Champion 100 HDPW Service Manual

Installation and Service Guide with Service Replacement Parts

Beginning with Serial No. R3448 and above

E-series Rack Conveyor Dishwasher Models

Basic Single Tank Single Tank w/Prewash

Single Tank Model 44

Single Tank w/Prewash Model 66 PW

Two Tank w/Prewash Model 64

44 66 PW 70 FFPW 80 HDPW 44 LT 66 LTPW 70 LTFFPW 80 LTHDPW

44 DR 66 DRPW 70 DRFFPW 80 DRHDPW 44 DRWS 66 DRWSPW 70 DRWSFFPW 80 DRWSHDPW

44WS 66WSPW 70 WSFFPW 80 WSHDPW

54 DR 76 DRPW 80 DRFFPW 90 DRHDPW

Basic Two Tank Two Tank w/ Prewash 64 86 PW 90 FFPW 100 HDPW

84 106 PW

110 FFPW 120 HDPW

www.championindustries.com

P.O. Box 4149 Winston-Salem, NC 27115 336/661-1556 Fax: 336/661-1660 Toll-free: 800.858.4477

Dishwasher serial no.

Issue Date: 6.12.07

Manual P/N 114315 rev.-

For machines beginning with S/N R3448 and above

2674 N. Service Road, Jordan Station Ontario, Canada L0R 1S0 905/562-4195 Fax: 905/562-4618 Toll-free: 800.263.5798

For future reference, record your dishwasher information in the box below.

Model Number__________________________ Serial Number_______________________

Voltage________________Hertz_____________ Phase__________________

Champion Service Agent __________________________________ Tel:______________________

Champion Parts Distributor _________________________________ Tel:______________________

For all models:

The data plate mounts to one side of the top-mounted control cabinet.

National Service Department

In Canada: In the USA:

Toll-free: 800/ 263-5798 Toll-free: 800/ 858-4477 Tel: 905/ 562-4195 Tel: 336/ 661-1556 Fax: 905/ 562-4618 Fax: 336/ 661-1660 email: service@moyerdiebellimited.com email: service@championindustries.com

ATTENTION:

The dishwasher model number,

serial number, voltage, hertz and phase

are needed to identify your machine and to

answer questions.

Please have this information on-hand

if you call for service assistance.

We support

Champion Industries, Inc.

P.O.Box 4149

Winston-Salem, NC 27115-4149

Revisionstothismanual

________________________ Revisions to this manual

This is where we record changes to the manual. A revision might be a part number change, new

• instructions, or information that was not available at print time.

We reserve the right to make changes to this manual without notice and without incurring any liability

• by making the changes..

Dishwasher owners may request a revised manual, at no charge, by calling (800.858.4477) in the

• USA or (800.263.5798) in Canada.

Revision Revised Serial Number Revision Date Pages Effectivity Description

9.1.04 All R3448  Releasedrstedition7.0608.1

Dear Owner: Thank-you for choosing our dishwasher. We appreciate your business.

This manual covers the E-series Rack Conveyor Dishwashers:

Electric high temperature single tank and multiple tank rack conveyor dishwashers with built-in electric boosters in 40°F/22°C rise or optional 70°F/39°C rise.

Steam high temperature single tank and multiple tank rack conveyor dishwasher with built-in steam booster in 40°F/22°C rise or an optional 70°F/39°C rise booster.

Electric low temperature chemical sanitizing single tank and multiple tank rack conveyor dishwasher

Theinstallation,andinitialstart-upofyourdishwashermustbeperformedbyqualied electricians,plumbers,andauthorizedservicetechnicianstrainedincommercial dishwashers.

Championprovidesauthorizedfactorytrainedserviceagentstosupervisetheassembly andinitialstart-upofyourdishwasher.

Defectsandrepairscausedbyunauthorizedinstallerswillnotbecoveredbythe

dishwasherwarranty.

