Champion 40KPRB, PR36-40KB, FFPR26-40KB, 60KB, 60KPRB Service Manual

...

Technical Manual

Two Tank Rack Conveyor

with/without Prewash

With (FFPR26) Basic With (PR22) With (PR36) 26" Front Feed Model 22" Prewash 36" Prewash Prewash

40KB 40KPRB PR36/40KB FFPR26/40KB 60KB 60KPRB PR36/60KB FFPR26/60KB 64KB 64KPRB PR36/64KB FFPR26/64KB

Machine Serial No.

June, 2005

Manual P/N 112951 Rev. I

P.O. Box 4149 2674 N. Service Road Winston-Salem, North Carolina 27115-4149 Jordan Station, Ontario,Canada L0R 1S0 336/661-1556 Fax: 336/661-1660 905/562-4195 Fax:905/562-4618

www.championindustries.com

For machines beginning with serial no. R1247 and above

Complete the information below so it will be available for quick reference.

Model Number Serial Number

Voltage and Phase

Champion Service Agency Phone

Champion Parts Source Phone

Champion Service:

Champion (USA) Champion (Canada) Phone: 1 (336) 661-1556 Phone: 1 (905) 562-4195

1 (800) 858-4477 1 (800) 263-5798

Fax: 1 (336) 661-1660 Fax: 1 (905) 562-4618

We strongly recommend that you Fax your orders.

NOTE: When calling to order parts, be sure to have the model number, serial number,

voltage and phase of your machine.

Machine Data Plate with Model No., Serial No., Voltage and Phase is located on the right or left side of the Control Cabinet

Top of Machine

Control Cabinet

Left to Right Model Shown

Revision History

Revision Revised Serial Number Comments

Date Pages Effectivity

3/10/99 All R-1247 First Issue of Manual and service replacement parts 1/26/00 35 ––– Added cradle assy P/N's 1/26/00 90 R1666 Changed motor contactor P/N 111642 to Motor

contactor P/N 108122 1/26/00 95 ––– Added dual float switch, P/N 11019 to par ts list 5/23/00 39 R-1810 Changed pump assembly parts 10/1/00 95 ––– Corrected float switch, P/N 111019 10/10/00 35 ––– Added 40-60 KB cradle part numbers 11/01/00 54 R1529 Added new piping due to change in location of

pressure switch 11/01/00 58 All Inserted new drawing for all Serial numbers with no

booster or with Steam booster 4/3/01 89 ––– Revised machines for 12' thermometer – 109499 1/03/02 55,59 R2441 Change vacuum breaker 3/4" 1044129 to 113222 1/03/02 56,60,63,73,77 Change vacuum breaker 1/4" 107069 to 113218 1/03/02 56,59,63,73,77 R2441 Change Parker/Evans 1/4" solenoid valve 109885 to

GC solenoid valve 1/2" 113352 along with repair kit,

coils and piping changes 1/03/02 73,77 Added track stiffener 325667 5/20/02 56,60,63,73,77 Added 900836 Kit* Repair, 1/4" & 1/2" Vacuum

Breaker and 900837 Kit* Repair 3/4" Vacuum Breaker 2/5/03 39 Replaced impellers with new part numbers. 2/5/03 89 Replaced 108391 with 113622 thermometer. 2/5/03 91 Replaced Furnace (Siemens) overloads with

Telemecanique (Square D) overloads. 2/5/03 92, 115, 117 Replaced P/N 111826 with P/N 111827. 7/23/03 55, 56, 59, 60, 63, Revised plastic style vacuum breakers with

73, 74, 77, 78 bronze style. 7/23/03 89 Corrected part numbers for overlays. 3/11/04 43, 45, 67, 69 R3285 Replaced 111090 with 113721 reed switch.

71, 73

3/11/04 124 ––– Revised schematic 700935 revision H to revision I.

REVISIONS

Revision History (Cont.)

iii

CONTENTS

Page

REVISION HISTORY...................................................................................................................... i

WARRANTY .................................................................................................................................. vi

KEY COMPONENTS...................................................................................................................... 1

INTRODUCTION .......................................................................................................................... 2

GENERAL........................................................................................................................................ 3

INSTALLATION ............................................................................................................................ 5

Unpacking .......................................................................................................................... 5

Electrical Connections ........................................................................................................ 5

Plumbing Connections ........................................................................................................ 6

Ventilation Connections ...................................................................................................... 6

Chemical Connections ........................................................................................................ 6

Curtain Locations ................................................................................................................ 7

Completing Installation ...................................................................................................... 7

OPERATION.................................................................................................................................... 8

MAINTENANCE ............................................................................................................................ 11

Maintenance Schedule ........................................................................................................ 11

Deliming.............................................................................................................................. 12

TROUBLESHOOTING .................................................................................................................. 13

ELECTRICAL SERVICE ................................................................................................................ 15

MECHANICAL SERVICE ..............................................................................................................23

TABLE LIMIT SWITCH INSTALLATION.................................................................................... 27

REPLACEMENT PARTS ................................................................................................................ 31

ELECTRICAL SCHEMATICS ...................................................................................................... 111

LIST OF FIGURES

Figure 1 — Fuse Blocks .............................................................................................................. 15

