Champion 44, 64, 66PW Service Manual

Champion

The Dishwashing Machine Specialists

For models beginning wit/i Serial No. R31 71

For models beginning with Serial No. R3171

Single Tank

44LT

66LT

44W5

44WS

66PWWS

44 MODULAR

44DR

44DRWS

66DRPW

66DRPW 66DRWSPW

66DRW SPW

Technical Manual

E-Series Single Tank

and Two Tank

Rack Conveyor

Rack Conveyor with/without Prewash

with/without Prewash

Two Tank

84 64 MODULAR

64 MODULAR

Single Tank wlPrewash

Single Tank w/Prewash

66PW

7OFFPW 8ODRIIDPW

70FFPW

66PW

May, 2005

P. 0. Box 4149

P. O. Box 4149

Winston-Salem, North Carolina 27115-4149

336/661-1556 Fax: 336/661-1660

8OHDPW

80HDPW

66PW MODULAR

76PW

8OFFPW

80FFPW

9OHDPW

90HDPW

Two Tank wlPrewash

Two Tank w/Prewash

86PW 94FFPW

86PW 90FFPW

9OFFPW 1O8HDPW

100HDPW 1O6PW

100HDPW 86PW MODULAR

86PW MODULAR 11OFFPW

94PW 12OHDPW

94PW

66DRPW

66DRPW 80DRHDPW

8ODRW SHDPW

80DRWSHDPW

94FFPW 108HDPW 106PW 110FFPW 120HDPW

Machine Serial No.

Manual PIN 113867 Rev D

Manual P/N 113867 Rev D

2674 N. Serice Road

2674 N. Service Road

Jordan Station, Ontario, Canada LOR iSO

Jordan Station, Ontario, Canada L0R 1S0

905/562-4195 Fax: 905/562-4618

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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.

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REVISIONS

REVISION HISTREVISION HIST

REVISION HIST

REVISION HISTREVISION HIST

Revision Revised Serial Number Comments Date Pages Effectivity

07/15/04 All First issue of manual and replacement parts

08/31/04 7 Revised operation procedure.

08/31/04 12 Revised the pump timer operation sequence.

08/31/04 13 Revised the float switch inforamtion.

8/31/04 14 Revised the terminal connections drawings and

8/31/04 18 Added drive motor wiring drawings and information.

09/01/04 20 Part number 328473 replaced by 328977. Added 36"

9/01/04 20, 23, 25 R3448 Added new door catch components.

9/01/04 23 Part number 327890 relpaced by 328974. Added

9/01/04 25 Part number 327891 replaced by 328975. Added E84

OROR

inserted figure number for electric booster.

Prewash panels.

entrance and exit curtain baffles.

front panels.

9/01/04 31 Part number 328799 replaced by 328450. Added new

cradle bracket for two tank machines.

9/01/04 37 Updated part numbers for scrap screens and refuse

baskets.

9/01/04 61, 63 Updated part numbers for drain levers and overflow

rod.

9/01/04 64, 66 Corrected piping drawings.

9/01/04 73 Changed part number 113727 discharge hose

to 112807.

12/16/04 Added 575 volt elements and corrected part number

2/16/05 Added revised schematics.

5/16/05 Added revised schematics.

51, 53, 77

for 10KW element.

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REVISIONS

REV ISI ON RECORDREV ISI ON RECORD

REV ISI ON RECORD

REV ISI ON RECORDREV ISI ON RECORD (CON T’D)(CON T’D)

(CON T’D)

(CON T’D)(CON T’D)

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TABLE OF CONTENTS

CON TEN TS

Page

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

WARRANTY .................................................................................................................................. v

SAFETY SUMMARY..................................................................................................................... vi

INTRODUCTION ........................................................................................................................... 1

GENERAL....................................................................................................................................... 2

INSTALLATION ............................................................................................................................ 3

Unpacking........................................................................................................................... 3

Plumbing Connnections ................................................................................................... 3

Electrical Connections ...................................................................................................... 4

Ventilation Connections ................................................................................................... 4

Chemical Connections...................................................................................................... 5

Curtain Locations .............................................................................................................. 5

Completing Installation .................................................................................................... 6

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

Inital Startup ...................................................................................................................... 8

Basic Operation ................................................................................................................. 8