TableofContents

E series Rack Conveyor Dishwashers

Revisions to this manual ___________________________________________________________ i Limited Warranty _________________________________________________________________ iv

Installation _____________________________________________________ 1

Unpack and Place Plumbing Connections Drain Connections Electrical Connections Ventilation Initial Start-up

Operating Instructions __________________________________________ 9

How to Operate your Dishwasher: Cleaning and Maintenance

Troubleshooting

Basic Service ___________________________________________________ 19

Electrical Mechanical

Service Replacement Parts ______________________________________ 33

Electrical Schematics ______________________________________ 109

iii

LimitedWarranty

LIMITED WARRANTY

Champion Industries Inc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 27115, and P.O. Box 301, 2674 N. Service Road, Jordan Station, Canada, L0R 1S0, warrants machines, and parts, as set out below.

Warranty of Machines: Champion warrants all new machines of its manufacture bearing the name

"Champion" and installed within the United States and Canada to be free from defects in material and workman

ship for a period of one (1) year after the date of installation or fteen (15) months after the date of shipment by Champion, whichever occurs rst. [See below for special provisions relating to glasswashers.] The warranty

registration card must be returned to Champion within ten (10) days after installation. If warranty card is not returned to Champion within such period, the warranty will expire after one year from the date of shipment.

Champion will not assume any responsibility for extra costs for installation in any area where there are jurisdictional problems with local trades or unions.

If a defect in workmanship or material is found to exist within the warranty period, Champion, at its election, will either repair or replace the defective machine or accept return of the machine for full credit; provided; however, as to glasswashers, Champion's obligation with respect to labor associated with any repairs shall end

(a) 120 days after shipment, or (b) 90 days after installation, whichever occurs rst. In the event that Champion

elects to repair, the labor and work to be performed in connection with the warranty shall be done during regular working hours by a Champion authorized service technician. Defective parts become the property of Champion. Use of replacement parts not authorized by Champion will relieve Champion of all further liability in connection with its warranty. In no event will Champion's warranty obligation exceed Champion's charge for the machine. The following are not covered by Champion's warranty:

a. Lighting of gas pilots or burners. b. Cleaning of gas lines. c. Replacement of fuses or resetting of overload breakers. d. Adjustment of thermostats. e. Adjustment of clutches. f. Opening or closing of utility supply valves or switching of electrical supply current. g. Cleaning of valves, strainers, screens, nozzles, or spray pipes. h. Performance of regular maintenance and cleaning as outlined in operator’s guide. i. Damages resulting from water conditions, accidents, alterations, improper use, abuse, tampering, improper installation, or failure to follow maintenance and operation procedures. j. Wear on Pulper cutter blocks, pulse vanes, and auger brush.

 Examplesofthedefectsnotcoveredbywarrantyinclude,butarenotlimitedto: (1) Damage to the exterior or

interior nish as a result of the above, (2) Use with utility service other than that designated on the rating plate,

(3) Improper connection to utility service, (4) Inadequate or excessive water pressure, (5) Corrosion from chemicals dispensed in excess of recommended concentrations, (6) Failure of electrical components due to connection of chemical dispensing equipment installed by others, (7) Leaks or damage resulting from such leaks caused by the installer, including those at machine table connections or by connection of chemical dispensing equipment installed by others, (8) Failure to comply with local building codes, (9) Damage caused by labor dispute.

Warranty of Parts: Champion warrants all new machine parts produced or authorized by Champion to be free

from defects in material and workmanship for a period of 90 days from date of invoice. If any defect in material and workmanship is found to exist within the warranty period Champion will replace the defective part without charge.

DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY. CHAMPION'S WARRANTY IS ONLY TO THE EXTENT REFLECTED ABOVE. CHAMPION MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED, TO ANY WARRANTY OF MERCHANTABILITY, OR FITNESS OF PURPOSE. CHAMPION SHALL NOT BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. THE REMEDIES SET OUT ABOVE ARE THE EXCLUSIVE REMEDIES FOR ANY DEFECTS FOUND TO EXIST IN CHAMPION DISHWASHING MACHINES AND CHAMPION PARTS, AND ALL OTHER REMEDIES ARE EXCLUDED, INCLUDING ANY LIABILITY FOR INCIDENTALS OR CONSEQUENTIAL DAMAGES.

Champion does not authorize any other person, including persons who deal in Champion dishwashing machines to change this warranty or create any other obligation in connection with Champion Dishwashing Machines.

Model Descriptions

Champion single tank and two tank rack conveyor dishwashers are fully automatic. Standard equipment includes 1HP prewash, 2HP wash and 2HP power rinse pumps. The conveyor drive is a 1/6 HP motor. All models are available in right-to-left (R-L) or left-to-right (L-R) direction.

Model Numbers

Single Tank - Basic .......................................... 44, 54, 44 WS, 44 LT

Single Tank with 22" Prewash .......................... 66 PW, 76 PW, 66 WS, 66 LT PW

Single Tank with 36" Prewash .......................... 80 HDPW, 90 HDPW, 80WS HDPW

Single Tank with 26" Front Feed Prewash ....... 70 FFPW,80 FFPW, 70 WS FFPW

• The 44 DR and 54 DR basic models are high temperature 180°F/80°C hot final rinse water sanitizing dishwashers. Prewash options are available in 22", 36", and 26" front feed. Built-in stainless steel electric booster heaters in 40°F/22°C and 70°F/39°C rise are available and steam booster heaters in 40°F/22°C and 70°F/39°C rise. Dual-Rinse (DR) models feature a recirculating rinse that conserves energy.

• The 44 WS and 44 DRWS models are WaterSaver high temperature 180°F/80°C hot final rinse water sanitizing dishwashers. Prewash options are available in 22", 36", and 26" front feed. Built-in stainless steel electric booster heaters in 40°F/22°C and 70°F/39°C rise are available and steam booster heaters in 40°F/22°C and 70°F/39°C rise. Dual-Rinse (DR) models feature a recirculating rinse that conserves energy.

• The 44 LT and 66 LT models are low temperature 140°F/60°C sodium hypochlorite (chlorine bleach) sanitizing final rinse to maintain a minimum concentration of 50 PPM on the wares. The concentration of sanitizer must be tested at regular intervals using chlorine test papers.

Two Tank - Basic ................................................64, 72, 84

Two Tank with 22" Prewash ...............................86 PW, 94 PW, 106 PW

Two Tank with 36" Prewash ...............................100 HDPW, 108 HDPW, 120 HDPW

Two Tank with 26" Front Feed Prewash .............90 FFPW, 98 FFPW, 110 FFPW

• The 64, and 84 basic models are high temperature 180°F/80°C hot water final rinse sanitizing models. Prewash options are available in 22", 36", and 26" front feed. Built-in stainless steel electric booster heaters in 40°F/22°C and 70°F/39°C rise are available and steam booster heaters in 40°F/22°C and 70°F/39°C rise.

• All rack conveyor dishwasher models are covered by a 1-year parts and labor limited warranty.

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Installation

Unpack and Place

!!ATTENTION!!

Use caution when moving or lifting the dishwasher to prevent

damaging the dishwasher or the installation site. Check doorway and passageway clearance before moving

the dishwasher. Remove dishwasher front panels and check under the

machine base for obstructions before moving.

1. Inspect the dishwasher for shipping damage and immediately report any damage to the freight carrier. Save all packing materials.

2. Check the dishwasher interior for curtains, panels and other supplies.

3. Lift the dishwasher off the shipping pallet and move the machine to its permanent location.

4. Leave a minimum of 6" between walls and the rear of the dishwasher.

5. Level the dishwasher side-to-side and front-to-back using a bubble level. The dishwasher legs are adjusted by screwing them in or out.

