Champion D-H1M4 Service Manual

The Dishwashing Machine Specialists

Technical Manual

Door-Type Dishwasher

Model D-HBM4

High Temperature with Built-in Booster

D-H1M4 High Temperature

D-LFM4 Low Temperature

February, 2003

P.O. Box 4149 Winston-Salem, North Carolina 27115-4149 336/661-1556 Fax: 336/661-1660

Manual P/N 113137 Rev. C

Champion

Machine Serial No.

www.championindustries.com

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

For machines beginning with serial no. D2099 thru D3693

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.

Machine Data Plate with Model & Serial number located on left side of control cabinet.

Revision History

Revision Revised Serial Number Comments

Date Pages Effectivity

4/2/01 All —— Issue temporary manual with replacement parts lists 8/16/01 All D2099 Issued as permanent manual 8/16/01 D2964 First S/N with electrical drain valve 113315

and timer 113314

8/16/01 39 Added P/N 900830 Drain Valve kit

for machines S/N D2099 thru D2963 11/05/01 27 Corrected Corner Machine Side Door 1/03/02 47, 51 D3291 Change vacuum breaker 3/4" 104429 to 113222 1/03/02 32, 33 Added straight track assembly 5/20/02 47, 51 Added 900837 Kit* Repair 3/4" Vacuum Breaker 12/18/02 55 D3857 Inserted timer control board kit P/N 900911

to replace 112676 2/5/03 27 — Replaced P/N 108391 with 113622. 2/5/03 53 — Replaced P/N 11143 with 113248. 2/5/03 55 — Replaced Furnace (Siemens) overloads

with Telemecanique (Square D) overloads.

REVISIONS

CONTENTS

Page

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

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

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

Model Numbers...................................................................................................................2

Standard Equipment ............................................................................................................ 2

Options................................................................................................................................. 2

Accessories.......................................................................................................................... 2

Electrical Power Requirements ........................................................................................... 3

INSTALLATION........................................................................................................................ 4

Unpacking............................................................................................................................ 4

Changing from Straight-through to Corner Operation........................................................ 4

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

Plumbing Connections......................................................................................................... 5

Water Connections...............................................................................................................6

Drain Connections...............................................................................................................6

Chemical Connections......................................................................................................... 7

Model D-HB, D-H1 and D-LF ..................................................................................... 7

Detergent.............................................................................................................................. 7

Rinse Aid/Sanitizer .............................................................................................................. 8

INITIAL START-UP .................................................................................................................. 10

Model D-HB, D-H1 and D-LF

OPERATION.............................................................................................................................. 11

Model D-HB, D-H1 and D-LF

MAINTENANCE....................................................................................................................... 12

Maintenance Schedule......................................................................................................... 12

CLEANING .................................................................................................................. 12

Every 2 Hours or After Each Meal Period

Model D-HB, D-H1 and D-LF ........................................................................ 12

Every 8 Hours or at the End of the Day

Model D-HB, D-H1 and D-LF ........................................................................ 12

DELIMING................................................................................................................... 13

Deliming process

Model D-HB, D-H1 and D-LF ........................................................................ 13

OPERATION CHECKS................................................................................................ 14

Daily ....................................................................................................................... 14

Weekly.................................................................................................................... 14

CONTENTS

Page

TROUBLESHOOTING............................................................................................................. 14

BASIC SERVICE....................................................................................................................... 16

Electrical Service................................................................................................................. 16

Fuses .......................................................................................................................... 17

Motor Overloads ........................................................................................................... 17

Solid State Control Board............................................................................................. 18

Low Water Tank Heat Protection.................................................................................. 20

Heater Element Wiring ................................................................................................. 21

Motor Connections........................................................................................................ 22

Mechanical Service..............................................................................................................23

Pump Seal Replacement ............................................................................................... 23

REPLACEMENT PARTS LIST................................................................................................ 25

ELECTRICAL SCHEMATICS ................................................................................................. 65

