Champion D-HBTM5, DHBTCM5 Operation Manual

Installation/Operation Manual with Service Replacement Parts

For machines beginning with S/N D3684 and above

Door-type Extended Hood Dishwasher

Models:

D-HBTM5, DHBTCM5 High Temperature Extended Hood with Built-in Booster Heater

D-H1TM5, DH1TCM5 High Temperature Extended Hood without Built-in Booster Heater

www.championindustries.com

Champion Industries, INC. 3765 Champion Boulevard, Winston-Sale, NC 27105 P.O. Box 4149 Winston-Salem, NC 27115-4149 1-800 232-8591 Fax: 1-800-661-1556

Issued 1.18.10

Manual P/N 113492 Rev. G

2674 N. Service Road, Jordan Station Ontario, Canada L0R 1S0 1-800 263-5798 Fax: 1-905 562-4618

Printed in U.S.A.

For future reference, record your dishwasher information in the box below.

Model Number__________________________ Serial Number_______________________

Voltage________________Hertz_____________ Phase__________________

Service Agent __________________________________ Tel:______________________

Parts Distributor _________________________________ Tel:______________________

National Service Department

In Canada: In the USA:

Toll-free: 800/ 263-5798 Toll-free: 800/ 858-4477 Tel: 905/ 562-4195 Tel: 336/ 661-1556 Fax: 905/ 562-4618 Fax: 336/ 661-1660 email: service@moyerdiebellimited.com email: service@championindustries.com

ATTENTION:

The model no., serial no., voltage, Hz

and phase are needed to identify your

machine and to answer questions.

The machine data plate is located

on the front panel of the machine

Please have this information ready

if you call for service assistance.

The USGBC and the CaGBC Member Logos are trademarks owned by the U.S. Green Building Council and The Canadian Green

Building Council, respectively, and are used by permission. The logos signify only that Champion Industries and Moyer Diebel

are a USGBC member and a CaGBC member respectively. USGBC and CaGBC do not review, certify nor endorse the products

or services offered by its members.

ATTENTION:

Complete the back of the POSTAGE PAID WARRANTY CARD below, then cut along the dashed lines and mail immediately to make sure that your machine warranty is validated.

USE CANADIAN WARRANTY CARD IN CANADA AND USA WARRANTY CARD IN THE UNITED STATES.

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED STATES

BUSINESS REPLY MAIL

FIRST-CLASS MAIL PERMIT NO. 2101 WINSTON-SALEM, NC

POSTAGE WILL BE PAID BY ADDRESSEE

CHAMPION INDUSTRIES INC PO BOX 4149 WINSTON-SALEM, NC 27119-0981

IMPORTANT IMPORTANT

Model

WARRANTY REGISTRATION CARD

Date of Installation:

Company Name:

Serial #

Address:

Telephone #: ( ) ---

Contact:

Installation Company:

Address:

Telephone #:

Contact:

(Street) State or Province Zip Code

This Card Must Be Returned to Validate Machine Warranty:

Model

Date of Installation:

Company Name:

Address:

Telephone #: ( ) ---

Contact:

Installation Company:

Address:

Telephone #:

Contact:

This Card Must Be Returned to Validate Machine Warranty:

(Street) State or Province Zip Code

Serial #

IMPORTANT IMPORTANT

Revision History

A revision might be a part number change, new instructions, or information that was not available at the time of printing. We reserve the right to make changes to this manual without notice and without incurring any liability by making changes. Dishwasher owners may request a revised manual at no charge by calling (800) 858-4477 in the USA or (800) 263-5798 in Canada.

Revision Date Pages Serial No. Effectivity Description

7.1.02 All D3694 Release of First Edition

10.18.02 3 D3864 Revised rated amp listing

10.18.02 11,15 D3864 Added control panel decal

10.18.02 13,15,17,24 D3864 Revised cycle times

10.18.02 33 D3864 Added new panel P/N 327262

10.18.02 35,37 D3864 Added new door P/N's

10.24.02 44,45 D3864 Revised rinse arm bearing P/N's Bearing 112164 replaced by 113514, 0707452 replaced by

414111.

10.24.02 45 D3864 Added new rinse arm P/N 414110.

10.24.02 47 D3864 Added water deector P/N 327283.

10.24.02 54,55 D3864 Added bushing P/N 100171.

10.24.02 60,61 D3864 Added new control panel.

10.24.02 63 D3864 Added new timer bd. P/N 113547.

12.18.02 63 D3957 Added timer bd. kit P/N 900911 to convert bds. to P/N 113597.

