Champion D-H1 Service Manual

Champion

The Dishwashing Machine Specialists

Technical Manual

Door-Type Dishwasher

with Built-in Booster

Model

D-HB

High Temperature

D-H1

High Temperature D-LF Low Temperature

Machine Serial No.

Manual P/N 111807

April, 1996

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

336/661-1556 Fax: 336/661-1660 Email: champion@championindustries.com

Champion Industries, Inc.

2674 N. Service Road Jordan Station, Ontario, Canada LOR ISO 905/562-4195 Fax: 905/562-4618

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

Model Number -_____________________________ Serial Number - _________________________

Voltage and Phase______________________________________________________________________ Champion Parts Distributor ______________________________________ Phone ______________

______________________________________________________________________________________

Champion Service Agency- ______________________________________ Phone ______________ ______________________________________________________________________________________

Champion Industries Service: 1 (800) 858-4477 Champion Service Fax: 1 (336) 661-1660 In Canada:

Champion Service: 1 (800) 263-5798 Canada Service 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.

Revision History

Revision Revised Serial Number Comments Date Pages Effectivity

4/16/96 — — Reissue manual with new replacement parts lists 9/16/96 11-12 — Revised straight-through to comer conversion instructions

CONTENTS

The Dishwashing Formula 6 WARRANTY 7 INTRODUCTION 8 GENERAL 9 Model Numbers 9 Standard Equipment 9 Options 9 Accessories 9 Electrical Power Requirements 10 INSTALLATION 11 Unpacking 11 Changing from Straight -through to Comer Operation 11 Electrical Connections 12 Plumbing Connections 13 Water Connections 13 Drain Connections 14 Chemical Connections 14 Model D-HB, D-H1 and D-LF 15 Detergent 15 Rinse Aid/Sanitizer 16 INITIAL START-UP 18 Model D-HB, D-H1 and D-LF OPERATION 19 Model D-HB, D-H1 and D-LF MAINTENANCE 20 Maintenance Schedule 20 CLEANING 20 Every 2 Hours or After Each Meal Period Model D-HB, D-H1 and D-LF 20 Every 8 Hours or at the End of the Day Model D-HB, D-H1 and D-LF 20 DELIMING 21 Deliming process Model D-HB, D-H1 and D-LF 21 OPERATION CHECKS 22 Daily 22 Weekly 22

Page

CONTENTS

Page TROUBLESHOOTING 22 BASIC SERVICE 24 Electrical Service 24 Fuses 25 Motor Overloads 25 Timers 26 Timed Fill/Low Water Tank Heat Protection 27 Heater Element Wiring 28 Motor Connections 29 Mechanical Service 30 Pump Seal Replacement 30 REPLACEMENT PARTS LIST 31 ELECTRICAL SCHEMATICS & DIAGRAMS 67 LIST OF FIGURES Figure 1 — Placement for Comer Operation 11 Figure 2 — Changing the Track Assembly 12 a — Straight -Through Configuration b — Comer Configuration Figure 3 — Drain Connection 14 Figure 4 — Chemical Connection Points 15 Figure 5 — Detergent Probe Insertion Point 15 Figure 6 — Rinse Aid Insertion Point 16 Figure 7 — Rinse Aid/Sanitizer Injection Points 17 Figure 8 — Operator Controls 18 Figure 9 — Door Activated Drain Lever Assembly 18 Figure 10 — Fuses 25 Figure 11 — Motor Overload 25 Figure 12 — Cycle Timer 26 Figure 13 — Cycle Timer Chart 26 Figure 14 — Fill Timer 26 Figure 15 — Fill Timer Chart 26 Figure 16 — Float Switch 27 Figure 17 — Float Switch Troubleshooting Chart 27 Figure 18 — Pump Motor Wiring Diagrams 29 Figure 19 — Pump Seal Replacement 30 Figure 20 — Doors, Panels and Gauges 32 Figure 21 — Door Handle Assembly and Springs 34 Figure 22 — Door Linkage 35 Figure 23 — Track Assembly, Float Switch and Drain Assembly 36 Figure 24 — Wash/Rinse Spray System Assembly (Beginning with S/N 11599 and above) 38