LIST OF FIGURES

Figure 1 — D-HB 3/4" NPT Water Supply Connection...................................................... 5

Figure 2 — D-H1/ D-LF 3/4" NPT Water Supply Connection............................................ 5

Figure 3 — Chemical Connection Points............................................................................. 7

Figure 4 — Wash Tank Detergent Equipment Insertion Points.......................................... 7

Figure 5 — Rinse Aid Injection Point (D-HB, D-H1 Only)................................................ 8

Figure 6 — Rinse Aid/Sanitizer Injection Points (D-LF).................................................... 9

Figure 7 — Operator Controls.............................................................................................. 10

Figure 8 — Door Activated Drain Lever Assembly............................................................ 10

Figure 9 — Fuses.................................................................................................................. 17

Figure 10 — Motor Overload................................................................................................. 17

Figure 11 — Solid State Control Board................................................................................. 19

Figure 12 — Float Switch ...................................................................................................... 20

Figure 13 — Float Switch Troubleshooting Chart................................................................. 20

Figure 14 — Pump Motor Wiring Diagrams ......................................................................... 22

Figure 15 — Pump Seal Replacement ................................................................................... 23

Figure 16 — Doors, Panels and Gauges ................................................................................ 26

Figure 17 — Door Guides, Stops, and Lift Bracket............................................................... 28

Figure 18 — Door Handle and Spring Assembly ................................................................. 30

Figure 19A — Straight Track Assembly................................................................................... 32

Figure 19B — Corner Track Assembly .................................................................................... 32

Figure 20 — Wash/Rinse Spray Piping.................................................................................. 34

Figure 21 — Wash/Rinse Spray Arms .................................................................................. 36

Figure 22 — Drain Assembly and Scrap Screens.................................................................. 38

Figure 23 — Wash Tank Heat, Thermostats, and Float Switch............................................. 40

Figure 24 — Electric Booster and Thermostat (D-HB Only)................................................ 42

Figure 25 — D-HB Lower Fill Piping Assembly.................................................................. 44

iii

CONTENTS

LIST OF FIGURES (cont’d)

Page

Figure 26 — D-HB, D-H1 Upper Fill Piping Assembly........................................................... 46

Figure 27 — D-H1, D-LF Lower Fill Piping Assembly ........................................................... 48

Figure 28 — D-LF Upper Fill Piping Assembly....................................................................... 50

Figure 29 — Pump Assembly.................................................................................................... 52

Figure 30 — Control Cabinet .................................................................................................... 54

Figure 31 — Dishracks and PRV............................................................................................... 56

APPENDIXES

Appendix A — Conversion Information .................................................................................. 60

Appendix B — Straight to Corner (Door Conversion Kit)...................................................... 61

Appendix C — Corner to Straight (Door Conversion Kit)...................................................... 63

Appendix D — Drain/Timer Circuit........................................................................................ 64

ELECTRIC SCHEMATICS

B701650/E — Wiring Diagram (D-HB, D-H1, D-LF Steam/Electric 1 & 3 Phase) .............. 65

CONTENTS

THIS PAGE

INTENTIONALLY

LEFT BLANK

WARRANTY

LIMITED WARRANTY

Champion Industries Inc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 27115, and P.O. Box 301, 2674 North Service Road, Jordan Station, Ontario, 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 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 with any repairs shall end (a) 120 days after shipment, or (b) 90 days after installation, whichever occurs first. In the event that Champion elects to repair, the labor and work to be performed in connection with the warranty shall be done during regular working hours by a Champion authorized service technician. Defective parts become the property of Champion. Use of replacement parts not authorized by Champion will relieve Champion of all further liability in connection with its warranty. In no event will Champion’s warranty obligation exceed Champion’s charge for the machine. The following are not covered by Champion’s warranty:

a. Lighting of gas pilots or burners. b. Cleaning of gas lines. c. Replacement of fuses or resetting of overload breakers. d. Adjustment of thermostats. e. Adjustment of clutches. f. Opening or closing of utility supply valves or switching of electrical supply current. g. Cleaning of valves, strainers, screens, nozzles, or spray pipes. h. Performance of regular maintenance and cleaning as outlined in operator’s guide. i. Damages resulting from water conditions, accidents, alterations, improper use, abuse,

tampering, improper installation, or failure to follow maintenance and operation procedures.