MAINTENANCE ........................................................................................................................... 9

Maintenance Schedule...................................................................................................... 9

Deliming ............................................................................................................................ 10

ELECTRICAL SERVICE ............................................................................................................... 11

REPLACEMENT PARTS ...............................................................................................................19

ELECTRICAL SCHEMATICS ...................................................................................................... 93

LIST OF FIGU RES

Figure 1 — Motor Rotation ....................................................................................................... 4

Figure 2 — Scrap Basket Removal ........................................................................................... 9

Figure 3 — Motor Overload ...................................................................................................... 9

Figure 4 — Unhooking Upper Arm ......................................................................................... 9

Figure 5 — Upper Wash Arm Removal ................................................................................... 9

Figure 6 — Lower Wash Arm Removal ................................................................................... 9

Figure 7 — End Cap Removal .................................................................................................. 9

Figure 8 — Fuse Blocks ............................................................................................................ 11

Figure 9 — Motor Overloads .................................................................................................... 11

Figure 10 — Pump Timer ............................................................................................................ 1 2

Figure 11 — Dual Float Switch ................................................................................................... 1 3

Figure 12 — Tank Heat Thermostats .......................................................................................... 14

Figure 13 — Booster Thermostat Location ................................................................................ 1 4

Figure 14 — Booster High Limit Thermostat ............................................................................ 1 4

Figure 15 — Prewash Panels, Doors and Miscellaneous .......................................................... 20

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iii

TABLE OF CONTENTS

Figure 16 — Single Tank Panels, Doors and Miscellaneous .................................................... 22

Figure 17 — Two Tank Doors, Panels and Miscellaneous ....................................................... 24

Figure 18 — Drive Motor Assembly .......................................................................................... 2 6

Figure 19 — Drive Assembly...................................................................................................... 2 8

Figure 20 — Prewash Track and Cradle Assembly ................................................................... 3 0

Figure 21 — Single Tank Track and Cradle Assembly............................................................. 3 2

Figure 22 — Two Tank Track and Cradle Assembly ................................................................ 34

Figure 23 — Prewash Screens ..................................................................................................... 36

Figure 24 — Single Tank Scrap Screens .................................................................................... 28

Figure 25 — Two Tank Scrap Screens ....................................................................................... 40

Figure 26 — Prewash Spray Arms .............................................................................................. 42

Figure 27 — Single Tank Wash Arms (Left to Right Shown) .................................................. 4 4

Figure 28 — Two Tank Wash and Rinse Arms ( Left to Right Shown) .................................. 46

Figure 29 — Float Switch ............................................................................................................ 48

Figure 30 — Single Tank Electric Tank Heat ............................................................................ 50

Figure 31 — Two Tank Electric Tank Heat ................................................................................ 52

Figure 32 — Single Tank Steam Tank Heat ............................................................................... 54

Figure 33 — Two Tank Steam Tank Heat .................................................................................. 56

Figure 34 — Tank Thermostats ................................................................................................... 58

Figure 35 — Prewash Overflow .................................................................................................. 60

Figure 36 — Single Tank and Two Tank Overflow Assembly ................................................ 62

Figure 37 — Final Rinse Piping w/Booster ................................................................................ 6 4

Figure 38 — Final Rinse Piping no Booster/ with Steam Booster ........................................... 6 6

Figure 39 — Final Rinse Drain Assembly ................................................................................. 68

Figure 40 — Prewash Pump Suction/Discharge ........................................................................ 7 0

Figure 41 — Wash/Rinse Pump Suction/Discharge .................................................................. 72

Figure 42 — Pump Assembly ..................................................................................................... 7 4

Figure 43 — 40°/60° Rise Electric Booster ............................................................................... 76

Figure 44 — 70° Rise Electric Booster ....................................................................................... 7 8

Figure 45 — Control Cabinet ...................................................................................................... 80

Figure 46 — New Style Vent Cowls (Shown Mounted to Prewash)(Optional) ...................... 8 2

Figure 47 — Standard Vent Cowls (Optional) ........................................................................... 84

Figure 48 — Racks ....................................................................................................................... 88

CON TENTS (CON T.)

