DEMA Chemaster DM-813-PLLL-1T Manual de usuario

I-729 Pg 1 of 15

Rev D 11/01

DEMA 813 PROBELESS DEMAMasterTM

INSTALLATION INSTRUCTIONS

Models:

DM-813-PLLL-1T

DM-813-PDLL-1T

DM-813-PLLL-2T

DM-813-PDLL-2T

I-729 Pg 2 of 15

Rev D 11/01

System Overview

The DEMA DEMAMaster probeless series is designed for long reliable use with simplicity in mind for both

the installer and user. The system is based on the reliable DEMA peristaltic pump. The pumps are installed

in a heavy plastic housing with a sealed cover that uses a Lexanlabel with visible function indicators.

Pumps are available with three different motor/gear box speeds, 15, 60, and 105 RPM.

There are micro controllers housed in the unit that control the operation of the pumps. The detergent pump

is controlled by a set of DIP switches that can be arranged to supply a selected amount of detergent based on

door counts or time depending on the application. The rinse aid is set by a potentiometer that controls the

speed of pump and can be delayed up to 12 seconds. In addition, the probeless detergent board has the

ability to keep track of time and deliver a new initial charge when in the door mode.

The DEMAMaster is supplied with a transformer mounted in housing that allows primary voltage hook up of

120, 208 or 240 at 50/60Hz.

Please read all instructions before proceeding with the DEMAMaster installation.

Dishroom Room Survey

A complete survey of the dish machine sight should be completed before the DEMAMaster installation.

1. Locate the power connection points on the dish machine. This power must be 120, 208 or 240 volts

50/60Hz.

Note: When installing a DEMAMaster probeless on a door operated dish machine, keep in

mind that the detergent control will need to recognize door openings based on power

“on” and “off” to the DEMAMaster. In addition, all installations will require that the

rinse control recognize the dish machine rinse cycle.

2. Select location to mount the DEMAMaster on a wall that will allow access to the chemical product

containers and the chemical product feeds points on the dish machine. The DEMAMaster should be

kept away from moisture releasing machinery and from water being splashed directly on the unit.

3. Mount the DEMAMaster on a wall by use of the supplied hanger. Use appropriate wall anchors

when mounting on dry wall.

I-729 Pg 3 of 15

Rev D 11/01

Electrical Installation

1. BEFORE GOING ANY FURTHER, ALL ELECTRICAL POWER MUST BE TURNED OFF TO

THE DISH MACHINE AND ANY OTHER CIRCUIT THAT IS TO BE USED FOR THIS

INSTALLATION. LOCKOUT AND TAG PROCEDURES SHOULD BE OBSERVED WHEN

INSTALLING THIS DEVICE. NEVER OPEN THE DEMAMASTER UNLESS POWER HAS

BEEN TURNED OFF. SIGNALS MAY BE PRESENT FROM DISH MACHINE, EVEN WITH

THE POWER TURNED OFF. ONLY USE ELECTRICAL CODE APPROVED INSULATED

WIRING AND ELECTRICAL FIXTURES WITH THIS INSTALLATION.

Note: The DEMAMaster is equipped with 1 or 2 transformers depending on the model. If

there are 2 transformers, the detergent control will be powered by one while the rinse

aid control, will be powered by the other.

If the DEMAMaster is equipped with 1 transformer, both the detergent and rinse

control, will be powered by the same transformer. In this case it will be necessary to

wire the unit so that the rinse aid control will only run during the rinse cycle. This can

be done via a pressure switch, which should be wired to the DEMAMaster terminal

block connections labeled “pressure switch”.

2. Connect the power to the DEMAMaster. The DEMAMaster will accept 120VAC, 208VAC or

240VAC 50/60Hz. The detergent control is normally wired to something that is common to the

pump operation, thus signaling a wash cycle. The rinse control is normally wired to something that is

common to the rinse solenoid valve, thus signaling a rinse cycle. Some dish machines may have a

terminal block setup for power for both detergent and rinse, see schematic or owners manual of the

dish machine to determine if this option is available.