LIST OF FIGURES (cont'd)

Figure

Figur

Figure

Figure 25 Wash/Rinse Spray Arms (Beginning with S/N 77855 through S/N 11599) 40 Figure 26 Wash/Rinse Spray Arms (Prior to S/N 77854) 42

Tank Heater Element and Thermostat 44 Fill Piping Assembly 46 Fill Piping Assembly 48 Pump Assembly 50 Electric Booster Assembly and Thermostat 52 Control Cabinet 54 Dishracks 56 Steam Coil/Steam Injector Fill Piping 60 Steam Coil and Booster Assembly 62 Steam Injector and Booster Assembly 64 Electrical Schematic D-HB/D-H1, 3 Phase 68 Wiring Diagram D-HB, 3 Phase 69 Electrical Schematic D-HB/D-H1/D-LF, 1 Phase 70 Wiring Diagram D-HB, 1 Phase 71 Wiring Diagram D-H1/D-LF, 3 Phase 72

D-HB COMPONENT DIAGRAM

COMPONENT DIAGRAM

The Dishwasher Formula

Five Elements for Cleaning Dishes

A Perfect Score means Clean Ware for your customers

Peak Dishwasher Performance for you.

Point Value

1. Time .................................................................................. 20

Wash and rinse times (set by NSF and Champion) allow everything to work.

2. Temperature...................................................................... 20

Heated water penetrates and loosens soil on dishes.

3. Mechanical Action............................................................ 20

Pumps produce water pressure which flushes the soil off dishes.

4. Chemical Action ............................................................... 20

Detergent breaks down grease and loosens soil particles.

5. Procedure.......................................................................... 20

Pre-scraping and rinsing removes large food particles from the dishes. Proper washroom ventilation and humidity shortens dish drying time.

SCORE 100

LIMITED WARRANTY

Champion Industries Inc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 27115, 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 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 warranty period, Champion, at its election, will either repair or replace the defective machine or accept return of the machine for full credit; provided, however, as to glasswashers, Champion's obligation with respect to labor associated wit h 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 Ch ampion'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 cleanin g 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.

INTRODUCTION

Welcome to Champion ...

and thank you for allowing us to take care of your dishwashing needs.

This manual covers the door -type series dishwasher models D-H1, D-HB, and D-LF. Your machine was completely assembled, inspected, and thoroughly test ed 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 parts distributor or 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 door type dishwashing machine. These machines are fully automatic and come equipped with a 1 -HP pump motor.

The D-series dishwasher is available in the following models:

Model Numbers

D-H1,D-HB,D-LF The D-H1 model is a high temperature (180°F/82°C rinse) sanitizing model without booster. The D-HB model is a high temperature (180°F/82°C rinse) sanitizing model with booster.

The D-LF is a low temperature (Min. 1200F/490C-1400F/600C Optimum) sanitizing model for use with a sodium hypochlorite (Chlorine) based sanitizer at a minimum concentration of 50PPM in the final rinse.

Standard Equipment includes:

D-H1, D-HB, D-LF

• Automatic tank fill

• Built-in electric or steam booster heater (DHB only)

• Door activated drain

• Field convertible to comer model

• Electric tank heat

• Balanced three door lift system

• Low -water tank heat protection

• 1-hp drip-proof pump motor

• Door safety switches

• Common utility connections

• Two dish racks (peg and flat bottom)

• Detergent/chemical connection provisions

• Stainless steel front and side panels

• Top-mounted, splash-proof control console

• 60-second time cycle

• 1-1/2" O.D. gravity drain connection

• Water pressure regulating valve (mounted) (D-HB only)

• Interchangeable upper and lower spray arms

Options (D-HB only)

• Electric booster (70°F/39°C temperature rise) heater for 110°F/43°C supply water

• Steam injector or steam coil tank heat (steam booster 40°F/23°C - 70°F/39°C rise)

• Single source gas booster system

Accessories

Additional dishracks: Dish rack (peg) Silverware rack (flat bottom)