j. Wear on Pulper cutter blocks, pulse vanes, and auger brush. Examples of the defects not covered by warranty include, but are not limited to: (1) Damage to the exterior or

interior finish as a result of the above. (2) Use with utility service other than that designated on the rating plate. (3) Improper connection to utility service. (4) Inadequate or excessive water pressure. (5) Corrosion from chemicals dispensed in excess of recommended concentrations. (6) Failure of electrical components due to connection of chemical dispensing equipment installed by others. (7) Leaks or damage resulting from such leaks caused by the installer, including those at machine table connections or by connection of chemical dispensing equipment installed by others. (8) Failure to comply with local building codes. (9) Damage caused by labor dispute.

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

from defects in material and workmanship for a period of 90 days from date of invoice. If any defect in material and workmanship is found to exist within the 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 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 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. 140°F/60°C) 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 • Common utility connections

• Built-in electric (D-HB only) or • Two dish racks (peg and flat bottom)

steam booster heater (D-HB only) • Detergent/chemical connection provisions

• Drain Valve – Electric • Stainless steel front and side panels

• Specified as straight-through or corner model • Top-mounted, splash-proof control console

• Electric tank heat • 60-second time cycle

• Balanced three door lift system • 2" O.D. gravity drain connection

• Low-water tank heat protection • Water pressure regulating valve

• 1-Hp drip-proof pump motor (mounted) (D-HB only)

• Door safety switches • 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)

Accessories

Additional dishracks: Dish rack (peg) P/N 101285 Silverware rack (flat bottom) P/N 101273 3/4” Pressure reducing valve (PRV) P/N 112387

GENERAL

Electrical Power Requirements for Electric Heat / Electric Booster

Booster Rise Rated Minimum Supply Ckt. Maximum Overcurrent

Model Voltage (D-HB Only) Amps Conductor Ampacity Protective Device

D-H1/LF 115/60/1 — 49 Amps 60 Amps 60 Amps D-H1/LF 208/60/1 — 25 Amps 35 Amps 35 Amps D-H1/LF 220/60/1 — 26 Amps 35 Amps 35 Amps D-H1/LF 230/60/1 — 26 Amps 35 Amps 35 Amps D-H1/LF 240/60/1 — 26 Amps 35 Amps 35 Amps D-H1/LF 208/60/3 — 14 Amps 20 Amps 20 Amps D-H1/LF 220/60/3 — 14 Amps 20 Amps 20 Amps D-H1/LF 230/60/3 — 14 Amps 20 Amps 20 Amps D-H1/LF 240/60/3 — 15 Amps 20 Amps 20 Amps D-H1/LF 380/60/3 — 9 Amps 15 Amps 15 Amps D-H1/LF 415/60/3 — 9 Amps 15 Amps 15 Amps D-H1/LF 480/60/3 — 7 Amps 15 Amps 15 Amps D-H1/LF 575/60/3 — 6 Amps 15 Amps 15 Amps