6. Do not remove tags attached to the utility connections.

7. Remove the protective film from the dishwasher exterior. Remove any foreign material from the dishwasher interior.

Plumbing - Hot water supply

NOTE:

Only qualied personnel should make dishwasher plumbing connections. Connections must meet local plumbing and sanitary codes.

Improper installation is not covered by the dishwasher limited warranty.

1. Connect a 3/4" NPT hot water supply line to the line strainer located at the top rear of the dishwasher.

For a dishwasher without a booster heater, the hot water connection must supply a

minimum of 180ºF/80ºC (measured at the dishwasher).

For a 40ºF/22ºC rise booster heater, the hot water connection must supply a minimum of

140ºF/60ºC (measured at the dishwasher).

For a 70ºF/39ºC rise booster heater, the hot water connection must supply a minimum of

110ºF/45ºC (measured at the dishwasher).

For a low temperature chemical sanitizing machine, the hot water connection must supply

a minimum of 140ºF/60ºC (measured at the dishwasher).

2. Install a pressure reducing valve (PRV) before the dishwasher supply connection if the flowing line pressure is greater than 25psi [173kPa] at the machine. Set the PRV flowing pressure to 20-22psi [138-151 kPa]. PRV's are supplied by Champion or others.

Installation

Plumbing Connections - Hot water supply continued

3. Install service shut-off valves in the supply line as close to the dishwasher as possible. Valves must be the same size or larger than the supply line.

Cold water supply

1. Connect a 1/2" NPT cold water supply line for dishwashers equipped with a prewash cold water tempering option. Connection is located at the top rear of the dishwasher load end.

2. Connect a 1/2" NPT cold water supply line for dishwashers equipped with a drain cold water tempering option. Connection location can vary depending on site requirements.

Drain Connections

1. The drain trunk line was removed and packed inside the dishwasher prior to shipping. Install the drain trunk line. Dual-Rinse (DR) models also have PVC drain lines that were packed inside the dishwasher. Install the PVC piping on the unload end of the dishwasher.

2. Connect a 1-1/2" NPT or larger gravity drain line to the dishwasher. Observe local plumbing and sanitary codes.

Steam Supply and Condensate Connections

1. Connect a steam supply line the same size or larger to the dishwasher at the steam supply strainer located at the steam booster heater.

2. Connect a gravity condensate return line to the dishwasher. A condensate drain water lift pump (supplied by others) must be installed if the condensate return line rises above the finished floor (AFF).

Ventilation

DO NOT VENT THE DISHWASHER INTO WALLS, CEILINGS, OR CONCEALED SPACES.

1. Connect stainless steel water-tight duct INSIDE the 4” x 16” [102mm x 407mm] vent stacks at the load and unload ends of the dishwasher.

2. A minimum of 6 air changes per hour of kitchen air is recommended.

3. Follow the ventilation requirements below.

Dishwasher with prewash tank Load end -150 CFM @ 1/4” (SP), [71 Liters/Sec] Unload end - 400 CFM @ 1/4” (SP), [189 Liters/Sec]

Dishwasher without prewash tank Load end -200 CFM @ 1/4” (SP), [95 Liters/Sec] Unload end - 400 CFM @ 1/4” (SP), [189 Liters/Sec]

4. Dishwasher vents are equipped with adjustable dampers.

MACHINE ELECTRICAL CONNECTION

Electrical Connections

WARNING !

ELECTRIC SHOCK may cause INJURY OR DEATH.

THIS DISHWASHER mAY HAvE mULTIpLE pOWER SERvICE CONNECTIONS.

DO NOT WORK ON ANY ENERGIzED CIRCUIT.

Turn off all main power service disconnect switches. Attach a label to the breaker indicating that work is being done on the electric circuits.

Installation

!!ATTENTION!!

Electrical and grounding connections must comply with the National Electrical Code and Local Electrical Codes.