Figure 2 — Motor Overload ...................................................................................................... 15

Figure 3 — Pump Timer ..............................................................................................................16

Figure 4 — Dual Float Switch .................................................................................................... 17

Figure 5 — Tank Heat Ther mostats ............................................................................................ 18

Figure 6 — Booster Thermostat Locations (Electric) ................................................................ 18

Figure 7 — Booster High Limit Thermostat (Electric) .............................................................. 18

Figure 8 — Front View Typical 40°F/22°C rise Booster, One Tank 36 Kw shown .................. 22

Figure 9 — F ront View Typical 70°F/39°C rise Booster, Two Tank 57 Kw shown .................... 22

Figure 10 — Idle Pump Switch Assembly .................................................................................... 24

REVISIONS

LIST OF FIGURES (Cont.)

Figure 11 — Magnetic Switch and Magnet .................................................................................. 24

Figure 12 — Rinse-Saver Switch Mechanism .............................................................................. 24

Figure 13 — Crank Assembl y........................................................................................................ 25

Figure 14 — Conveyor Drive Assembly........................................................................................ 25

Figure 15 — View of Load End of Machine ................................................................................ 26

Figure 16 — Close-up View of Bearing Housing ........................................................................ 26

Figure 17 — Close-up View of Clutch Assembly .......................................................................... 26

Figure 18 — Conveyor Drive Assembly........................................................................................ 32

Figure 19 — Track and Cradle Assembly .................................................................................... 34

Figure 20 — Track and Cradle Assembly-PR22, PR36 ................................................................ 36

Figure 21 — Motor and Pump Assembly (Wash, Power Rinse, Prewash) .................................... 38

Figure 22 — Idle Pump Mechanism ............................................................................................ 42

Figure 23 — Idle Pump Switch (FFPR26 Only) (All S/N’s) ........................................................ 44

Figure 24 — Wash System Assembly (Wash Tank and Power Rinse Tank).................................. 46

Figure 25 — Wash System Assembly (PR22, FFPR26)................................................................ 48

Figure 26 — Wash System Assembly (PR36) .............................................................................. 50

Figure 27 — Outside Rinse Piping with Electric Booster ............................................................ 52

Figure 28 — Outside Rinse Piping with Electric Booster After R1529 ...................................... 54

Figure 29 — Fill and Outside Rinse Piping, w/No Booster and Steam w/Booster ...................... 58

Figure 30 — Cold Water Thermostat for Prewash Option .......................................................... 62

Figure 31 — Inside Rinse Piping .................................................................................................. 64

Figure 32 — Rinse Saver Mechanism (L-R) ................................................................................ 66

Figure 33 — Rinse Saver Mechanism (R-L) .............................................................................. 68

Figure 34 — Doors, Curtains, Miscellaneous................................................................................ 70

Figure 35 — Hood (PR22, PR36) ................................................................................................ 72

Figure 36 — Hood (FFPR26) ...................................................................................................... 76

Figure 37 — Tank (PR22).............................................................................................................. 80

Figure 38 — Tank (PR36) ............................................................................................................ 82

Figure 39 — Tank (FFPR26) ...................................................................................................... 84

Figure 40 — Drain Unit and Screens Wash/Power Rinse Tank .................................................... 86

Figure 41 — Control Cabinet ........................................................................................................88

Figure 42 — Control Panel............................................................................................................ 90

Figure 43 — Tank Heat (Electric, R-L Shown) ............................................................................ 94

Figure 44 — Tank Heat (Steam Coils, R-L Shown) ...................................................................... 96

Figure 45 — Tank Heat (Steam Supply Piping)............................................................................ 98

Figure 46 — Tank Heat (Condensate Piping)................................................................................ 100

Figure 47 — Tank Heat (Steam Injector, R-L Shown) .................................................................. 102

Figure 48 — Electric Booster (40°F/22°C Rise) .......................................................................... 104

Figure 49 — Electric Booster (70°F/39°C Rise) .......................................................................... 106

Figure 50 — K2 Steam Booster .................................................................................................... 108

CONTENTS

Figure 51 — Thrush Steam Booster (40°F/22°C - 70°F/39°C Rise) ............................................ 110

Figure 52 — Thrush Steam Booster (80°F/44°C Rise) ................................................................ 112

Figure 53 — Control Panel, Electric Booster (70°F/39°C Rise) .................................................. 114

Figure 54 — Control Panel, Electric Booster (40°F/22°C Rise) .................................................. 116

Figure 55 — Vent Hood Assembly ................................................................................................ 118

Figure 56 — Dish Racks................................................................................................................ 120

ELECTRICAL SCHEMATICS

B700935/I — Wiring Diagram (64KB, 40KB, 60KB Steam/Electric) B700936/G— Wiring Diagram (64KPRB, 40KPRB, 60KPRB Steam/Electric)

REVISIONS

LIMITED W ARRANTY

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 par ts, 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 workmanship for a period of one (1) year after the date of installation or fifteen (15) months after the date of shipment by Champion, whichever occurs first. [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 war ranty 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 first. 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

finish 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 war ranty 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.