LIST OF FIGU RES

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LI MI TED WARRAN TYLI MI TED WARRAN TY

LI MI TED WARRAN TY

LI MI TED WARRAN TYLI MI TED WARRAN TY

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 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 warranty period, Champion, at its election, will either repair or replace the defective machine or accept return of the machine for full credit; provided, how ever, 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:

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 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.

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SAFETY SUMMARY

SAFET Y SU MM ARSAFET Y SU MM AR

SAFET Y SU MM AR

SAFET Y SU MM ARSAFET Y SU MM AR

Safet y Sym bols

• The following symbols appear throughut this manual alerting you to potential hazards. Statements associated with each symbol are printed on italics.

WARN I NG:

Warning statements indicate any condition or practice that could result in personal injury or possible loss of life.

CAU TI ON :

Caution statements indicate any condition or practice which, if not strictly observed or remedied, could result in damage to or destruction of the dishwasher.

NOTE:

Note statements indicate any condition or practice which, if observed, will help in the safe completion of a task.

Gene ral Sa fe t y Rule s

• The following general safety rules must be observed in addition to the specific cautions

and warnings presented in this manual.

• Your Champion pot and pan washer uses hot water to clean and sanitize a variety of wares.

Machine surfaces and wares become hot during and immediately following normal operations. Operators should use caution when loading and unloading wares from the machine.

• Operators must NOT bypass a safety interlock or control(s) to operate unit.

• The service and maintenance instructions contained in this manual are intended for

qualified service personnel. These instructions assume that you are trained in basic electricity and mechanical theory. If you are not a trained technician, then do not attempt to adjust or repair the dishwasher as serious personal injury or damage to the dishwasher may result.

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INTRODUCTION

INTRODU CTI ON

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 instructions

• Maintenance instructions

• Troubleshooting guide

• Basic service information

• Replacement parts lists

• Electrical schematics

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

All information, illustrations and specifications 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, factory authorized parts 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.

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GENERAL

This manual covers the Champion single tank and two tank rack conveyor dishwashing machines. These machines are fully automatic and are equipped with 1 HP prewash and 2HP wash and rinse pump motors (depending on the model) and a 1/6 HP conveyor drive motor. All models are available for a right-to-left or left-to-right operation.

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

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 and 54 basic models along with their respective prewash options, are high temperature (180°F/80°C final rinse) sanitizing models.

• The 44 WS models along with their respective prewash options, are water and energy saving, high temperature (180°F/80°C final rinse) sanitizing models.

• The 44 LT model, along with its respective prewash option, is a low temperature (140°F/ 60°C final rinse), chemical sanitizing model for use with sodium hypochlorite solution (chlorine bleach) as the sanitizing agent.

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, 72 and 84 basic models, along with their respective prewash options, are high temperature (180°F/80°C final rinse) sanitizing models.

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INSTALLATION

Unpacking

CAUTION:

Care should be taken when lifting the machine to avoid damaging the piping under the base. Remove the dishwasher front panels and lift 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 immediately.

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 top of the machine and adjust the feet. Level the machine by unscrewing the feet from the base. Adjust from the front-to-back and side-to-side.

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

3. If the incoming hot water supply pressure exceeds 25psi [173kPa] at machine, a PRV must be installed and set to 20-22psi [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 servicing the machine. The valve should be the same size as/or larger than the supply line.

5. Provide suitable gravity drain to connect to a 1-1/2" NPT drain pipe.

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INSTALLATION

INSTALLATION (CONT.)

Electrical Connections

1. Compare the electrical specifications on the machine electrical connection plate (located

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.

NOTE:

Electric boosters require a separate electrical connection (except the 44WS and 66 WS PW models that have a single point connection).

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

inside the control cabinet) to the electrical power supply before connecting to the incoming service at a fused disconnect switch.

2. Motor rotation is set at the factory. Ensure proper rotation of the conveyor drive shaft (red arrow on side of motor shows direction of rotation). Single phase drive motor (208-240V only) rotation must be changed at the drive motor junction box. Three phase drive motor (480-575V) rotation must be reversed in the control cabinet. Reversing the pump motor(s) direction is done in the control cabinet by reversing the wires L1 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.

Ventilation

CAUTION:

Exhaust air should never be vented into a wall, ceiling, or concealed space if a building as condensation will cause damage.