A qualied electrician MUST compare the electrical power supply with the machine

electrical specications stamped on the

MACHINE ELECTRICAL CONNECTION PLATE located inside the control cabinet before

connecting the main power to the dishwasher.

1. The Main incoming power to the dishwasher is made at the top of machine in the control cabinet.

2. The electrician must connect the incoming power based on the information that is stamped on the Machine Electrical Connection Plate.

3. Any change to the Machine Electrical Connection Plate must be approved by the factory in advance.

4. The dishwasher main power terminal block is located inside the top-mounted control cabinet.

5. A knock-out plug is provided at the rear of the control cabinet for electrical service connections.

6. Built-in electric booster heaters have a separate main power connection except Models 44 WS and 66WS.

7. Electric blower-dryers have a separate main power connection.

Installation

Electrical Connections continued

8. Motor rotation was set at the factory.

9. The conveyor drive motor rotation is indicated by a red arrow located on the side of the motor.

10. The single phase drive motor (208-240V only) rotation must be changed at the drive motor junction box.

11. Three phase drive motor (480-575V) rotation must be reversed in the control cabinet.

12. Reverse the L1 and L2 wires on the output side of the dishwasher Main Terminal Block (MTB) located inside the top-mounted control cabinet.

The photograph to the right shows the conveyor drive motor with its direction arrow.

A wash pump/motor assembly can be seen in the background.

Chemical Connections

1. Use a qualified detergent/chemical supplier for detergent/chemical and dispensing equipment needs.

2. Labeled detergent control circuit connection terminals are provided in the control cabinet for detergent and rinse agent/sanitizer dispensing equipment (supplied by others).

3. The illustration on the right, shows the terminal board for the current production machines . The signal connection points include:

• Detergent signal 120VAC, 1Amp max amp load

• Rinse aid/Sanitizer signal 120VAC, 1Amp max amp load

4. A removable black plug is provided in the load end side of the wash tank (behind the drive motor) for installation of the detergent conductivity cell.

Installation

Curtain Locations

1. Refer to the illustrations below and hang the curtains as shown. J-hooks are located in the corners of each section to accept the curtain rods.

• Standard long curtains 24” x 20-1/4”

• High hood long curtains 24” x 22-3/4”

• Standard short curtains 24” x 13-/14”

• High hood short curtains 24” x 20-1/4”

• Final rinse curtain 24” x 6-1/4”

2. Make sure the that the short flaps of the curtains face the load end of the dishwasher. The longest curtains always go on each end of the dishwasher.

Installation

Attach the dishtables

1. Attach dishtables (supplied by others) to the load and unload ends of the dishwasher.

2. The table must fit over the dishwasher end flange and extend down into the dishwasher.

3. The dishtables must angle toward the dishwasher so water on the tables will drain into the dishwasher. The dishtables should have adjustable feet to adjust the angles.

4. Use a food grade silicon sealant to seal the joints between the dishtables and the dishwasher.

Install a table-limit switch

A table-limit switch prevents damage to the dishwasher conveyor drive if dishracks pile up on the unload dishtable and jam the conveyor.

A TABLE-LIMIT SWITCH INSTALLATION KIT, P/N 407400 with installation instructions is available from Champion.

!!ATTENTION!!

Damage to the dishwasher conveyor drive can happen

when dishracks jam together on the unload dishtable.

Champion strongly recommends

the installation of a table-limit switch to prevent

dishrack jams at the unload of the dishwasher.

Final Installation Checks

1. Remove any foreign material from inside of the machine.

2. Check dishwasher drain/overflows are closed

3. Install scrap screens and baskets

4. Turn utilities on.

5. Turn dishwasher on to fill tanks with water.

6. Check tank water temperatures reach proper levels.

7. Check for leaks.

8. Drain the dishwasher and check that floor drains handle the water volume leaving the dishwasher.

Operation

IMPORTANT

Please read the steps below before you operate your dishwasher.

