faulty vacuum breaker kit

Replace vac. Brkr kit, P/N 03623.00

Machine only runs when start/fill

switch is depressed

Faulty #1 micro switch (start/stop) Replace micro switch, P/N 00411.00

Faulty magnetic door switch

Replace door switch, P/N 00556.10

Will not start/ nothing works

Wall breaker tripped

Reset breaker

Master on/off switch faulty or in off

position

Reset or replace switch, P/N 00471.10

Runs, but none of the other

functions engage

Faulty #2 Micro switch (cycle

reset)

Replace micro switch, P/N 411.00

Faulty ice cube relay (yellow relay) Replace relay, P/N 00636.00

MODEL EST-FL Front Loader INSTALLATION & OPERATION MANUAL Rev. 1.00 10/26/15

Page

Addendum for Machines Installed in the City of Chicago

"All food dispensing establishments using chlorine or other approved chemical sanitizers shall, at
all times, maintain an adequate testing device."

"Dishes and other eating and drinking utensils to be washed in a dishwashing machine shall be
properly scraped and pre-rinsed and shall be stacked in racks or trays so as to avoid
overcrowding, and so as to permit the wash and rinse waters to reach all surfaces of each
utensil."

"In machine washing, multi-use eating and drinking utensils shall be washed in water containing a
suitable detergent at a temperature from 120 degrees F. to 140 degrees F. or other method
approved by the Department of Health.

"The water in the wash tank shall be changed during operation as often as is necessary to keep it
reasonably clean. An effective concentration of detergent in the wash water shall be maintained
at all times."

"Bactericidal treatment shall consist of exposure of all surfaces of dishes and utensils being
washed to a rinse of clean water, at a temperature of not less than 180 degrees F. or other
method approved by the Department of Health."

"All dishwashing machines shall maintain a flow pressure not less than 15 or more than 25
pounds per square inch on the fresh water line at the machine and not less than 10 pounds per
square inch at the rinse nozzles. A suitable gauge cock shall be provided immediately upstream
from the final rinse spray to permit checking the flow of the final rinse water. An easily readable
thermometer accurate to

2 degrees F. shall be provided on both the wash and rinse water lines

of the dishwashing machine which will indicate the temperature of the water solution therein."

"Dishwashing machines shall be thoroughly cleaned at least once each day. The pumps and the
wash and rinse sprays or jets shall be so designed that a forceful stream of water will reach all
surfaces of the utensils when they are properly racked.  These parts shall be thoroughly cleaned
at least once each day.  The pumps and the wash and rinse sprays or jets shall be so designed
that a forceful stream of water will reach all surfaces of the utensils when they are properly
racked. These parts shall be readily accessible for inspection and cleaning."

"After bactericidal treatment, utensils and containers shall be stored at a sufficient height above
the floor in a clean, dry place, protected from flies, splash, dust, overhead leakage and
condensation, and other contamination. Containers and utensils shall be inverted, covered, or
otherwise protected from contamination until used for serving."

Drain racks, trays, and shelves shall be made of non-corrodible material and shall be kept clean.

In handling containers and utensils the surfaces thereof which come in contact with food or drink
shall not be touched by the hands, except during the process of washing.

Tables for clean and dirty dishes and food shall be so arranged that the dirty dishes will be as far
removed from the food and clean dishes as may be possible.

All single-service articles and utensils shall be purchased in sanitary cartons and stored therein in
a clean, dry place until used, and after removal from the cartons, these articles shall be handled
in such a manner as to prevent contamination.

Please note the following procedures must be followed for City of Chicago
Approval:

1. All low energy models must have low-level sani alarms, both

visual and audio.

2. All models must have a City of Chicago approval data label

affixed to the machine.

3. Chlorine sanitizer must be a minimum of 100 PPM.

Electrical Diagram

MODEL EST-FL Front Loader INSTALLATION & OPERATION MANUAL Rev. 1.00 10/26/15

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Electrical Diagram

OFF

SANI

SWITCH

DET

SWITCH

RINSE

SWITCH

PUMP

MOTOR

COUNTER

115 VAC

NEUTRAL

GND

DELIME

NORMAL

WATER

SOLENOID

VALVE

RINSE

SANI

DET

DRAIN

SOLENOID

VALVE

FILL

/ START

SWITCH

WASH PUMP

CONTACTOR

POWER

SWITCH

POWER

BLOCK

8 CAM TIMER

START /STOP

RELAY

DRAIN

SWITCH

WIRE DIAGRAM FOR MODEL : EST-FL

DOOR SAFETY SWITCH

HEATER

CONTACTOR

ADJ.

THERMO

STAT

SUSTAINER

HEATER

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