Vacuum Breaker

Line Strainer

Power Rinse Tank Heat Control and High Limit

Thermostats Power Rinse tank Pump/Motor Assembly

Dual Float Switch Auto Fill/Low Water Tank Heat Protection

Door-activated Drain-overflow Tube Assembly

Final Rinse-Saver Mechanism (Switch and Magnet)

Final Rinse Booster Tank Assy

(Electric Only)

Power Rinse Tank Heater Element

Final Rinse Piping

Pushbutton Stop Switch (Red)

Wash Spray Arms

Pushbutton Start Switch (Green)

Main Power Switch/ Circuit Breaker

Control Transformer

Solenoid Valve

Pressure Gauge

Pressure Reducing Valve, PRV,

(Factory installed on machines with boosters)

Top Mounted Control Cabinet

Temperature Gauges

Conveyor Crank and Crosshead Roller Assembly

Conveyor Dr ive Clutch and Gear Reducer

Cradle Assembly

Idle Pump Mechanism (Switch and Magnet)

Rack Conveyor Key Component Locations

(Right to Left Electrical Machine Shown)

KEY COMPONENTS

INTRODUCTION

Welcome to Champion.

...and thank you for allowing us to take care of your dishwashing needs. This manual covers several models. Model numbers are shown on the front cover. Your machine has been completely assembled, inspected, and thoroughly tested at our factory

before it was shipped to your installation site. This manual contains:

• Warranty information

• Operation and cleaning instr uctions

• Maintenance instr uctions

• Troubleshooting guide

• Basic ser vice infor mation

• Replacement par ts lists

• Electrical schematics

Complete and return your warranty registration card within ten (10) days after the installation of your machine.

All information, illustrations and specif ications contained in this manual are based upon the latest product information available at the time of publication. Champion constantly improves its products and reserves the right to make changes at any time or to change specifications or design without notice and without incurring obligation.

For your protection, factor y authorized par ts should always be used for repairs. Replacement parts may be ordered from your Champion authorized service agency. When

ordering parts, please supply the model number, serial number, voltage and phase of your machine, the part number, part description, and quantity.

GENERAL

This manual covers the Champion two tank rack conveyor dishwashing machine. This machine is fully automatic and is equipped with 2 H.P. wash/rinse pump motors and a 1/4 H.P. conveyor drive motor. All models are available for right-to-left or left-to-right operation.

This series of dishwashers is modular in design. The following models and options are covered in this manual:

Model Numbers

Two tank - Basic.................................................... 64KB, 40KB, 60KB

Two tank with 22" Prewash .................................. 64KPRB, 40KPRB, 60KPRB

Two tank with 36" Prewash .................................. PR36/64KB, PR36/40KB, PR36/60KB

Two tank with 26" Front Feed Prewash ................ FFPR26/64KB, FFPR26/40KB, FFPR26/60KB

• The 64KB basic model, along with its respective prewash option, is a high temperature (180˚F/82°C final rinse) sanitizing model.

• The 40KB basic model, along with its respective prewash option, is a high temperature (180˚F/82°C final rinse) sanitizing model.

• The 60KB basic model, along with its respective prewash option, is a high temperature (180˚F/82°C final rinse) sanitizing model.

THIS PAGE

INTENTIONALLY

LEFT BLANK

GENERAL

INSTALLATION

Unpacking

CAUTION:

Care should be taken when lifting the machine. The piping under the base can be damaged. Remove the dishwasher front panels if lifting from the front with a forklift.

1. Immediately after unpacking your machine, inspect for any shipping damage. If damage is found, save the packing material and contact the carrier upon receipt of the machine.

2. Remove the dishwasher from the skids. Adjust the feet if required, then move the machine to its permanent location. The machine should not be installed within 6 inches [153mm] of any wall or structure.

3. Level the machine by placing a level on the top of the machine and adjusting the feet. Level front-to-back and side-to-side.

Electrical Connections

NOTE:

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

WARNING:

When working on the dishwasher, disconnect the electric service and tag it to indicate work is being done on that circuit.

1. The electrician should compare the electrical specifications on the machine electrical connection plate (located inside the control cabinet) to the electrical power supply before connecting to the incoming service at a fused disconnect switch.

2. Motor rotation was set at the factory. Ensure proper rotation of the conveyor drive shaft (red arrow on shaft shows direction of rotation). Reversing the motor direction is done in the control cabinet by reversing the wires Ll and L2 on the disconnect switch side of the main electrical connection terminal block (Refer to the electrical diagrams in the back of this manual).

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

NOTE:

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

NOTE:

Electric boosters require a separate electrical connection.

A fused disconnect switch or circuit breaker (supplied by user) is required to protect each

INSTALLATION

Chemical Connection

Terminal Board

INSTALLATION

Plumbing Connections

CAUTION:

Plumbing connections must comply with local sanitary and plumbing codes.

1. Connect the hot water supply at the final rinse piping connection located behind the control cabinet at the top of the machine.

2. A “Y” line strainer is provided by Champion for machines without boosters. A pressure reducing valve (PRV) is provided by Champion for machines with built-in boosters.

3. If the incoming hot water supply pressure exceeds 25 psi [173 kPa], a PRV must be installed and set to 20-22 psi [138-151 kPa]. The PRV may be purchased from Champion or supplied by others.