1. Make sure the dishwasher was properly installed and tested prior to operation.

2. Read the operating instructions completely before you operate your dishwasher for

the rst time.

3. Keep these instructions available for quick reference.

4. Contact your supervisor immediately if you have questions about the dishwasher.

5. Contact your local authorized Champion service agency for technical support.

6. Our National Service Department provides 24 hour support 365 days a year with a Toll-free number in the United States.

USA National Service

M-F • 8 AM - 5PM EST

Toll-free: 1 (800) 858-44772

In the USA, a factory technician will return your call after-hours and during holidays.

Canadian National Service

M-F • 8:30 AM - 4:30PM EST

Toll-free: 1 (800) 263-5798

Operation

Follow the procedure below to operate your dishwasher properly.

1. Check that the spray pipes, curtains, and scrap screens are in place and clean.

2. Check that the overflow drains are closed.

3. Turn on the detergent dispenser switches and check the detergent supply.

4. Turn on the exhaust vent system (if applicable), and make sure it is operating.

5. Close the door(s). Push the power switch ON, light will illuminate. Machine will begin to fill via the fill valve and the final rinse piping.

6. When the tanks are full, wait until the wash tank has reached the proper temperature. Check the wash tank temperature gauges located on the control cabinet. Minimum wash temperatures are:

• 44 LT, 66 LT PW -140°F/60°C

• 44, 54, 44 WS - 160°F/71°C

• 66 PW, 76 PW, 66 WS PW - 160°F/71°C

7. Push the Green start button. The pushbutton illuminates indicating the dishwasher is ready for automatic operation.

8. Pre-scrap wares to remove large food particles and load wares into the dishracks. DO NOT OVERLOAD RACKS.

9. Pegged racks are for plates and/or trays. Flat racks are for bowls and/or silverware. Spread silverware evenly in a single layer in a flat rack or upright (loosely packed) in a cutlery rack/cylinder.

9. Push a dishrack into the load-end of the dishwasher until it contacts the idle pump switch lever; the conveyor and pumps will start.

The dishwasher will run for 90 seconds to wash, rinse and move the dishrack out

of the unload-end of the dishwasher.

10. Inserting another dishrack into the machine before the first rack exits will keep the dishwasher running until the last dishrack exits the machine.

10. Check the final rinse pressure and temperature as the racks pass through the final rinse. This final rinse pressure MUST be 20-22 psi [138-151 kPa] and the final rinse temperature MUST be a minimum of 180°F/82°C .

11. The pumps and the conveyor drive will automatically stop after the last rack exits the machine.

12. The machine may be stopped at any time during the cycle by pressing the red STOP pushbutton. The green light will go off on the green START pushbutton.

13. Check the interior of the dishwasher for any dishracks still in the machine. These dishracks must be washed again to ensure they are washed and sanitized completely.

14. To restart, push the green START pushbutton and push another dishrack into the dishwasher load-end until the pumps and conveyor start again.

15. Repeat steps 7-10 until all wares are washed.

Operation

Door Safety Switches

Dishwasher access doors are equipped with a door safety switch that automatically stops the dishwasher pumps and conveyor drive if a door is raised while the dishwasher is running. In addition, the diswasher will not start if a door is left open.

1. If the dishwasher is running and a door is raised, then lighted GREEN START pushbutton goes out and the pumps and conveyor drive stop.

2. Check the interior of the dishwasher for any dishracks still in the machine. These dishracks must be washed again to ensure they are washed and sanitized completely.

3. To restart the dishwasher, make sure all doors are closed, then push the GREEN START pushbutton.

4. Insert a dishrack into the dishwasher until the pumps and conveyor run.

Sprayarms and Scrap Screens

Operation

The illustrations below and on the proceeding pages illustrate how to install and remove the sprayarm assemblies and scrap screens.

