Champion CTD-1800H Service Manual

Champion

The Dishwashing Machine Specialists

Technical Manual

No Heat Tray
Dryer

Model
CTD-1800H

November, 1992 111483

P.O. Box 4149 Winston-Salem, North Carolina
27115-4149

Champion Industries, Inc. 919/661-1556 FAX:[phone]

CONTENTS

WARRANTY 2
INTRODUCTION 3

GENERAL 4
INSTALLATION 5

Unpacking 5
Electrical Connections 5
Plumbing Connections 6
Completing Installation 6

OPERATION 7
MAINTENANCE 8

Maintenance Schedule 8
Deliming 9

TROUBLESHOOTING 10
REPLACEMENT PARTS 11

Page

LIST OF FIGURES

Figure 1— Load Access Cover/Stan-Stop Assembly 12
Figure 2— Drive Assembly 14
Figure 3— Tray Accumulator Assembly 16
Figure 4— Shaft/Belt Assembly (Upper) 18

Figure 5— Shaft/Belt Assembly (Lower) 20
Figure 6— Blower/Duct Assembly - Lower 22

Figure 7— Upper Panel/Unload Access Door Assembly 24
Figure 8— Blower & Duct Assembly (Upper) 26
Figure 9— Hood Base/Panel Assembly 28
Figure 10— Panel Assembly. Tray Accumulator 30
Figure 11— Electrical Control Panel 32

Figure 12— Wiring Diagram 34

LIMITED WARRANTY

2

Champion Industries Inc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 27115. warrants machines,
and pans, 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 to be free from defects in material and workmanship for a period of one (1) year
after the dale of installation or fifteen (15) months after the date of shipment by Champion, whichever occurs first. (Sec 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 pans 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 ratine 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 pans 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 detect in material

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.

and workmanship is found to exist within the warranty period Champion will replace the defective pan without, charge.

INTRODUCTION

Welcome to Champion.
Thank you for choosing Champion and for allowing us to take care of your tray drying needs.
This manual covers the model CTD-1800H.

Your machine has been completely assembled, inspected, and thoroughly tested at our factor y to
eliminate problems at installation before it was shipped to your installation site. This manual
provides:

• Warranty information and registration card

• Installation and operation procedures

• Maintenance instructions

• Troubleshooting guide

• Replacement pans lists.

Complete and return your warrant) registration card as soon as possible.
Champion constantly improves its products; therefore, specifications contained in this manual may

have changed.
For your protection, factory authorized parts should always be used.

Replacement pans may be ordered directly from Champion Industries, or from your Champion
authorized pans distributor or service agency*. When ordering parts, supply the model number.
serial number, voltage and phase of your machine, the pa n number, pan description, and quantity.

*Champion can only ship pans 10 customers with accounts or by C.O.D.

3

GENERAL

This manual covers the Champion "no heat" horizontal tray dryer with tray accumulator. This machine is
fully automatic and is equipped with (two) 3-horsepower blower assemblies. The model CTD-1800H can be
used for either direction operation.

Standard equipment includes:

-Common utility connections -Receptacle for plug

-120 volt control circuit -Tray accumulator

-Convenient top-mounted controls -Stainless steel heavy-gauge construction

-Enclosure panels (4 sides) -Easy access for cleaning

-Energy sentinel (full tray) -Power cords with a 240V, 30A plug
accumulator shut-off) -Easily removable filter

-Portable (casters)

This model tray dryer, CTD-1800H, has a maximum drying speed of 1800 trays per hour (based on a 14 inch
by 18-inch tray).

Options

- Machine Electrical Options:

• 208V -60Hz-3PH

• 240V -60H2-3PH

- Tray Accumulator Options:

• Load and tray shelves for tray sizes: 14 inch by 18 inch, and 15 inch by 20 inch.

4

INSTALLATION
Unpacking

1. Immediately after unpacking your machine, inspect it for any shipping damage. If damage is found, save the
packing material and contact the carrier within 10 days.

2. Remove the tray dryer from the skid. Move it to the desired location.

Electrical Connections

1. The tray dryer comes equipped with a 9-foot power cord and mating receptacle. Select a location for the
receptacle convenient to the tray dryer working area.

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

3. Have a licensed electrician install the receptacle.

4. The electrician should compare the electrical specifications on the machine electrical connection plate
(located inside the control cabinet) 10 the electrical power supply before connecting it to the incoming
service at a fused disconnect switch.

5. Insert the power cord plug into the receptacle. Turn the disconnect ON. Push the power switch ON. The
internal pilot light will come on indicating the unit is ready to start. Depress the green START button to
start the unit.

6. Motor rotation was set at the factory (red arrow shows direction of rotation). Remove the upper end panel
on the unload end to verify correct motor rotation. Reversing the motor direction is done in the Control
Cabinet by reversing the wires LI and L2 on the disconnect switch side of the main electrical connection
terminal block. (Refer to the electrical diagrams, Fig. 11 and 12).