4. Install a manual shut-off valve in the steam and water supply lines to accommodate ser vicing the machine. The valve should be the same size as or larger than the supply line.

5. Provide a suitable gravity drain to connect to a 1-5/8" OD drain tube.

Ventilation

1. Stainless steel watertight ducting should be installed INSIDE the 4" x 16" [102mm x 407mm] vent stacks at the load and unload ends. A minimum of 6 air changes per hour of kitchen air is recommended. The typical exhaust ventilation requirements for a rack machine using a 180˚F/82°C final rinse are:

• The load end requires 150 CFM @ 1/4" (SP), [71 Liters/sec] with prewash.

• The load end requires 200 CFM @ 1/4" (SP), [95 Liters/sec] without prewash.

• The unload end requires 400 CFM @ 1/4" (SP), [189 Liters/sec].

2. An adjustable damper is supplied with the vent stacks for adjusting the exhaust volume.

CAUTION:

Exhaust air should not be vented into a wall, ceiling, or concealed space of a building. Condensation will cause damage.

Chemical Connections

1. Use a qualified detergent/chemical supplier.

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

3. Refer to the illustration below. The illustration shows the terminal board for current production machines. Signal connection points include:

• Detergent signal 120VAC, 1 Amp Max amp load.

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

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

SIGNAL ONLY

120V

RINSE AID/ SANI

COMMON

DETERGENT

1R001

Short cur tain

Long curtain

Load End

Curtain Locations

(Machine with prewash shown)

Long curtain

Short

flaps

Short flaps on long curtains

face the load end of dishwasher

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 curtain 24" x 20-1/4" [610mm x 515mm]

• High hood long curtain 24" x 22-3/4" [610mm x 578mm]

• Standard short curtain 24" x 13-1/4" [610mm x 337mm]

• High hood short curtain 24" x 20-1/4" [610mm x 515mm]

2. Make sure the short flaps of the long cur tains f ace the load end of the dishwasher. The longest curtains always go on each end of the dishwasher.

INSTALLATION

Completing Installation

WARNING:

Do not insert racks into machine before tanks fill with water. Operating pumps dry will cause pump seal damage and leakage that can result in a motor failure.

1. Remove any foreign material from inside the machine.

2. Check to insure that drains and overflow pipes are operational and sealed.

3. Position scrap screens on supports above the tanks.

4. After plumbing and electrical connections are completed, fill the tank and wait 10 minutes. Check all plumbing connections for leaks.

5. Drain the tank and check the drain lines for leaks.

6. The for med down lip of the dishtable should be placed inside the machine. The dishtable should be pitched toward the dishwasher for proper draining by adjusting its leveling feet. The dishtable should be sealed to the dishwasher.

1R003

WASH

PRE

WASH

R-L Direction

Power Rinse

1R002a

Simplified Rack Conveyor Dishwasher

Right to Left Model

OPERATION PROCEDURE

OPERATION

Final Rinse Water

Wash Water

Temperature Gauge

Vacuum

Breaker

Long Curtain

Idle Pump

Magnet

Idle Pump

Magnetic Switch

Conveyor Crank

Conveyor Drive

Motor and Gear

Clutch

Assembly

Reducer

Control Cabinet

Green Start Button

Lighted On-Off

Rocker Switch

Pressure

Regulating

Rinse Valve

Red Stop Button

Vacuum

Breaker

Fill Valve

Valve

Wash Arm Spray Pipes

Right to Left Model

Conveyor Direction

Wash Arm Spray Pipes

Booster

E lectric Tank

Heaters

Pump

Strainer

Wash

Pump

Dual Float

Switch

Short Curtain

Rinse-Saver

Final Rinse

Drain-off

Adjustment

Magnet

Rinse-Saver

Magnetic Switch

Door Activated

Drain-overflow

Assembly

Long Curtain

Upper Final Rinse Pipe

Lower Final Rinse Pipe

OPERATION

Rack Conveyor Machine

Operation Procedure

Action Result

Turn Power Switch on

Press green start button

Insert soiled rack

Rack conveys thru machine

Rack activates final rinse

Rack exits the machine

Press stop push button

Drain machine for cleaning

after each meal period

or every 2 hours of use

Lighted On-Off Rocker Switch

on control cabinet will illuminate

Float switch activated

Tank(s) fill with water

When machine is full float

switch cuts off water

and calls for heat.

(Wait for proper temperature)

Conveyor drive motor

is activated

Wash pump starts

Continuous power on wire #13

and #2 120V Detergent signal

20 psi required flow pressure

Power to wire #70 and #2 120V

Rinse/Sanitize signal

Wash pumps shut down (timer)

Conveyor continues to run

Conveyor drive will stop

Check detergent and rinse aid

supply. Replenish if necessary

Doors are closed

Door activated drains

are closed

OPERATION

Follow the procedure below to operate your dishwasher properly.

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

2. Turn on detergent dispenser switches and check detergent supply.

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

4. Close door(s). Push the power switch to the ON position. Tanks will begin filling with water.

5. When tanks are full, check wash tank temperature gauge. Minimum wash temperatures are:

• 64KB, 40KB, 60KB Wash tank - 150°F/66°C

• 64KB, 40KB, 60KB Power rinse tank - 160°F/71°C

• Prewash tanks do not have tank heaters

6. Press the START button on the control cabinet. Only the conveyor will start. The pumps WILL NOT OPERATE until the first rack enters the machine.