D-HB 115/60/1 — — — D-HB 208/60/1 40°F/23°C 69 Amps 80 Amps 80 Amps D-HB 220/60/1 40°F/23°C 76 Amps 80 Amps 80 Amps D-HB 230/60/1 40°F/23°C 76 Amps 80 Amps 80 Amps D-HB 240/60/1 40°F/23°C 76 Amps 90 Amps 90 Amps D-HB 208/60/3 40°F/23°C 39 Amps 45 Amps 45 Amps D-HB 220/60/3 40°F/23°C 39 Amps 45 Amps 45 Amps D-HB 230/60/3 40°F/23°C 43 Amps 45 Amps 45 Amps D-HB 240/60/3 40°F/23°C 43 Amps 50 Amps 50 Amps D-HB 380/60/3 40°F/23°C 24 Amps 30 Amps 30 Amps D-HB 415/60/3 40°F/23°C 25 Amps 30 Amps 30 Amps D-HB 480/60/3 40°F/23°C 18 Amps 25 Amps 25 Amps D-HB 575/60/3 40°F/23°C 15 Amps 20 Amps 20 Amps

D-HB 115/60/1 — — — — 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 51 Amps 70 Amps 70 Amps D-HB 220/60/3 70°F/39°C 51 Amps 70 Amps 70 Amps D-HB 230/60/3 70°F/39°C 58 Amps 70 Amps 70 Amps D-HB 240/60/3 70°F/39°C 58 Amps 80 Amps 80 Amps D-HB 380/60/3 70°F/39°C 31 Amps 40 Amps 40 Amps D-HB 415/60/3 70°F/39°C 34 Amps 45 Amps 45 Amps D-HB 480/60/3 70°F/39°C 29 Amps 35 Amps 35 Amps D-HB 575/60/3 70°F/39°C 24 Amps 30 Amps 30 Amps

Electrical Power Requirements for Steam or Gas Heat / Steam or Gas Booster

Booster Rise Rated Minimum Supply Ckt. Maximum Overcurrent

Model Voltage (D-HB Only) Amps Conductor Ampacity Protective Device

D-H1/LF 115/60/1 — 22 Amps 30 Amps 30 Amps D-H1/LF 208/60/1 — 13 Amps 15 Amps 15 Amps D-H1/LF 220/60/1 — 13 Amps 15 Amps 15 Amps D-H1/LF 230/60/1 — 13 Amps 15 Amps 15 Amps D-H1/LF 240/60/1 — 11 Amps 15 Amps 15 Amps D-H1/LF 208/60/3 — 6 Amps 15 Amps 15 Amps D-H1/LF 220/60/3 — 6 Amps 15 Amps 15 Amps D-H1/LF 230/60/3 — 6 Amps 15 Amps 15 Amps D-H1/LF 240/60/3 — 6 Amps 15 Amps 15 Amps D-H1/LF 380/60/3 — 4 Amps 15 Amps 15 Amps D-H1/LF 415/60/3 — 4 Amps 15 Amps 15 Amps D-H1/LF 480/60/3 — 3 Amps 15 Amps 15 Amps D-H1/LF 575/60/3 — 3 Amps 15 Amps 15 Amps

D-HB 115/60/1 — — — D-HB 208/60/1 40°F/23°C 22 Amps 30 Amps 30 Amps D-HB 220/60/1 40°F/23°C 13 Amps 15 Amps 15 Amps D-HB 230/60/1 40°F/23°C 13 Amps 15 Amps 15 Amps D-HB 240/60/1 40°F/23°C 13 Amps 15 Amps 15 Amps D-HB 208/60/3 40°F/23°C 6 Amps 15 Amps 15 Amps D-HB 220/60/3 40°F/23°C 6 Amps 15 Amps 15 Amps D-HB 230/60/3 40°F/23°C 6 Amps 15 Amps 15 Amps D-HB 240/60/3 40°F/23°C 6 Amps 15 Amps 15 Amps D-HB 380/60/3 40°F/23°C 4 Amps 15 Amps 15 Amps D-HB 415/60/3 40°F/23°C 4 Amps 15 Amps 15 Amps D-HB 480/60/3 40°F/23°C 3 Amps 15 Amps 15 Amps D-HB 575/60/3 40°F/23°C 3 Amps 15 Amps 15 Amps