5

Plumbing Connections

1. The tray dryer is supplied with a gravity drain and a 1 -1 /4 inch I.D. flexible drain hose (located near the
load end of the unit). The end of the drain hose is approximately 3 inches above the floor. The drain
water should be di rected to a floor drain. The drain rate could reach approximately 1 quart per hour
depending upon usage.

Completing Installation

1. Remove any foreign material from inside the machine.

2. Check to ensure that the drain strainer is clean.

3. Peel away any plastic protective coating from the exterior of the machine.

Tray Accumulator Set-Up

There are many types of trays used today, making it difficult to accurately predetermine the correct tray­lowering rate for each installation.

The tray accumulator is supplied with a limit switch that stops the tray dryer when the accumulator
is full, avoiding an overloading situation.

The ideal height of stacked trays in the accumulator is 21 inches when the limit switch is tripped (activated).
To check your tray accumulator limit switch, begin by depressing the START button. Feed the trays (cupped

side up) into the tray dryer until the accumulator is filled. If properly adjusted, the limit switch should stop the
tray dryer. If not properly adjusted, you should depress the STOP button when the accumulator is full. You
must adjust the tray accumulator by following the tray accumulator adjustment procedure.

Tray Accumulator Adjustment

1. Locate the access door on the end of the accumulator and remove the screw from the upper center of the
door.

2. Remove the access door by lifting up and pulling out this expose a series of springs.

3. If the accumulator limit switch did not stop the tray dryer, there are too many springs engaged.

4. Remove one spring at a lime until the accumul ator limit switch trips with a full stack of

trays.

5. In the unlikely event that the limit switch stops the tray dryer before the tray accumulator is full,
additional springs must be added. Refer to Figure 3 to order additional springs.

6

OPERATION

The operation of your tray dryer will be more efficient when these procedures are followed:

1. Check that the filter holder assembly is in place. It is located at the unload end of the dryer.

2. Push the power switch to the ON position.

3. Depress the START button on the control panel.

4. Load trays in the center of the load shelf, cupped side up.

5. Push each tray into the tray dryer until the conveyor pulls it into the machine.

6. The machine will automatically stop when the tray accumulator is full. You must depress the START

button to restart the dryer.

7. The machine may be stopped at any lime by depressing the STOP button on the control panel.

8. CLEAN the drain strainer by lifting up the load shelf after each meal period.

7

MAINTENANCE

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

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

Maintenance Schedule

• Daily (Every 8 Hours)

1. Turn the power switch to OFF.

2. Lift the access door and load shelf and clean the drain strainer (Item #1, Figure 9).

3. Check and clear the air discharge ducts of any obstructions.

4. Wipe down the interior of the machine from the loading end.

5. Check the bells for any damage and make sure they are engaged in the pulleys.

6. Close the access door and load shelf.

7. Open the unload access door.

8. Check the bottom of the blower support (Item #12, Figure 8) for any obstructions
covering the upper blower air intake holes.

9. Wipe down the interior of the machine from the unloading end.

10. Close the access door.

11. Check and clean the louvers on the air intake panel (Item #22, Figure 9) of any
obstructions.

12. Check the filter (Item #20, Figure 9) for any obstructions.

a. With the operator facing the load end of the tray dryer, the filler holder is located on

the right side of the unload end.

b. To remove the filter holder, insert finger into opening, lift up and pull out.
c. To remove filter from holder, slide up and pull out from the bottom.

13. Report any unusual conditions to your supervisor.

8

•Weekly

1. Wash the air intake filter.

2. Clean the exterior of the machine of all foreign residue.

3. Check the alignment of the belt on the pulleys.

4. Check all bearings for free rotation. Grease the bearings using the fittings provided.

Deliming

Depending on the mineral content of your water, your tray dryer may need deliming.

Inspect your machine interior for lime deposits. If deliming is required, a deliming agent should be
used for best results.

9

TROUBLESHOOTING

Start switch faulty

Contact your service agency

Main switch off

Check disconnect

Overload protector tripped

Reset overload in Control Box

Defective motor

Contact your service agency

Pulley not aligned

Align and lighten pulley set screw

Filter needs cleaning

Bottom blower not working

Reset overload switch and clean filter

Drive belt loose

Adjust drive motor

Before determining any specific cause of a breakdown or abnormal operation of your tray dryer,
check that:

1. Power switch is ON

2. Tray accumulator is not full.

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

CONDITION CAUSE SOLUTION

Machine will not start

Tray accumulator full Remove trays

Overload protector tripped Reset overload in Control Box Any motor not running

Trays jamming

Trays not drying

Bell not on pulley Check, locate belt on pulley

Bell broken Check or replace belt
Feeding trays too fast Slower insertion of trays

Top blower not working Reset overload switch and clean upper

blower air intake holes
(Item #12. Figure 8)

Bell broken Check or replace bell Conveyor not running

10