1. Stainless steel watertight ducting should be installed 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.

INSIDE the 4" x 16" [102mm x

Figure 1- Motor

Rotation

• 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 optional vent stacks for regulating the exhaust volume.

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INSTALLATION (CONT.)

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

SIGNAL ONLY

120V

RINSE AID/ SANI

COMMON

DETERGENT

120V

INSTALLATION

1R001

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.

Chemical Connection

Terminal Board

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" [610mm x 515mm]

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

• Standard short curtains 24" x 13-/14" [610mm x 337mm]

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

• Final rinse curtain 24" x 6-1/4" [610mm x 159mm]

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.

Final rinse curtain

R-L Direction

Center Curtain

Long curtain

1R002

Short Row

1R003

Long curtain

Load End

Short row of curtains face out to the load end (or unload

WASH

PRE

WASH

Curtain Locations

(machine with prewash shown)

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depending the location of the curtain) of the dishwasher.

INSTALLATION

INSTALLATION (CONT’)

Completing Installation

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

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

3. Position scrap screens on the supports above the tanks.

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

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

6. The formed down lip of the dishtable should be placed inside of the machine. The

WARNING:

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

minutes. Check all plumbing connections for leaks.

dishtable should be pitched toward the dishwasher for proper draining by adjusting its leveling feet. The dishtable should be sealed to the dishwasher.

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OPERATION

Follow the procedure below to operate your dishwasher properly.

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

2. Verify 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 (with or without a booster, machine fills thru the fill valve and through the final rinse).

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 - 150°/66°C

OPERATION

• 66 PW, 76 PW, 66 WS PW - 160°/71°C

7. Press the Green Lighted START Pushbutton on the control cabinet. This will activate the automatic operation for the drive motor and the pumps. The green light will come on. No other noticeable action will happen until the first rack is loaded into the machine.

8. Scrap and pre-flush all items to be placed and load items into racks.

NOTE:

DO NOT OVERLOAD RACKS.

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 the rack into the machine, the conveyor and drive system will grab the rack and pull it into the machine. The rack start lever (idle pump switch) will start the pumps and the system will run a cycle for 90 seconds. When another rack is inserted it resets the pumps for another 90 second cycle.

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 leaves the machine and the 90 second cycle time has completed.

12. The machine may be stopped at any time during the cycle by pressing the red STOP pushbutton on the control cabinet. The green light will go off on the green START pushbutton, the power is removed from the idle pump circuit but the heaters and fill remain on. To restart, push the green START pushbutton to reset the automatic cycle. Insert another loaded rack to start the idle pump switches. When the rack that was inside of machine has exited, reinsert that rack back into machine to make sure that the complete sanitation cycle of the original rack has been completed.

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OPERATION

OPERATION (CONT’)

13. The machine may also be stopped at any time during the cycle if the door(s) are raised.

14. CLEAN the scrap screens and scrap baskets (if necessary) and REPLACE the tank water

When the door is raised the light on the green START pushbutton goes off. The power is removed from the idle pump switch and the heat circuit. To reset the unit, close the door(s) follow the same procedure as in step 12. Push the green START pushbutton to reset the automatic cycle. Insert another loaded rack to start the idle pump switches. When the rack that was inside of machine has exited, reinsert that rack back into machine to make sure that the complete sanitation cycle of the original rack has been completed.

after each meal period or every 2 hours of operation. Check the chemical supply.

CAUTION:

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

CAUTION:

DO NOT leave water in the tanks over night.

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MAINTENANCE

The efficiency and life of your machine is increased by regularly scheduled preventive maintenance. A well maintained machine gives better results and service.

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 faced with abnormal working conditions, hard water, or multiple shift operations.

Ma int e na nc e Sc he dule

Cleaning

• Daily/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 (internal and external ,if applicable). Clean inside of the tanks and flush with clean water. Back flush the scrap screens until clean. (See Figs 2 & 3)

Figure 2-

Scrap Screen Removal

Figure 3-

Scrap Basket Removal

NOTE:

DO NOT strike or bang screens or baskets against solid objects

3. Remove the spray pipes (Figs. 4-6) Remove the end cap from each spray pipe (Fig. 7). Flush the pipes and nozzles until clean.