D-HB 115/60/1 — — — — 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 6 Amps 15 Amps 15 Amps D-HB 220/60/3 70°F/39°C 6 Amps 15 Amps 15 Amps D-HB 230/60/3 70°F/39°C 6 Amps 15 Amps 15 Amps D-HB 240/60/3 70°F/39°C 6 Amps 15 Amps 15 Amps D-HB 380/60/3 70°F/39°C 4 Amps 15 Amps 15 Amps D-HB 415/60/3 70°F/39°C 4 Amps 15 Amps 15 Amps D-HB 480/60/3 70°F/39°C 3 Amps 15 Amps 15 Amps D-HB 575/60/3 70°F/39°C 3 Amps 15 Amps 15 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 and pressure gauge from the interior of the machine. Install the pressure gauge in the upper fill piping of the dishwasher in the petcock provided.

NOTE:

The installation of your machine must meet local health codes.

Changing from Straight-through to Corner Operation

Your door-type dishwasher was specified to the factory as a straight-through configuration or corner configuration. Your machine can be converted from straight-through to corner or from corner to straight-through. The factory has kits for these conversions available. For instructions and part numbers, see Appendixes A, B, and C.

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 L1 and L2 on the disconnect side of

! !

Electrical Connections (cont’d)

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.

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 using a 3/4” NPT connection. The connection point is located behind the lower front panel of the dishwasher. Supply enters from underneath the machine.

Figure 1 Figure 2

D-HB D-H1, D-LF

3/4” NPT Water Supply Connection 3/4” NPT Water Supply Connection

Behind Front Panel Behind Front Panel

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 140°F/60°C)

(Min./Max. flow pressure 20 – 22 psi/138 Kpa)

INSTALLATION

8-7/8"

[225 mm]

FLOOR

8-7/8"

[225 mm]

FLOOR

INSTALLATION

Water Connections (cont’d)

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

1. Models D-HB, D-H1, and D-LF are GRAVITY DRAIN machines equipped with a 2" hose connection point.

• Drain height for ALL MODELS must not exceed 8-7/8" [225 mm] 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.

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.

INSTALLATION

Chemical Connections

NOTE:

Consult a qualified chemical supplier for your chemical needs.

Models D-HB, D-H1 and D-LF Refer to Figure 3.

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

Signal connection points include:

• Detergent signal 120VAC between Wire #10 and Wire #2

(1 AMP MAX AMP LOAD)

• Rinse Aid/Sanitizer signal 120VAC between Wire #15 and Wire #2

(1 AMP MAX AMP LOAD)

Figure 3

D-HB, D-H1, D-LF

Chemical Connection Points

Left Side Interior of Control Cabinet

Detergent

Refer to Figure 4.

1. Two removable black plugs, located on the rear and left side of the wash tank are provided as detergent equipment insertion points.

Figure 4

D-HB, D-H1, D-LF

Wash Tank Detergent Equipment

Insertion Points

1/2" Black Removable Plug

Detergent Sensor Point

1/2" Black Removable Plug

Detergent Injection Point

CAUTION

120V SUPPLY DISPENSERS ONLY

RINSE/SANI

COMMON

RETURN

DETERGENT

18 19 15

INSTALLATION

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 Figure 5.

1. A rinse aid injection point is provided via a 1/4" NPT plug located in the final rinse piping. The plug is located in a cross 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 5

Rinse Aid Injection Point

D-HB, D-H1 Only

NOTE:

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

INSTALLATION

Chemical Connections (cont’d)

Rinse Aid/Sanitizer (cont’d)

Model D-LF Refer to Figure 6.

2. Use a liquid rinse aid.

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

Figure 6

D-LF

Rinse Aid/Sanitizer 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

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 Figures 7 and 8 below.

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

2. Make sure wash and rinse arms are installed correctly.

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, flip the power switch to OFF and machine will drain for ten minutes.