7. Scrap and pre-flush all items to be washed, and load the items into the rack. DO NOT OVERLOAD RACKS. Place dishes edgewise in a peg rack, cups and bowls upside down in a flat rack. Spread silverware evenly in a single layer in a flat rack or upright (loosely packed) in a cutlery rack.

8. Push the rack into the machine, and the pumps will star t automatically.

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

10. The pumps will automatically stop shortly after the last rack leaves the machine. The conveyor will continue to run.

11. The machine may be stopped any time during the cycle by pressing the STOP button on the control cabinet. When restarted, items inside the machine will be fully washed and rinsed.

12. CLEAN scrap screens, scrap baskets (if applicable) and REPLACE tank water every 2 hours of operation or after each meal period. Check chemical supply.

CAUTION:

DO NOT allow racks to remain on unload dishtable. This could cause the conveyor to jam and may damage machine. The installation of a table limit switch is highly recommended and will reduce the risk of damage.

WARNING:

Do not leave water in tanks overnight.

MAINTENANCE

The efficiency and life of your machine is increased by regularly scheduled preventive maintenance. A well maintained machine gives better results and ser vice. An investment of a few minutes of daily maintenance will be worthwhile.

The best maintenance you can provide is to keep your machine clean. Components that are not regularly cleaned and flushed will clog and become inoperative.

Intervals shown in the following schedules represent an average length of time between necessary maintenance. Maintenance intervals should be shortened whenever your machine is f aced with abnormal working conditions, hard water, or multiple shift operations.

Maintenance Schedule CLEANING

• Daily-Every 2 Hours of Operation

1. Turn power switch to OFF.

2. Remove all scrap screens, scrap baskets (if applicable), and pull drain lever(s) to drain water. Clean inside of tanks and flush with clean water. Backflush scrap screens until clean.

Do not strike screens against solid objects.

3. Remove the spray pipes by a 1/4 tur n, counterclockwise. Remove the end plug from each spray pipe. Flush pipe and nozzles until clean. Do not strike spray pipes against solid objects. Replace end plugs, verify that rubber seals are in place on manifolds. Reinstall spray pipes using a 1/4 clockwise turn.

4. Remove and clean curtains. Hang them off the dishtable to dry.

5. Leave the doors open between operations to allow dr ying.

6. Verify that final rinse nozzles are clean and free of inter nal hard water deposits. Clean rinse nozzle orifices with a small paper clip. Consult your chemical supplier for the proper use and kind of deliming chemical.

7. Repor t any unusual conditions to your supervisor.

• As Required

1. Check temperature and pressure gauge readings.

2. Inspect machine and check pump motor for leaks around the shaft.

3. Check chemical supplies and refill as necessar y.

• Weekly

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

2. Clean all detergent residue from exterior of machine.

3. Check drain/overflow tube for leaks.

4. Clean accumulated scale from heating element.

5. Remove and closely inspect each spray ar m for blockage.

MAINTENANCE

• Weekly (Cont.)

6. Straighten a paper clip and use it to clear each rinse nozzle.

7. Inspect pawl bars and drive assembly for wear and freedom of travel.

8. Check float switches in tank for freedom of travel.

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

DELIMING

Your dishwasher should be delimed regularly as required. This will depend on the mineral content of your water.

Inspect your machine interior for lime deposits. If deliming is required, a deliming agent should be used for best results. Consult your chemical supplier for proper type and procedures.

DANGER:

Deliming solution, rinse agents, or other acids must not come in contact with household bleach (sodium hypochlorite) or any chemicals containing chlorine, iodine, bromine, or fluorine. Mixing may cause hazardous gases to form. Consult your chemical supplier.

TROUBLESHOOTING

In order to find the cause of a breakdown or abnormal operating condition in your dishwasher please ensure that:

1. All switches are ON

2. Drain and overflow tube are in place and seated

3. Wash pipe and rinse nozzles are clean

4. Scrap screen(s) and scrap basket (if applicable) are properly positioned

5. Spray pipes are in their proper positions

6. Ther mostat(s) are at their cor rect setting

7. Sanitizer, detergent, and rinse additive dispensers are adequately filled

8. Doors are fully closed.

If a problem still exists, use the following table for troubleshooting

CONDITION CAUSE SOLUTION

Machine will not start Door not closed .................................. Make sure doors are fully closed

Door safety switch faulty .................. Contact your service agency

Start switch faulty.............................. Contact your ser vice agency

Main switch off.................................. Check disconnect

No rack inserted ................................ Place rack in unit

Overload protector tripped ................ Reset overload in control box

Low or no water Main water supply is turned off ........ Turn on house water supply

Drain/overflow tube is not

in place and seated ............................ Place and seat drain tube

Machine doors not fully closed ........ Close doors securely

Faulty fill valve.................................. Contact your service agency

Stuck or defective float...................... Check floats and clean

Clogged ‘Y’strainer .......................... Clean or replace

Continuous water filling Stuck or defective float...................... Check floats and clean