NOTE:

DO NOT strike or bang wash pipes against solid objects

Replace the end caps and verify the rubber o-rings are in place. Reinstall the spray pipes.

4. Remove and clean the curtains. Hang them off the dishtable and allow them to dry at the end of the day.

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

6. Verify that the final rinse nozzles are clean and free of any internal hard water deposits. If necessary, clean the nozzle orifices with a small paper clip. Consult your chemical supplier for proper use and the kind of deliming chemicals needed.

7. Report any unusual conditions to your supervisor.

Figure 4-

Unhooking Upper Arm

Figure 5-

Upper Wash Arm

Removal

Figure 6-

Lower Wash Arm Removal

• As Required

1. Check the temperature and pressure gauge readings

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

3. Check the chemical supplies and refill as necessary.

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Figure 7-

End Cap Removal

MAINTENANCE

MAINTENANCE (CONT’)

• Weekly

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

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

3. Check the drain/overflow tube for any leaks,

4. Clean the accumulated scale from the heating element.

5. Remove and closely inspect each spray arm for blockage.

6. Straighten a small paper clip to clear each final rinse nozzle.

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

8. Check the float switch(es) in the tank(s) for freedom of travel.

9. Check the idle pump(s) and final rinse lever 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 machines interior for lime deposits. If required, consult your chemical supplier for the proper type and procedures on deliming agents.

If you have a chemical sanitizing model 44 LT or 66 LT PW, CAREFULLY follow the procedure below before deliming:

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.

1. Remove the suction tube assembly from the bleach container and place it as close as possible to the floor. Place a catch pan underneath it.

2. Cycle the machine approximately six times to purge the lines of the bleach.

3. Proceed with the deliming procedures.

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ELECTRICAL SERVICE

Fuse Blocks - 12OVAC Control Voltage

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. The fuses

are marked 1FU and 2FU on the electrical schematic.

To replace the fuse:

To re pla c e t he fuse :

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

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

• Remove the fuse and replace it.

Remove the fuse and replace it.

• Turn the main power on.

Turn the main power on.

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

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

• DETERMINE THE CAUSE OF THE OVERLOAD.

DETERMINE THE CAUSE OF THE OVERLOAD.

Fig. 5 shows the fuses and fuse blocks.

ELECTRICAL SERVICE

Figure 8-

Fuse Blocks

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 12OVAC

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. Refer to Fig.6.

Note the Switch Lever on the Overload

Not e t he Sw it c h Lever on t he Ove r load

• If the red OFF switch lever is down with the

If the red OFF switch lever is down with the

"OFF" showing then the overload has tripped

“OFF” showing then the overload has tripped

on an overload.

To Reset the Motor Overload:

To Rese t t he Motor Ove r loa d:

Push the start switch down with "ON" showing.

• Push the start switch down with “ON” showing.

• Run the dishwasher and test the AMP draw of the

Run the dishwasher and test the AMP draw of the

motor in question. If the motor checks ok then there

may be a wiring problem or the overload may be

defective.

To Replace a Motor Overload:

To Repla c e a M otor Over loa d:

• Disconnect the wires to the overload.

Disconnect the wires to the overload.

Figure 9-

Motor Overload

• Pull forward and lift out.

Pull forward and lift out.

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

Snap the new overload into place and reconnect the wires.

To Adjust the Overload Setting:

To Adjust the Ove r loa d Set t ing:

The screwdriver in Fig. 6 is positioned to adjust the motor overload AMP setting.

• Read the FLA motor amps that applies for the machine voltage

Read the FLA motor amps that applies for the machine voltage

on the Motor Nameplate.

• Flip up the plastic cover. Turn the setting to match the nameplate FLA.

Flip up the plastic cover. Turn the setting to match the nameplate FLA.

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ELECTRICAL SERVICE

ELECTRICAL SERVICE (CONT')

ELECTRICAL SERVICE (CONT’)

Pump Timer

The automatic timer located in the left center of the control cabinet

is preset at the manufacturer.

The Pump Timer controls the amount of time that the pump(s) and the

drive motor will run after the last rack enters the load end of the

dishwasher tunnel.

The Pump Timer is an OFF DELAY timer. One timer controls all

pumps no matter what the model it may be. Cycle time is 90 seconds.