Removing the lower sprayarm assembly

Operation

Removing the sprayarm end plugs for Cleaning

Installing the lower sprayarm assembly

Operation

Installing the upper sprayarm assembly

Removing the sprayarm end plugs for cleaning

Operation

Removing the Dual Rinse (DR) scrap screens

Operation

Removing the Dual Rinse (DR) scrap screens (continued)

Maintenance

Cleaning your dishwasher is the best maintenance you can do. The cleaning intervals below are the minimum requirements for most dishwashers. You may need to clean your dishwasher more often when washing heavily soiled wares

or during long hours of continuous operation.

Cleaning

Cleaning Intervals

• Daily or every 2 hours of operation

1. Turn power switch to OFF.

2. Pull drain lever(s) to drain water. Remove scrap screens and scrap baskets. Clean inside of the tanks and flush with clean water. Back flush the scrap screens until clean.

DO NOT STRIKE SCREENS OR BASKETS AGAINST SOLID OBJECTS

3. Remove the sprayarm assemblies. Remove the end cap from each sprayarm. Flush the sprayarms and nozzles to remove any debris. Replace the end caps. Check the condition of the manifold O-ring. Reinstall the sprayarms.

4. Remove and clean the curtains. Allow them to dry at the end of the day.

5. Leave the doors open between operations, allowing the machine to dry.

6. Make sure that the final rinse nozzles are clear of mineral deposits. Straighten a metal paper clip to clean the nozzles.

7. Check the temperature and pressure gauge readings during operation.

8. Inspect the machine for signs of water leaks.

9. Check the chemical supplies and refill as necessary.

10. Report unusual conditions to your supervisor.

Maintenance

Cleaning

• Weekly

1. Inspect all water lines for leaks and tighten at joints if required.

2. Clean any detergent residue from the exterior of the machine.

3. Check that the drain/overflow pipes seat tightly in their drains.

4. Clean any accumulated scale from the heating element.

5. Inspect the sprayarms for any damage or missing parts.

6. Inspect the final rinse arms for missing parts.

7. Inspect the pawl bar and drive assembly for damage or missing parts.

8. Check that float switches move freely.

9. Check the idle pump actuator and the final rinse actuator for freedom of travel.

Deliming

The word SCALE refers to the mineral deposits that form as a white film inside and sometimes outside the dishwasher. If allowed to build-up, scale can significantly reduce the performance and life-span of a dishwasher.

Scale must be removed using strong chemicals (deliming agents) that are supplied by a qualified chemical supplier. Your supplier will explain the safety procedures you must follow to prevent personal injury and possible damage to the dishwasher.

Deliming agents vary in compostion and strength so it is impossible for Champion to provide detailed instructions for the large number of products on the market;

therefore, Champion strongly recommends that you do not use any deliming agent without the proper training.

WARNING: Death or injury can result from toxic fume when deliming agents come in contact with Chlorine Bleach, or other chemicals that contain iodine, bromine, or flourine. clothing as instructed by a qualified chemical supplier.

USE EXTREME CAUTION WHEN HANDLING ANY DELIMING AGENT

CAUTION: Deliming agents can cause chemical burns. Wear rubber gloves, eye protection and any other protective clothing as instructed by a qualified chemical supplier.

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Basic Service

Electrical • Basic Service

Electrical Service

Fuse Blocks - 120VAC Control Voltage

Two fuse blocks, located in the center of the front of the main control cabinet protect the main control transformer. Each fuse block holds one fuse. Always replace a blown fuse with a fuse of the same AMP rating. DO NOT INCREASE THE FUSE RATING.

Motor Overloads Motor overloads are located to the left of the fuse block inside the control cabinet. Each

motor has one overload to protect it from line voltage electrical overloads. In addition, an auxiliary set of switch contacts is attaches to the overload. The switch contacts disconnect 120VAC power to the motor contactor coils in the event of an overload condition.

A motor Overload has 2 rocker switches, OFF/STOP and ON/START.