Fill valve will not close...................... Clean or replace

Drain tube not in place ...................... Look for drain tube in tank

Any motor not running Overload protector tripped ................ Reset overload in control box

Defective motor ................................ Contact your service agency

Wash tank water temperature Incoming water temperature

is low when in use at machine too low ............................ Raise temperature to: 140°F/60°C

Defective thermometer ...................... Check or replace

Defective thermostat.......................... Check for proper setting or replace

Defective heater element .................. Check or replace

Low steam pressure .......................... Check steam supply pressure

Defective steam trap.......................... Check or replace

Defective solenoid valve.................... Check or replace

TROUBLESHOOTING

CONDITION CAUSE SOLUTION

Insufficient pumped spray Clogged pump intake screen.............. Clean

pressure Clogged spray pipe............................ Clean

Scrap screen full ................................ Must be kept clean and in place

Low water level in tank...................... Check drain and overflow tube

Pump motor rotation incorrect .......... Reverse connection between L1

and L2 in control cabinet (3 phase only)

Defective pump seal .......................... Contact service agent

Insufficient f inal rinse or no Faulty pressure reducing valve .......... Clean or replace

final rinse Improper setting on pressure

reducing valve.................................... Set flow pressure to 20-22 psi [138-151 kPa]

Clogged rinse nozzle and/or

pipe .................................................... Clean with paper clip/delime

Improper water line size.................... Have installer change to proper size

Clogged ‘Y’strainer .......................... Clean or replace

Low final rinse temperature Low incoming water ........................ Check the booster (KB, KPRB models)

be sure the thermostat is set to maintain 180°F/82°C temperature. Check valve to be sure it is clean and operating.

Defective thermometer ...................... Check for proper setting or replace

Poor washing results Detergent dispenser not

operating properly.............................. Contact detergent supplier

Insufficient detergents ...................... Contact detergent supplier

Food Soil concentration too

high in wash tank .............................. Drain tank, clean and refill every 2 hours of

operation or after each meal period. Wash water temperature

too low .............................................. See condition “Wash Tank

W ater Temperature” above

Wash ar m clogged .............................. Clean

Improperly scraped dishes ................ Check scraping procedures

Ware improperly

placed in rack .................................... Use proper racks. Do not overload racks

Improperly cleaned

equipment .......................................... Unclog wash sprays and rinse nozzles

to maintain proper pressure and flow

conditions. Overflows must be open.

Keep wash water as clean as possible. Electric elements or steam

coils has soil/lime buildup ................ Clean and delime

TROUBLESHOOTING

1R005

1R004

Figure 1

Fuse Blocks

Figure 2

Motor Overload

ELECTRICAL SERVICE

Fuse Blocks—120VAC Control Voltage

Two fuse blocks, located in the center rear of the main control cabinet protect the main control transformer. Each fuse block holds a fuse. The fuses are marked 1FU and 2FU on the electrical schematic.

To Replace the fuse:

• Disconnect power to the machine at the main service switch.

• Flip the tab on the top of the fuse block to open the block.

• Remove the fuse and replace it.

• Close the fuse block and turn the main power on.

• If the fuse blows again, DO NOT INCREASE THE FUSE SIZE.

• DETERMINE THE CAUSE OF THE OVERLOAD. Fig. 1 shows the fuse block opened and the fuse exposed.

Motor Overloads

Motor overloads are located to the left of the fuse blocks inside the control cabinet. Each motor has one overload to protect it from line voltage electrical overloads. In addition, an auxilary set of switch contacts is built into the overload. The switch contacts disconnect 120VAC power to the motor contactor coils in the event of an overload condition. Refer to Fig. 2.

Note the Switch Lever on the Overload.

• If the switch lever is off with the “0” showing

then the overload has tripped on an overload.

To Reset the Motor Overload:

• Flip the star ter switch to the On position.

• Run the dishwasher and test the AMP draw of the motor in question. If the motor checks okay then there may be a wiring problem or the overload may be defective.

To Replace a Motor Overload:

• Disconnect the wires to the overload.

• Release the mounting catch on the front side of the overload, push forward and lift out.

• Snap the new overload into place and reconnect the wires.

To adjust the overload setting:

The screwdriver in Fig. 2 is positioned to adjust the motor overload AMP setting.

• Read the FLA motor amps that applies for the machine voltage on the Motor Nameplate.

• Turn the setting to match nameplate FLA.

BackFront

Pump Timer

Refer to Fig. 3 The automatic timer located in the left center of the control cabinet is set at the factory.

The Pump Timer controls the amount of time that the pumps will run before the last rack enters the load end of the dishwasher tunnel.

The Pump Timer is an OFF DELAY timer. Each timer is marked

with a tag noting the time set by the factory.

The timer has the following user defined settings:

1. Adjustable timer range

2. Timer knob setting

3. Indicator light (ON when timer is counting)

4. 50 Hz or 60 Hz setting on the back of the timer

To Replace a Timer:

• Disconnect power to the machine at the main service switch.

• Remove the defective timer and install the replacement.

• Adjust the new timer setting to match the setting of the original timer.

Operation Sequence:

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

• Nor mally closed contacts of the idle pump switch open, de-energizing control relay 1CR.