To Replace a Timer:

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

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

Remove the wires connected to the timer. Remove the screw in

• Remove the wires connected to the timer. Remove the screw in

the center of the timer.

Figure 10-

Pump Timer

Remove the defective timer and install the replacement.

• Remove the defective timer and install the replacement.

Reinstall the screw and reinsert the wires.

• Reinstall the screw and reinsert the wires.

Operation Sequence:

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

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

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

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

• Normally closed contacts of 1CR close and apply a signal to pump timer. The timer

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.

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

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 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

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:

Use a stop watch to check the timing cycle.

Turn the power on.

• Turn the power on.

Press the green lighted START pushbutton.

• Press the green lighted START pushbutton.

Place a rack in to the conveyor.

• Place a rack in to the conveyor.

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

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

Start the stop watch when the rack clears the idle pump switch. Stop the stop watch

• Start the stop watch when the rack clears the idle pump switch. Stop the stop watch

when the machine stops. The lengthof the cycle should be 90 seconds +I 2 seconds.

when the machine stops. The lengthof the cycle should be 90 seconds +/- 2 seconds.

If the timer is not within this range replae the timer.

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ELECTRICAL SERVICE (CONT')

ELECTRICAL SERVICE (CONT’)

Automatic Fill/Low Water Heat Protection

Dual Float Switches

Dua l Floa t Sw it c he s

Each tank contains a dual float switch (see Fig.8). The device consists

of an angled stem containing two reed switches. Two stainless steel

ball floats, containing magnets, slide over the stem and are free to move

up and down. When the float moves on the stem, it opens and closes the

associated reed switch inside the stem. The reed switches control

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. The float switch(es) and their relay(s) operate on a 120V circuit.

Circuit Explanation

Circ uit Ex plana t ion

Refer to the electrical schematic on your machine for a detailed

description of the individual float(s), relay(s) and wiring.

Bottom Float and Reed Switch

Bot t om Floa t and Re e d Sw it c h

The bottom float controls the heat.

• The bottom float controls the heat.

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

• 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.

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

relays.

ELECTRICAL SERVICE

Figure 11-

Dual Float Switch

Top Float and Reed Switch

Top Float a nd Re e d Sw it ch

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

• 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 down, the top reed switch contacts are open.

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

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

Initial Fill

Init ia l Fill

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

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 dc-energized.

• 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.

• 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.

• 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.

• 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.

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

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

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

The fill valve dc-energizes.

• The fill valve de-energizes.

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

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

During Normal Operation

During N or mal Ope ra t ion

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

• 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

• 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 dc-energizes. The fill and rinse valve energizes and refills the tank.

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

The heat circuit will dc-energize until the water level in the tank raises the top float

• 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

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

of the bottom float.

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ELECTRICAL SERVICE

ELECTRICAL SERVICE (CONT')

ELECTRICAL SERVICE (CONT’)

Thermostat Locations and Adjustments

Electric tank heat is controlled by two thermostats.

The control thermostat which regulates the electric tank heat

1. The control thermostat which regulates the electric tank heat

temperature.

The high limit thermostat which protects the tank from

2. The high limit thermostat which protects the tank from

overheating.

Location

Loc a t ion

Both thermostats are located on the front of the tank, inside of a

heater box enclosed in a stainless steel panel, behind the front

access panel.

Adjust m e nt

Adjustment

The Control Thermostat has an adjustment screw.

High Limit

Thermostat

Figure 12-

Tank Heat Thermostats

The thermostat is wire Normally Closed.

• The thermostat is wire Normally Closed.

Turn the adjustment screw clockwise to increase the

• 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 on its center.

The red button pops out if the temperature in the tank

• 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

• Press the red button in to reset the high limit.

DETERMINE THE CAUSE OF THE HIGH

TEMPERATURE CONDITION.

Refer to Fig 13 & Fig 14

Electric Booster Heat is controlled by two thermostats.

The control thermostat regulates the temperature.

1. The control thermostat regulates the temperature.

The high limit thermostat protects the booster from

2. The high limit thermostat protects the booster from

overheating.

Each tank has a control and a high limit thermostat.

3. Each tank has a control and a high limit thermostat.

Loc a t ion:

Location:

The control thermostat is in the junction box on the wash tank.