Figure 7

Operator Controls

Top Mounted Control Cabinet

Figure 8

Drain Assembly

INITIAL START-UP

Main power switch

circuit breaker

Green pushbutton

start switch

Green in cycle lite

Pressure gauge

Temperature Gauges

POWER

OFF

START

WAR NING!

TURN OFF POWER BEFORE

SERVICING MACHINE

CYCLE

Champion

POWER

WASH RINSE

OFF

OPERATION

Model D-HB, D-H1 and D-LF

1. Close the door and flip power switch ON Power light illuminates. Drain valve closes. 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. 120°F-140°F/49°C-60°C 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 begins.

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

6. During Final Rinse monitor pressure Machine final rinses for 14 sec. Pressure gauge and final rinse temperature 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° – 140°F/49°C – 60°C Optimum (D-LF Only)

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 Turn power switch to OFF position and

hours operation machine will drain for ten minutes. Flush

interior and clean scrap screens and pump intake strainer. Check spray arms and clean if necessary. Flip power switch ON and OFF to drain remaining water repeat as 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.

MAINTENANCE

Cleaning your machine is the best maintenance that you can provide. Components that are not regularly flushed and cleaned do not perform well.

The Maintenance intervals shown in the following schedules are the minimum requirements necessary for the proper performance of your machine. Maintenance intervals should be shortened whenever your machine is faced with abnormal working conditions, hard water, or multiple shift operations.

Maintenance Schedule

CLEANING

• Every 2 Hours or After Each Meal Period

Model D-HB, D-H1, and D-LF

1. Flip the power switch OFF.

2. Machine drain valve will open for 10 minutes automatically.

3. Flush tank interior with fresh water.

4. Remove and clean the scrap screens. Clean the pump intake screen.

5. Inspect the spray arm nozzles and rinse nozzles. Clean if necessary.

6. Close door, flip power switch ON to refill machine.

• Every 8 Hours or at the End of the Day

Model D-HB, D-H1, and D-LF

1. Flip the power switch OFF.

2. Machine drain valve will open for 10 minutes automatically.

3. Flush tank interior with fresh water.

4. Remove and clean the scrap screens. Clean the pump intake screen.

5. Remove the spray arms.

6. Clean and inspect the spray arm bearings.

7. Flush the wash arm and rinse arm assemblies and nozzles.

8. Back flush the scrap screens and pump intake strainer.

9. Flip power switch ON then OFF to open drain valve for 10 minutes.

10. Reassemble the machine. Leave the door open to aid overnight drying.

CAUTION:

DO NOT LEAVE WATER IN WASH TANK OVERNIGHT

MAINTENANCE

DELIMING

Your dishwasher should be delimed regularly depending on the mineral content of your water. Inspect the machine interior for mineral deposits and use a deliming solution for the best cleaning results.

NOTE:

Consult your chemical supplier for an appropriate deliming solution.

WARNING:

Deliming solutions or other acids must not come in contact with household bleach (sodium hypochlorite) or any chemicals containing chlorine, iodine, bromine, or fluorine. Mixing will cause hazardous gases to form. Skin contact with deliming solutions can cause severe irritation and possible chemical burns. Consult your chemical supplier for specific safety precautions.

DELIMING PROCESS

Model D-HB, D-H1, and D-LF

1. Remove all dishes from machine.

2. Remove any chemical pick-up tubes from their containers.

3. Place each tube in a container of fresh water and prime the chemical lines for several minutes to thoroughly flush chemical from the lines. Leave pick-up tubes out of their containers.

4. Turn power switch to OFF position to drain machine for ten minutes, return power switch to ON position to refill with fresh water.

5. Spray interior walls with delimimg solution and let sit for 5 or 10 minutes depending on amount of build-up. Add deliming solution to wash tank. Do not let chemicals sit for longer than 15 minutes.

6. Push the Green start button and run an automatic cycle.

7. Repeat Steps 3-4 if necessary.

8. Repeat Step 4.

9. Refill the machine and run a complete cycle two additional times. Drain and refill the machine after each cycle to thoroughly flush any deliming solution from the interior of the machine.