• Nor mally closed contacts (1, 9) of 1CR close and apply 120VAC to reset coil of pump timer.

• Pump timer resets.

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

• 1CR energizes and contacts (1, 9) open removing 120VAC from the pump timer reset coil.

• The pump timer begins to time down for its preset 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 pumps off after the rack has exited the dishwasher.

To Check the Pump Timer Setting:

• Turn the power on.

• Place a rack on the conveyor.

• Press the Green star t button. The conveyor drive will start.

• When the rack enters the load end the pumps will star t.

• Wait for the rack to exit the tunnel at the unload end.

• When the pumps stop, push the red stop button.

• Measure the distance between the exit end of the tunnel and the rack.

• The rack should be about 1 foot past the end of the tunnel.

• If the distance is less than 1 foot, increase the pump timer setting. Continue to increase the timer setting a few seconds at a time until the proper distance is reached.

• If the measured distance is g reater than 1 foot, decrease the pump timer setting. Continue to decrease the timer setting a few seconds at a time until the proper distance is reached.

ELECTRICAL SERVICE

6 Omron H2C

1R006

1R007

Figure 3

Pump Timer

1R008

Figure 4

Dual Float

Switch

ELECTRICAL SERVICE (Cont.)

Automatic Fill/Low Water Heat Protection

Dual Float Switches –

Refer to F

ig. 4 Each tank contains a dual float. The device consists of an angled stem containing two reed switches. Two stainless steel ball floats slide over the stem and are free to move up and down. The floats contain magnets. When the float moves on the stem, it opens and closes its associated reed switch inside the stem. The reed switches control relays. The relays control the automatic fill and heat for different parts of the machine. Float switches and their relays operate on 24VAC.

Circuit Explanation –

The following is a general explanation of the float switch circuit. Refer to the electrical schematic on your machine for a detailed description of the individual floats, relays, and wiring.

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 close.

Top Float and Reed Switch:

• The top float controls a fill valve.

• 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 completely 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 NO 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 NO reed switch contacts close. Its control relay energizes.

• The fill valve de-energizes.

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

During Normal Operation –

• If the water level in a tank falls below the level of the top float, the top float moves down and

its reed switch contacts open.

• When the water level falls below the level of the bottom float, the bottom float moves down

and its reed switch opens.

• The control relay de-energizes. The fill valve energizes and refills the tank.

• The heat circuit will de-energize until the water level in the tank raises the top float again.

• The bottom float keeps the heat circuit ready as long as the water level is above the level of

the bottom float.

ELECTRICAL SERVICE

1R010

1R009

Figure 5

Tank Heat Thermostats

Figure 6

Booster Thermostat Locations

Figure 7

Booster – High Limit Thermostat

ELECTRICAL SERVICE

ELECTRICAL SERVICE (Cont.)

Thermostat Locations and Adjustments

Refer to Fig. 5 Electric tank heat is controlled by two ther mostats.

1. The control ther mostat which regulates the temperature.

2. The high limit ther mostat which protects from overheating.

Location:

Both thermostats are located on front of tank, inside a black enclosure box behind the front access panel.

Adjustment:

The Control Thermostat has an adjustment screw on one side.

• The ther mostat is wired Nor mally Closed.

• Turn the adjustment screw clockwise to increase the temperature in the tank and counterclockwise to decrease the temperature in the tank.

The High Limit Thermostat is not adjustable. It contains a red reset button in its center.

• The red button pops out if the temperature in the tank exceeds 210°F/99°C.

• Press the red button in to reset the high limit. Determine the cause of the high temperature condition.

Refer to F

ig. 6 and Fig. 7.

Electric Booster Heat is controlled by two ther mostats.

1. The control ther mostat which regulates the temperature.

2. The high limit ther mostat which protects from overheating.

3. Each tank has a control and a high limit ther mostat.

Location:

The control thermostat is enclosed in a black box mounted on the front of the wash tank behind the front access panel. The high limit thermostat is enclosed in a box mounted on top of the booster tank.

Adjustment:

The control thermostat has an adjustment screw on one side.

• The ther mostat is wired Nor mally Closed.

• Turn the adjustment screw clockwise to increase the booster tank temperature and counterclockwise to decrease the booster tank temperature.

The high limit thermostat is a bimetal snap design. It is not adjustable.

• A button with a red dot in the center pops out when the temperature exceeds 210°F/99°C.

• Press the red reset button in to reset the high limit. Determine the cause of the high temperature condition.

Control Thermostat

High limit Thermostat

High Limit Thermostat

Control Thermostat

1R011

480V/3 Phase

575V/3 Phase

Delta Connection

480V/3 Phase

575V/3 Phase

Delta Connection

480V/3 Phase

575V/3 Phase

Delta Connection

480V/3 Phase

575V/3 Phase

Delta Connection

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

208-240V/3 Phase

Delta Connection

208-240V/3 Phase

Delta Connection

208-240V/3 Phase

Delta Connection

208-240V/3 Phase

Delta Connection

208V/1 Phase

Configuration C

Booster tank element View of calrod coils

Terminal Connections view of element

Configuration D

Wash tank element View of calrod coils

Configuration B

Booster tank element View of calrod coils

Configuration A

Booster tank element View of calrod coils

Terminal Connections view of element

ELECTRICAL SERVICE (Cont.)