Figure 13-

Booster Thermostat Location

Insert thermostat probe

into tube in center

of element

The thermostat is wire Normally Closed.

• The thermostat is wire Normally Closed.

Turn the adjustment screw clockwise to increase the

• Turn the adjustment screw clockwise to increase the

booster tank temperature and counterclockwise to

decrease the booster tank temperature.

The high limit thermostat is also in the junction box on the

wash tank.

A red button that pops out when the temperature exceeds 210°F199°C.

• A red button that pops out when the temperature exceeds 210°F/99°C.

Press the red reset button to reset the high limit

• Press the red reset button to reset the high limit.

Determine the cause of the high limit temperature condition.

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Booster High Limit Thermostat

Figure 14-

ELECTRICAL SERVICE

ELECTRICAL SERVICE (CONT’)

Heater Element Wiring-Booster Tank and Wash Tank Heater Elements

Refer to the illustrations and follow the steps below to properly install terminal jumpers and to make line power connections to a replacement element.

Step 1. Hold the element assembly with the calrod coils facing toward you.

Step 2. Match your element coils to Configuration A or B

Step 3. Rotate your element coils to match the correct configuration.

Step 4. Flip the element over and match your element to the correct terminal configuration.

Step 5. Install the terminal jumpers according to the illustrations for your voltage requirement.

Step 6. Install the element and make your line connections 1L1, 1L2 or 1L3 per the

illustration.

Step 7. If installing a booster element (that requires the limiting thermostat), the limiting

thermostat should be inserted into the center of element. Thermostat should bottom out in the tube approximately 12" deep. The exposed capillary leads should be routed under the booster cover and fastened to the stud in the upper right side of the booster can with the clip and nut. See Figure 43 Electric Booster in Replacement Parts section.

Configuration A

Booster tank element View of calrod coils

Configuration B

Wash tank element View of calrod coils

1L1

1L2

208V/1 Phase

1L1

1L2

208V/1 Phase

Terminal Connections

1L1

1L3

1L2

208-240V/3 Phase

Delta Connection

1L1

1L2

480V/3 Phase 575V/3 Phase

Delta Connection

Terminal Connections

1L1

1L2

1L3

208-240V/3 Phase

Delta Connection

1L1

1L2

1L3

480V/3 Phase 575V/3 Phase

Delta Connection

view of element

1L3

view of element

1L2

1L1

1L3

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

1L3

1L1

1L2

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

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ELECTRICAL SERVICE

ELECTRICAL SERVICE (CONT’)

Electric Booster Heater- Element Installation

Champion built-in boosters are constructed of stainless steel and have locations for three electric booster heater elements. There are three booster configurations for the rack conveyor models:

40°F/22°C rise booster (minimum of 140°F/60°C incoming water) 60°F/34°C rise booster (minimum of 120°F/49°C to 140°F/60° incoming water) 70°F/39°C rise booster (minimum of 110°F/43°C incoming water)

The canisters and total Kw ratings of the booster assemblies are determined by the model number of the machine and the minimum temperature of the incoming water supply that the end user is able to supply to the machine. Machines can be supplied with 40°F/22°C rise booster or 60°F/34°C rise booster which use only one canister (nested boosted) with separate electrical connections. The 70°F/39°C rise models use two canisters in the booster assemblies, these also have separate electrical connections.

Water Saver (44 WS and 66 WS PW) models are supplied in only 40°F/22°C or 70°/39°c rise booster assemblies. These are single canister units in either option and are not separate electrical connections.

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ELECTRICAL SERVICE (CONT’)

Motors-Pump

Voltage: Standard motors are multi-voltage

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

Phase: Motors may be single or three phase.

Wiring Conne c t ions

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

ELECTRICAL SERVICE

Low voltage

208-230V/3PH

654

High voltage

460V/3PH

654

575V/3PH

Only

321

987

321

LINE

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

987

321

LINE

Low voltage

LINE

208-230V/1PH

Only

Troubleshooting

Mot or w ill not r un

1. Check incoming power to control cabinet.

2. Check for tripped manual motor starter (overload) in control cabinet.

(Refer to Motor Overload service section for proper settings).

3. Check power at motor contactor.

Mot or runs hot a nd t rips m ot or st a r t e r over loa d

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).