This product is designed only to be used as described in this instruction sheet. Adhere to all warnings and

cautions identified in this document.

WARNING: Electrical and grounding installation of DEMA products must comply with

electrical codes and regulations established by national, city, county, parish, provincial or

other agencies. It is possible that electrical codes and regulations require that a certified

electrical contractor or engineer perform the electrical installation.

For questions, contact a certified electrician.

DISCONNECT ALL ELECTRICAL POWER TO THE DISPENSER AND THE APPLIED

MACHINE WHEN SERVICING- FOLLOW LOCKOUT / TAGOUT PROCEDURES.



WARNING: Installations must conform to all local and national plumbing codes and use

approved backflow prevention and pressure relief devices where required.

ALWAYS DISCONNECT DISPENSER FROM WATER SOURCE WHEN DISPENSER

IS NOT IN USE.

Always read SDS for all chemicals used and follow personal protective guidelines.

I-729 Pg 4 of 15

Rev D 11/01

3. Locate the power terminal block inside the DEMAMaster enclosure. There will be 2 when there are

2 transformers. Connect “hot” or “live” wire to the terminal labeled “line”. Connect the “return

line” to the appropriate terminal block position based on supply voltage. The “earth ground” wire

must be connected to the terminal block by use of the grounding clip (supplied in installation kit).

The power line should be secured by use of a proper electrical fitting through access hole in

DEMAMaster enclosure. The power line must also be secured properly between the dish machine or

power source and DEMAMaster.

Note: When wiring is completed the DEMAMaster should feed detergent based on door counts or

time depending on type of machine (door or conveyor). The rinse aid should feed only during the

rinse cycle. It may be necessary to use a pressure switch to signal the rinse aid feed. Evaluate the

application for requirements to assure proper operation.

I-729 Pg 5 of 15

Rev D 11/01

24VDC RINSE OUT

UNUSED

24VAC IN

24VAC OUT

24VAC IN

24VDC OUT

LINE

120VAC RETURN

208VAC RETURN

240VAC RETURN

FUSE

1A. 250V

RINSE

MOTOR

DETERGENT

MOTOR OR

SOLENOID

VALVE

(SEE DRAWING

FOR PART NO.)

(SEE DRAWING FOR PART NO.)

TERMINAL BLOCK &

BRACKET ASSY.

BLACK

WHITE

BLUE

RED

PROBLESS DETERGENT

CONTROL BOARD

80-77-1

RINSE CONTROL BOARD

80-69-6

40 VA

TRANSFORMER

80-70

X20753-1

(81-32-1)

X20753-2

(81-32-2)

BLACK

RED

BLACK

RED

ORANGE

X20753-1 (81-32-1) MOTOR

X20753-6 (81-32-6) VALVE

X20753-2 (81-32-2) MOTOR

X20753-7 (81-32-7) VALVE

25457-16 (81-34-16) FUSE

20758-1 (81-35) FUSE HOLDER

20759-2

(81-36-2)

ORANGE

20759-2

(81-36-2)

RED

1A. 250V

FUSE

BLUE

25457-16 (81-34-16) FUSE

20758-1 (81-35) FUSE HOLDER

WHITE

BLACK

208VAC RETURN

(SEE DRAWING FOR PART NO.)

TERMINAL BLOCK &

BRACKET ASSY.

240VAC RETURN

LINE

120VAC RETURN

40 VA

TRANSFORMER

80-70

24VDC SANI OUT

X20753-1

(81-32-1)

X20753-2

(81-32-2)

BLACK

RED

MOTOR

(SEE DRAWING FOR PART NO.)

SANI

I-729 Pg 6 of 15

Rev D 11/01

24VDC RINSE OUT

UNUSED

24VDC SANI OUT

24VAC IN

24VAC OUT

24VAC IN

24VDC OUT

LINE

120VAC RETURN

208VAC RETURN

240VAC RETURN

PRESSURE

SWITCH

FUSE

1A. 250V

RINSE

MOTOR

DETERGENT

MOTOR OR

SOLENOID

VALVE

(SEE DRAWING FOR PART NO.)