Heater Element Wiring – Booster Tank and Wash Tank Heater Elements

Refer to the illustrations and follo

w the steps below to properly install ter minal jumpers and

to make line pow

er connections to a replacement element.

Step 1. Hold the element assembly with the calrod coils facing toward you. Step 2. Match your element coil to Configuration A, B, C, or D. Step 3. Rotate your element coils to match the correct conf iguration. Step 4. Flip the element over and match your element to the cor rect ter minal configuration. Step 5. Install terminal jumpers according to the illustration for your voltage requirement. Step 6. Install the element and make your line connections 1L1, 1L2, or 1L3 per the illustration.

ELECTRICAL SERVICE

1L1

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1L3

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L1

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1L3

1L1

1L2

1L3

Low voltage 208-230V/1PH

Only

Motors

Motor Specifications

Voltage: Standard motors are multi-voltage

Low voltage: 208-230VAC High voltage: 460VAC or 575VAC only

Phase: Motors may be single or three phase

Wiring Connections:

Refer to the diagrams below for 3 phase motor lead wiring.

Low voltage High Voltage 575V/3PH 208-230V/3PH 460V/3PH Only

Refer to the diagram at right for single phase motor lead wiring.

Troubleshooting:

Motor will not run:

1. Check incoming power to control cabinet.

2. Check for tripped manual motor star ter (overload) in control cabinet. (Refer to Motor Overload service section for the proper setting)

3. Check power at motor contactor.

Motor runs hot and trips motor starter overload:

1. Check for proper voltage between L1-L2, or (L1-L2, L2-L3, L1-L3 for 3 phase).

2. Check FLA on motor leads L1, L2, (also L3 for 3 phase) using amp tester. (Motor full load amp (FLA) ratings are stamped on motor nameplate).

Motor Replacement:

1. Disconnect the power to the machine.

2. Disconnect the wires at the motor junction box.

3. Make note of the motor connections in order to phase the replacement correctly.

4. Install the new motor and check for proper rotation.

5. Proper shaft rotation is clockwise looking at the rear of the motor.

6. Motor rotation can be reversed by switching L1 and L2 on 3 phase motors. Single phase motor rotation cannot be reversed

7. Replacement motors are available as complete assemblies.

8. Champion cannot provide replacement bearings, stators, or rotors for motor repair parts.

ELECTRICAL SERVICE

321

LINE

654

987

321

654

987

321

LINE

Dual Float Switches –

Troubleshooting:

The dual float controls fill and heat circuits.

Identifying a Dual Float Problem:

The most common trouble conditions associated with a dual float failure are:

1. The tank fills constantly.

2. The tank heat will not come on.

Inspect the Dual Float:

1. Be sure that the dual float assembly is clean and free of scale build-up.

2. Be sure that the stainless steel balls on the float assembly move up and down freely.

In addition to checking the float operation, perform the following—

System Checks:

1. All drain valves are fully closed.

2. Incoming water supply Flow Pressure is 20-22 psi [138-151 kPa].

3. Fuses in control cabinet are good (Electric Heat Only).

4. Tank Heat thermostats and/or High limit thermostats operate correctly.

5. Booster Heat ther mostats and/or High limit ther mostats operate cor rectly.

ELECTRICAL SERVICE

Dual Float Troubleshooting Diagrams:

YES

Water Shuts OFF

Machine is in

Final Rinse Mode

Not a Dual Float

Problem

System Checks

YES

Wash or Prewash

Tank Fills Constantly

Is Tank Full

of Water?

Are the Float

Balls Up?

Close Drain Valve

Clean

Float Assy

Is Heat ON when called

for?

Replace

Dual

Float

Check

Solenoid

Valve

Are the Float

Balls Up?

Check

Solenoid

Valve

Is Heat ON when called

for?

Replace

Dual

Float

Clean

Float Assy

Close Drain Valve

Is Tank Full

of Water?

Check to ensure

that

Rinse-Saver Lever

is not

Operated

Water Runs Constantly

Through Final Rinse Piping

Canister No.1

L-R Direction

Water Supply In

Canister No.1

Canister No.2

ELECTRICAL SERVICE

Figure 8

Front V ie w

Typical 40°F/22°C Rise Booster

One T ank – T otal 36Kw Shown

Figure 9

Front V ie w

Typical 70°F/39°C Rise Booster

Two-Tank – Total 57Kw Shown

12Kw

9Kw

9Kw9Kw

9Kw

12Kw

Dishwasher

Unload

End

12Kw

Electric Booster Heater — Element Installation

Refer to Fig. 8 and F

ig. 9

Champion built-in boosters are constructed of stainless steel and have locations for three electric booster heater elements.

1. The two booster conf igurations for rack conveyor models are:

Single tank - 40°F/22°C rise booster Two tank - 70°F/39°C rise booster

The total Kw rating of the booster assembly is determined by the model number of the machine and the minimum temperature of the incoming water supply.

2. The highest rated Kw element

should always be installed in the bottom right corner location of booster canister No. 1.

1R013

Highest Rated Kw Element

installed in bottom right corner

of Canister No.1

1R012

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