Mot or Re place m e nt

1. Disconnect the power to the machine.

2. Disconnect the wires to 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. (Proper rotation is clockwise looking from at the rear of the motor).

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

LINE

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ELECTRICAL SERVICE

ELECTRICAL SERVICE (CONT’)

Motors-Drive

Voltage: Standard motors are multi-voltage

208-240V 1Phase Wiring Diagram

To reverse motor rotation interchange yellow and orange leads.

Low Voltage: 208-240VAC 1 Phase Only

High Voltage: 380/480/575VAC 3 Phase Only

Motor 1/6 HP 208/240V

Run Winding

Start Winding

White Wire

Orange Wire

Yellow WIre

Brown Wire

Black Wire

Capacitor

10MFD

370VAC

Connect 208/240

Power Here

Run X Winding

Red Wire

380/480/575/V 3Phase Wiring Diagram

To reverse motor rotation interchange any two external connections.

Motor 1/6HP 380/480/575 Volt

P6 Orange Wire

P5 Tan Wire

P4 Blue Wire

T6 Purple Wire

T9 Brown Wire

T4 Yellow Wire

T7 Pink Wire

T5 Black Wire

T8 Red Wire

T3 Orange Wire

T1 Blue Wire

T2 Tan Wire

Connect 380/480/575

3 Phase

Power Here

Drive Interlock Switch

Drive interlock will activate when a jam has occured in the unit.

• When a jam occurs, the switch opens and the pump(s) and drive motor are then shut off, similar to the reaction of pushing the red STOP pushbutton (the green light goes out also).

• The switch will automatically reset when the jam is cleared. To restart/reset the machine push the green START pushbutton and insert a loaded rack.

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REPLACEMENT PARTS

REPLACEMENT

PA R T S

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REPLACEMENT PARTS

Prior to S/N R3447

After S/N R3448

Figure 15- Prewash Panels, Doors and Miscellaneous

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REPLACEMENT PARTS

PREWASH PANELS, DOORS

AND MISCELLANEOUS

Fig. 15 Part Item No. No. Part Description Qty

1 328977 Panel, Front Perimeter 22PW ...................................................... 1

1 328978 Panel, Front Perimeter 36PW ...................................................... 1

2 327857 Panel, 25" Prewash Perimeter ..................................................... 1

3 328030 Table Flange Support .................................................................. 1

4 328006 Support, 22 PW Rear Screen ...................................................... 1

5 108250 Rod Curtain 5/16 x 24-5/8......................................................... 1

6 108043 Curtain 24 x 13-1/4 ..................................................................... 1

7 206358 Rod, 22PW Door Catch (Prior to S/N R3447) .......................... 1

7 328909 Door Catch 22PW (After S/N R3448) ....................................... 1

8 327887 Bracket, Door Catch Mounting (Prior to S/N R3447) .............. 2

8 317345 Bracket, Door Catch (After S/N R3448) ................................... 2

9 100734 Bolt, 1/4-20 x 1/2 Hex Head ...................................................... 2

10 100141 Nut, Grip 1/4-20 SST .................................................................. 2

11 113691 Guide, U-channel Door............................................................... 2

12 327952 Door, 22PW .................................................................................. 1

--- 111026 Magnet, Door (Not Shown) ........................................................ 1

--- 113719 Switch, Reed Aleph (Not Shown) .............................................. 1

13 108966 Door Handle ................................................................................. 2

14 313359 Bracket, Door Stop ...................................................................... 1

A Panel Fasteners (Qty per Panel)

100007 Screw 10-32 x 3/8 Truss Head ...................................................... 4

B Table Flange Fasteners

C Screen Support Fasteners

Bolt Washer Nut

D Door and Scrap Basket Handle Fasteners (Qty per Handle)

100073 Screw1/4-20 x 1/2 Truss Head ...................................................... 2

E Door Guide Fasteners (Qty per Guide)

113486 Screw 8-32 x 5/8 Flat Head SST ................................................ 6

112431 Rivnut 8/32 Steel Zinc Plated ..................................................... 6

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REPLACEMENT PARTS

Prior to S/N R3447

After S/N R3448

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Figure 16- Single Tank Doors, Panels

and Miscellaneous

+ 82 hidden pages