10. Flip the power switch to OFF.

11. Machine drain valve will open for 10 minutes to drain machine completely.

12. Deliming is complete.

MAINTENANCE

OPERATION CHECKS

• Daily

1. Check temperature gauges for proper readings.

2. Check pressure gauge for proper reading (D-H1, D-HB ONLY).

3. Check for leaks.

4. Check chemical supplies and refill as necessary.

• Weekly

1. Inspect all water lines for leaks.

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

3. Check the drains for leaks.

4. Clean accumulated mineral deposits from the tank heating elements

5. Check that float switch moves freely.

TROUBLESHOOTING

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

Checklist

1. Main power and water supply are turned on to the machine

2. All switches are ON

3. Wash pipe and rinse nozzles are clean

4. Scrap screen(s) are properly positioned

5. Spray pipes are in their proper positions

6. Doors are fully closed

7. Thermostat(s) are at their correct setting

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

9. Drain valve/timer problems see Appendix D for trouble shooting.

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

TROUBLESHOOTING

CONDITION CAUSE SOLUTION

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

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

Start switch faulty . . . . . . . . . . . . . . . Contact your service agency

Main switch OFF . . . . . . . . . . . . . . . . Check disconnect

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

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

Faulty drain valve . . . . . . . . . . . . . . . . Contact your service agency

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

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

Defective circuit board . . . . . . . . . . . . Contact your service agency

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

Clogged “Y” strainer . . . . . . . . . . . . . Clean or replace

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

Drain valve will not close . . . . . . . . . Replace drain valve/Contact your service agency

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

Defective circuit board . . . . . . . . . . . . Contact your service agency

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

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

Wash tank water Incoming water temperature

temperature is low at machine too low . . . . . . . . . . . . . . Raise temperature to:

when in use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140°F/60°C for D-HB and D-LF,

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180°F/82°C for D-H1

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

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

Lime scale buildup

on heating elements . . . . . . . . . . . . . Delime element

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

Low steam pressure . . . . . . . . . . . . . . Check steam supply pressure (15 – 30 psi)

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

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

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

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

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

Low water level in tank . . . . . . . . . . . Check drain

Pump motor rotation incorrect . . . . . . Reverse connection between L1 and L2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in Control Cabinet (3PH machines only)

Defective pump seal . . . . . . . . . . . . . . Contact Service Agent

Insufficient final rinse or Faulty pressure reducing valve . . . . . Clean or replace

no final rinse Improper setting on pressure

reducing valve . . . . . . . . . . . . . . . . . Set psi flow pressure at 20 – 22 psi/138 Kpa

Clogged rinse nozzle and/or pipe . . . . Clean

Improper water line size . . . . . . . . . . . Have installer change to proper size (3/4" min.)

Clogged “Y” strainer . . . . . . . . . . . . . Clean or replace

Low final rinse temperature Low incoming water temperature . . . Check house supply water temperature

Improper setting of booster

thermostat . . . . . . . . . . . . . . . . . . . . . Be sure booster thermostat is set to maintain

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180°F/82°C temperature

Defective booster thermostat . . . . . . . Replace thermostat

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

Poor washing results Detergent dispenser not

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

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

Wash water temperature

too low . . . . . . . . . . . . . . . . . . . . . . . See condition “Wash tank water temperature”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . above.

Wash arm clogged . . . . . . . . . . . . . . . Clean

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

Ware being improperly placed

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

Improperly cleaned equipment . . . . . . Unclog wash sprays and rinse nozzles to

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . maintain proper pressure and flow conditions.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Keep wash water as clean as possible.

Electric Elements or steam

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

Poor drying results Insufficient rinse-aid . . . . . . . . . . . . . Contact chemical supplier

Low final rinse temp . . . . . . . . . . . . . See condition “Low final rinse temperature”

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . above.

+ 51 hidden pages