TERMINAL BLOCK &

BRACKET ASSY.

BLACK

WHITE

BLUE

RED

RINSE CONTROL BOARD

80-69-6

PROBLESS DETERGENT

CONTROL BOARD

80-77-1

40 VA

TRANSFORMER

80-70 ORANGE

ORANGE

20774-1

(81-94-1)

20774-2

(81-94-2)

X20753-1

(81-32-1)

X20753-2

(81-32-2)

BLACK

RED

ORANGE

20774-1

(81-94-1)

BLACK

RED

ORANGE

X20753-1 (81-32-1) MOTOR

X20753-6 (81-32-6) VALVE

X20753-2 (81-32-2) MOTOR

X20753-7 (81-32-7) VALVE

25457-16 (81-34-16) FUSE

20758-1 (81-35) FUSE HOLDER

20759-2

(81-36-2)

X20753-2

(81-32-2)

X20753-1

(81-32-1)

(SEE DRAWING FOR PART NO.)

SANI

MOTOR

BLACK

RED

I-729 Pg 7 of 15

Rev D 11/01

Tubing Connections

Included in the installation kit is a roll of low-density polyethylene (LDPE) tubing that can be used to

connect from the chemical container, to the pump, and from the pump to the injection fittings on the

machine.

Measure the length of the tubing needed on the suction side from the chemical container to the pump and cut

the tubing to proper length. Install the tubing into 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 approximately1/2-3/4”(15-20mm). Secure

the tubing with a tie wrap around the squeeze tube. Use the same procedure on the outlet of the squeeze

tubing and route the LDPE tubing to the injection point of the machine. Cut off all excess tubing and keep

tubing away from hot surfaces and sharp edges to prevent damage or leakage.

See Detergent and Rinse Tubing Connections below for specific information concerning discharge tube

connection.

Detergent Tubing Connections

Included with the kit is a bulkhead fitting that will accept the discharge of the detergent at the machine.

There are two fittings depending on the model. If the DEMAMaster has a detergent pump, then the fitting

will have a ¼” compression fitting that will accept the ¼” LDPE pump discharge tubing. It the unit has a

solenoid valve then the fitting will have a barb fitting designed for a 5/8” I.D. tube. A 7/8” diameter hole

will need to be cut above the waterline in the side of the dish machine wash tank to accommodate the

bulkhead fitting. The bulkhead fitting should not be located above the concentration probe.

When using the detergent pump simply run the tubing from the outlet of the pump to the ¼” compression

fitting on the bulkhead fitting.

When using the solenoid valve run the ¼” LDPE tubing from the ¼” compression fitting on the outlet of the

valve to the siphon breaker for the solid bowl or powder feeder.

Rinse Tubing Connections

Note: A check valve is included in the installation kit. The procedure below describes the installation of this

check valve. Other hardware may be needed to complete the installation properly.

Install ¼” compression by 1/8” NPT rinse injection check valve into the rinse input water between the

vacuum breaker and the final rinse arm. Drill an 11/32” hole and tap to 1/8” NPT. When installing to

copper pipe or tubing use saddle clamps.

Connect the ¼” OD poly tubing between the ¼” rinse check valve and the discharge side of the peristaltic

rinse squeeze tubing. Use a plastic tie to hold the ¼” polypropylene tubing into the peristaltic squeeze tube.

Detergent and Rinse Calibration

Detergent

Prior to calibration the system must be primed. The system is primed when the chemical is dispensing from

the injection point into the dish machine tank. This can only be done while power is being supplied to the

probeless detergent board. 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.

Note: If Detergent Prime button is held less than 5 seconds, the pump will run for the amount time

that has been set for initial charge or until button is pushed again.