• The motor overload has tripped if the Off/Stop switch is in the Off position. Set the rocker switch to STOP. Then, push the ON/START rocker switch to the ON position

• The motor overload rocker switch is in the START position when the pump is ON and in the STOP position when the motor is OFF.

• Turn the dishwaser power ON and insert a dishrack to start the pumps and conveyor. Troubleshoot the motor circuit. The motor overload may be faulty if motors are OK.

• Arrows indicate the Full load Amp (FLA) adjustment screws. Each screw should be set to the FLA rating found on the motor the data

plate.

Pump/Conveyor Run Timer

The solid-state pump/conveyor run timer is a xed 90-second timer that controls the maximum time that the pumps and conveyor drive motor runs after a dishrack enters the load-end of the dishwasher.

90-seconds is the time necessary for 1 dishrack to complete its travel through the dishwasher ensuring that wares are washed and rinsed before exiting the machine.

The timer resets to 90-seconds each time a dishrack enters the dishwasher. This ensures that every dishrack is processed completely.

A faulty pump/conveyor run timer is possible if the 90-second run time is off by plus or minus 2-seconds. The idle-pump start switch located on the load-

end dishwasher should be checked for proper operation before replacing the timer.

Basic Service • Electrical

Electrical Service (continued)

Pump/Conveyor Timer

Timer Sequence of Operation:

• A dishrack entering the machine contacts the idle pump switch lever.

• The contacts of the idle pump switch open, de-energizing control relay 1CR.

• Normally closed contacts of 1CR close and apply a signal to pump timer. The timer contacts close turning on the pump(s) and drive motor

• The dishrack moves off the idle pump switch lever and the switch contacts close.

• 1CR energizes and the notmally closed contacts open removing the signal from the pump timer.

• The pump timer begins to time down for its 90 seconds time setting.

• The timer is reset each time the idle pump switch is activated. If the timer is reset only once it will time out and shut the pump(s) and drive motor off after the time delay.

To Check the Pump Timer Setting:• Turn the power on.

• Press the green lighted START pushbutton.

• Place a rack in to the conveyor.

• When the rack enters the load end, the pump(s) and the drive motor will start.

• Time the conveyor and when the rack clears the idle pump switch. Note the elapsed time when the machine stops. The elapsed time should be within 2-seconds of the timers 90-second setting.the timer.

• Replace the timer if the is off more than 2-seconds.

Electrical • Basic Service

Electrical Service (continued)

Automatic Fill/Low Water Heat Protection

Dual Float Switches

Each tank contains a dual oat switch. The part consists of an angled stem containing two reed

switches. Two stainless steel ball oats, containing magnets,

slide over the stem and are free to move up and down. When the oat moves on the stem, it opens and closes the associated reed switch inside the stem. The reed switches

control relays. The relays control the automatic ll and heat for different parts of the machine. The oat switch(es) and their

relay(s) operate on a 120VAC circuit.

Operation Sequence

Bottom Float and Reed Switch

• The bottom float controls the heat.

• When the bottom float is down, the bottom reed switch contacts are open.

• When the bottom float is up, the bottom reed switch contacts are closed.

Top Float and Reed Switch

• The top float controls a fill valve, which controls the water level.

• When the top float is down, the top reed switch contacts are open.

• When the top float is up, the top reed switch contacts are closed.

Initial Fill

• When the tank is empty, both floats are down and their reed switch contacts are open.

• The control relay for the float switch is de-energized.

• The fill valve for the tank is energized and the tank begins to fill with water.

• As the water level in the tank rises, the bottom float begins to move up.

• When the bottom float is completely up, its reed switch contacts close.

• This prepares the heat circuit, but the heat DOES NOT energize at this time.

• The tank continues to fill until the top float is completely up.

• The top float’s reed switch contacts close. Its control relay energizes.

• The fill valve de-energizes.

• The heat circuit energizes through the contacts of the control relay.

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