P/N101285 P/N101273

Electrical Power Requirements

D-HB 115/60/1

Model Voltage Booster Rise Machine Power Requirement

D-H1/LF 115/60/1 — 48 Amps 60 Amps D-H1/LF 208/60/1 — 23 Amps 29 Amps D-H1/LF 220/60/1 — 23 Amps 29 Amps D-H1/LF 230/60/1 — 23 Amps 29 Amps D-H1/LF 240/60/1 — 24 Amps 30 Amps D-H1/LF 208/60/3 — 12 Amps 15 Amps D-H1/LF 220/60/3 — 13 Amps 16 Amps D-H1/LF 230/60/3 — 13 Amps 16 Amps D-H1/LF 240/60/3 — 13 Amps 16 Amps D-H1/LF 380/60/3 — 7 Amps 9 Amps D-H1/LF 415/60/3 — 8 Amps 10 Amps D-H1/LF 480/60/3 — 6 Amps 8 Amps D-H1/LF 575/60/3 — 5 Amps 6 Amps

D-HB 208/60/1 40°F/23°C 59 Amps 74 Amps D-HB 220/60/1 40°F/23°C 61 Amps 76 Amps D-HB 230/60/1 40°F/23°C 63 Amps 79 Amps D-HB 240/60/1 40°F/23°C 65 Amps 81 Amps D-HB 208/60/3 40°F/23°C 33 Amps 41 Amps D-HB 220/60/3 40°F/23°C 35 Amps 44 Amps D-HB 230/60/3 40°F/23°C 36 Amps 45 Amps D-HB 240/60/3 40°F/23°C 37 Amps 46 Amps D-HB 380/60/3 40°F/23°C 20 Amps 25 Amps D-HB 415/60/3 40°F/23°C 20 Amps 25 Amps D-HB 480/60/3 40°F/23°C 17 Amps 21 Amps D-HB 575/60/3 40°F/23°C 14 Amps 18 Amps

(D-HB Only) Full Load Amps (125% Service Factor)

D-HB 208/60/1 — — — D-HB 220/60/1 — — — D-HB 230/60/1 — — — D-HB 240/60/1 — — — D-HB 208/60/3 70°F/39°C 50 Amps 63 Amps D-HB 220/60/3 70°F/39°C 52 Amps 65 Amps D-HB 230/60/3 70°F/39°C 54 Amps 68 Amps D-HB 240/60/3 70°F/39°C 56 Amps 70 Amps D-HB 380/60/3 70°F/39°C 30 Amps 38 Amps D-HB 415/60/3 70°F/39°C 33 Amps 41 Amps D-HB 480/60/3 70°F/39°C 28 Amps 35 Amps D-HB 575/60/3 70°F/39°C 23 Amps 29 Amps

INSTALLATION

Unpacking

CAUTION:

Care should be taken when lifting the machine to prevent damage.

1. Immediately after unpacking the 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 skid. Adjust the feet if required, then move the machine to its permanent location.

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

4. Remove the two dishracks from the interior of the machine.

NOTE:

The installation of your machine must meet local health codes.

Changing from Straight -through to Corner Operation

Your door -type dishwasher is shipped from the factory in a straight-through configuration. The following instructions explain how to convert your machine for comer operation.

Refer to Fig. 1 below.

1. Place the dishwasher so the operator controls are readily accessible.

2. Minimum clearance from any comer wall is 5-1/4" (133mm).

Figure 1 Placement for Corner Operation

Changing from Straight -through to Corner Operation (cont'd)

Figure

Corner

Refer to Fig. 2 and perform the steps below.

1. Remove the front rack guide (A). Discard the square spacers.

2. Move front rack guide (A) to the left side of the rack tracks. (See Fig. 2b) Use existing hardware.

3. Unbolt the track (B) and rack support rod (C).

4. Remove and save the two remaining fasteners from rear track.

5. Bolt (B) and (C) as shown in Fig. 2b.

Figure 2 Changing the Track Assembly

Figure 2a Straight-Through Configuration

Configuration

Electrical Connections

WARNING:

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 place a tag at the disconnect switch to indicate work is being done on that circuit.