I-729 Pg 8 of 15

Rev D 11/01

1 MIN 50 SEC

123

45 SEC

55 SEC

50 SEC

213

40 SEC

30 SEC

35 SEC

321

213

681 MIN 45 SEC

56 8

5678

1 MIN 40 SEC

1 MIN 30 SEC

578

5678

51234 7

123457

1234

65 8

756 8

20 SEC

25 SEC

15 SEC

321

213

5 SEC

10 SEC

213

1 MIN 15 SEC

1 MIN 25 SEC

1 MIN 20 SEC

578

5678

1 MIN

1 MIN 5 SEC

1 MIN 10 SEC

5678

54321 78

1234 765 8

2143

1234

56 8

65 8

123457

54321 8

1234

21 43

5678

56 8

1234

5678

1234

4321

5678

1 MIN 35 SEC

2 MIN 5 SEC

2 MIN 10 SEC

2 MIN 15 SEC

2 MIN 20 SEC

2 MIN 25 SEC

2 MIN 35 SEC

2 MIN 30 SEC

2 MIN

1 MIN 55 SEC

123456 421 356

The detergent set up involves the use of the DIP switches on the pro-bless detergent control board. There are

a bank of 6 and a bank of 8 switches located directly on the control board. The detergent concentration

should be setup 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. Door or Conveyor mode: 6 DIP Switch Bank, Switch 1

2. Initial Charge Time: Sets the amount of Initial Charge based on time. See table below for the P switch

configuration.

I-729 Pg 9 of 15

Rev D 11/01

3A. Dead Cycle Count – Door Mode Only

Sets the amount of wash cycles (door operations) that will take place before a recharge will occur.

See table below for DIP switch configuration. Example: If the Dead Cycle Count is set to 3, there

will be three wash cycles where no detergent will be added. On the 4th cycle a recharge will occur.

3B. Dwell Time Setting – Conveyor Mode Only

Sets the amount of time between a charge and a recharge and recharges. See table below for DIP

switch configuration. Example: Dwell Time is set for 1 min 30 sec. After the probeless control

supplies an initial charge or a recharge, 1 minute and 30 seconds must expire before the next

recharge will occur.

614325

652341

14325

61423 5

1423 5

652341

14325

0 CYCLES

1 CYCLE

2 CYCLES

3 CYCLES

4 CYCLES

5 CYCLES

6 CYCLES

7 CYCLES

2 MIN 45 SEC

2 MIN 30 SEC

2 MIN 15 SEC

2 MIN

1 MIN 15 SEC

1 MIN 45 SEC

1 MIN 30 SEC

1 MIN

45 SEC

15 SEC

30 SEC

312 4

1234

2143

1234

1324

312 4

1234

2143

1234

4123

1234

2143

3 MIN 15 SEC

3 MIN 30 SEC

3 MIN 45 SEC 123

132

3 MIN 123

645

654

645

4 MIN 15 SEC

4 MIN 30 SEC

5 MIN 15 SEC

4 MIN 45 SEC

4 MIN

5 MIN

654231

312

546

456

312

564

456

546

5 MIN 30 SEC

6 MIN 15 SEC

5 MIN 45 SEC

6 MIN 45 SEC

6 MIN 30 SEC

7 MIN 30 SEC

7 MIN 45 SEC

7 MIN 15 SEC

7 MIN

6 MIN

321

456

546

321

546

456

312

546

456

564

321456

I-729 Pg 10 of 15

Rev D 11/01

4. Recharge Time: Sets the amount of recharge based on time. See table below for DIP switch

configuration.

5. Initial Charge Clock

This feature is adjustable as shown below while in door mode only. When the unit is in the

conveyor mode the initial charge clock defaults to 1 hour.

This feature is used to provide an initial charge after a set amount of time expired without

using the DEMAMaster. See the table below for the DIP switch configuration. Example:

Initial Charge Clock is set for 2 hours. If no power has been supplied to the probeless control

for at least 2 hours, the pro-bless control will provide an initial charge the next time power is

supplied.

Note: The DEMAMaster probeless board is designed with a 5 second delay when powered up. This

means that the detergent pump or valve will not operate until continuous power is supplied to

the board for at least 5 seconds.

421356

5432

178

51234 7

54321 78

54321 8

1234

76 8

54321 78

1 SEC

2 SEC

3 SEC

4 SEC

5 SEC

6 SEC

7 SEC

8 SEC

421356

65312 4

15 MIN

2 HOURS

3 HOURS

4 HOURS

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