1. A qualified electrician must compare the electrical power supply with the machine electrical specifications stamped on the MACHINE ELECTRICAL CONNECTION PLATE located inside the top mounted control cabinet before connecting to the incoming service at a fused disconnect switch.

2. Motor rotation was set at the factory. Check the rotation of the motor shaft (CW when viewed from rear of motor). For three phase machines, reversing the motor direction is done in the control cabinet by reversing the wires LI and L2 on the disconnect side of the main electrical connection block. For single phase machines, motor rotation is changed at the motor connection plate on the rear of the single phase motor.

Electrical Connections (cont'd)

3. A knock -out is provided at the rear of the top mounted control cabinet for the electrical service connection. A single source electrical connection has been provided. A fused disconnect switch or circuit breaker (supplied by others) is required to protect each power supply circuit.

Plumbing Connections

CAUTION:

Plumbing connections must comply with local sanitary and plumbing codes.

Water Connections

1. Connect the hot water supply to the "Y" strainer or pressure reducing valve (PRV) at the final rinse piping (located behind the control cabinet at the top of the machine).

2. Minimum incoming water supply temperature requirements are listed below:

D-HB with built-in 40°F/23°C rise electric booster (Minimum 140°F/60°C) (Min./Max. flow pressure 20-22 psi/138 Kpa)

D-HB with built-in 70°F/39°C rise electric booster (Minimum 110°F/43°C) (Min./Max. flow pressure 20-22 psi/138 Kpa)

D-H1 without built-in booster (Minimum 180°F/70°C) (Min./Max. flow pressure 20-22 psi/138 Kpa)

D-LF (Minimum 120°F/49°C - 140°F/60°C Optimum) (Min./Max. flow pressure 20-22 psi/138 Kpa)

3. A manual shut-off valve for steam and water (supplied by others) should be installed in supply line to allow for servicing of the machine. The shut-off valve should be the same size or larger than the supply line.

4. A 3/4" Pressure Regulating Valve (PRV), should be installed on the incoming water supply line if water flow pressure exceeds 20-22 psi/138 Kpa.

A PRV is standard equipment on Model D-HB. A PRV is not standard equipment on Models D-H1 and D-LF. The PRV

may be obtained locally or direct from Champion.

Drain Connections

Refer to Fig. 3 for the location of the machine drain.

1. Models D-HB, D-H1, and D-LF are GRAVITY DRAIN machines equipped with a 1-1/2" hose connection point. • Drain height for ALL MODELS must not exceed 15" above floor level.

WARNING:

Connection of the machine to a drain line higher than the machine drain height will prevent the machine from draining properly.

Figure 3 D-HB, D-H1, D-LF 1-1/2" Drain Connection Front Left Side of Machine

Ventilation

NOTE:

Ventilation must comply with local sanitary and plumbing codes.

CAUTION:

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

Chemical Connections

Figure

5 D-

HB, D-

H1, D-

NOTE:

Consult a qualified chemical supplier for your chemical needs.

Models D-HB. D-H1 and D-LF

1. Refer to Fig. 4 Labeled chemical signal connection points are provided inside the control cabinet for chemical dispensing equipment (supplied by others).

Signal connection points include:

• Detergent signal 120 VAC between Wire

#10 and Wire #2 (1 AMP MAX AMP LOAD)

• Rinse Aid/Sanitizer signal 120 VAC

between Wire #15 and Wire #2 (1 AMP

MAX AMP LOAD)

Figure 4 D-HB, D-H1, D-LF Chemical Connection Points Left Side Interior of Control Cabinet

Detergent

1. Refer to Fig. 5 A removable black plug, located on the rear of the wash tank is provided as a detergent probe insertion point.

Detergent Probe Insertion Point Wash Tank (Rear)

Chemical Connections (cont'd) Detergent (cont'd)

2. Detergent may be added manually if dishwasher is not equipped with dispensing equipment. Consult your chemical supplier for recommended amounts.

Rinse Aid/Sanitizer

Model D-HB and D-H1

Refer to Fig. 6

1. A rinse aid injection point is provided via a 1/8" NPT plug located in the final rinse piping. The plug is

located in a Tee fitting on the outlet side of the vacuum breaker. The vacuum breaker is located behind the control cabinet at the top of the machine.

2. Use a liquid rinse aid.

Figure 6 Rinse aid Insertion Point D-HB, D-H1 Only

NOTE:

Models D-HB and D-H1 do not require sanitizer.

Chemical Connections (cont'd)

Figure

7 D-

LF Rinse Aid/Sanitizer

Rinse Aid/Sanitizer (cont'd)

Model D-LF Refer to Fig. 7

1. A Rinse aid injection point is provided via a 1/8" NPT plug located in the final rinse piping. The plug is located in a Tee fitting on the outlet side of the vacuum breaker. The vacuum breaker is located behind the control cabinet at the top of the machine.

2. Use a liquid rinse aid.

3. A Sanitizer injection point is provided via a 1/4" NPT plug located in the final rinse piping. The plug is located in a Tee fitti ng on the outlet side of the vacuum breaker. The vacuum breaker is located behind the control cabinet at the top of the machine.

4. Use a sodium hypochlorite (Chlorine) based sanitizer at a minimum concentration of 50PPM in the final rinse. Use chlorine test papers to verify and monitor the 50PPM chlorine level.

Injection Points

WARNING:

Never premix rinse aid with the sanitizing agent. Mixing may cause hazardous gases to form.

CAUTION:

Some metal, including silver, aluminum, and pewter are attacked by sodium hypochlorite (chlorine sanitizer). Avoid cleaning these metals in a D-LF dishwasher.

INITIAL START-UP

Figure

Door Activated

After plumbing and electrical connections are completed, follow the steps below to place your machine in service. Model D-HB. D-H1 and D-LF Refer to

Figs. 8 and 9 below.

1. Remove any foreign material from inside the machine. Make sure scr ap screens are in place.

2. Make sure drain lever assembly is closed.

3. Close the Door.

4. Turn the water and main power sources to the dishwasher ON.

5. Flip the Power switch to the ON position. The "power on" light will illuminate and the machine will

automatically fill with water.

6. Check the machine for leaks.

7. Push the Green Start Button to check automatic cycle.

8. Check pump motor rotation. Rotation is CW when viewed from rear of motor.

9. If machine checks okay, lift the drain lever assembly to drain machine. 10. Flip the power switch

to OFF.

Figure 8 Operator Controls Top Mounted Control Cabinet

Drain Lever Assembly

OPERATION

Model D

HB, D

H1 and D

1. Close the door and flip power switch ON Power light illuminates. Tank fills automatically and tank heat comes on.

2. Monitor wash tank temperature gauge Wait for temperature reading to reach Min. 150°F/66°C (D-HB, D-H1 Only) Temperature reading must be Min. 1200F-1400F/490C-600C Optimum (For D-LF Only)

3. Prescrap and load ware into rack Place dishes edgewise in peg rack, cups and bowls upside down in flat rack, and silverware spread evenly in single layer in flat rack.

4. Open door, insert rack

5. Close door, Push Green start button Green cycle light will illuminate. Automatic cycle

6. During Final Rinse monitor pressure gauge and final

rinse temperature gauge

7. 60-second cycle complete Green cycle light goes out.

8. Open door, remove clean rack Insert another rack of soiled ware.

9. After each meal period or every two hours operation Lift drain lever assembly to drain machine. Flush interior

begins. Machine washes for 45 sec., then pauses for 1 sec.

Machine final rinses for 14 sec. Pressure gauge reading must read between 20-22 PSI. Temperature gauge must read 180-195 °F/82-91°C (D-HB, D-H1 Only) Min. 120°1400F/49°C-600C Optimum (D-LF Only)

and clean scrap screens and pump intake strainer. Check spray arms and clean if necessary.

NOTE:

Opening the door at any time during the cycle will stop the machine. Closing the door and pushing the Green start button will resume the cycle where it left off.

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