2.5.03 49,61 _____ Replaced P/N 108391 w/ 113622.

2.5.03 63 _____ Vendor change for overloads Square D in place of Siemans.

1.29.04 15 _____ Revised cycle time instructions.

2.3.04 52,53 D4237 Added PRV and line strainer

2.3.04 67 D4237 Update schematic to Rev. K

3.5.04 39 D4410 Changed door safety switch P/N 112659 to P/N 113721.

3.5.04 39 D4410 Added door handle and kit P/N 900860

9.3.09 67 _____ Update schematic to Rev. M

Revision History (continued)

Revision Date Pages Serial No. Effectivity Description

1.06.10 All D09117934 Release of Second Edition

Model Descriptions

Model Numbers

Model Descriptions

D-HBT - Straight-through with built-in booster

D-HBTC - Corner with built-in booster

D-H1T - Straight-through without built-in booster

D-H1TC - Corner without built-in booster

Standard Equipment

Automatic Tank Fill and start Adjustable cycle selector switch Combination dishwasher for dishes, pots, pans and utensils Built-in electric booster heater (DHBT, DHBTC only) in 40˚F/22˚C rise for 140˚F/60˚C supply water

Specied as straight-through or corner operation

2-door lift system Electric tank heat Low-water tank heat protection Door safety switch Automatic electric drain Common utility connection Chemical connection provisions Stainless steel front and side panels 2" O.D. gravity drain connection Mounted water pressure regulating valve (DHBT, DHBTC) Interchangeable upper and lower spray arms Stainless steel rinse arms

Two dish racks (1 peg, 1 at-bottom)

Options and Accessories

Built-in electric booster heater (DHBT, DHBTC only) in 70˚F/39˚C rise for 110˚F/43˚C supply water Externally mounted steam booster (steam booster 40˚F/22˚C - 70˚F/39˚C rise) Steam injector or steam coil tank heat (steam booster 40˚F/22˚C - 70˚F/39˚C rise) Single Source gas booster heater

Additional dish racks: Peg rack P/N 101285 Flat-bottom P/N 101273 Sheet Pan P/N 113281

3/4" NPT Pressure Regulating Valve (PRV) P/N 107550 3/4" NPT Line Strainer P/N 110768

iii

Limited 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 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 fteen (15) months after the date of shipment by Champion, whichever occurs rst. [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 rst. 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 nish 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.

Table of Contents

Model DHBT, DH1T Extended Hood Door-type Dishwashers

Revision History .................................................................................................................. i

Model Descriptions .............................................................................................................. iii

Limited Warranty ................................................................................................................. iv

Installation ............................................................................................................. 1

Operation ............................................................................................................... 13

Cleaning ................................................................................................................. 18

Maintenance .......................................................................................................... 20

Troubleshooting .................................................................................................... 22

Service Replacement Parts .................................................................................. 23

Electrical Schematic ............................................................................................. 65

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Intentionally

Left Blank

Installation

5-1/2" [140mm]

Control Cabinet

WASH

WARNING!

TURN OFF POWER BEFORE

SERVICING MACHINE

RINSE PRESSURE

Receiving

!!ATTENTION!!

Use caution when moving or lifting the dishwasher to prevent damaging the dishwasher

or the installation site. Check doorway and passageway clearance before moving the dishwasher. Remove dishwasher front panel and check under the machine base for obstructions before moving.

1. Inspect the dishwasher for shipping damage

2. Check the dishwasher interior for curtains, panels and other supplies.

3. Lift the dishwasher off the shipping pallet and move the machine near its permanent location.

4. Leave a minimum of 5-1/2" between walls and the rear of the dishwasher.

5. Level the dishwasher side-to-side and front-to-back using a bubble level. The dishwasher legs are adjusted by screwing them in or out.

6. Do not remove tags attached to the utility connections.

7. Remove the protective film from the dishwasher exterior.

8. Remove any foreign material from the dishwasher interior.

Front

Control Cabinet

5-1/2" [140mm] Min.

DHBTC, DH1TC

Corner Configuration

Straight-through Configuration

DHBT, DH1T

Remove two front panel screws

in preparation for utility connections

Installation

Electrical Connections

WARNING:

Electrocution or serious injury may result when working on an energized circuit.

Disconnect power at the main breaker or service disconnect switch before working on the circuit.

Lock-out and tag the breaker to indicate that work is being performed on the circuit.

ATTENTION

A qualified electrician must connect the main incoming power to the dishwasher in accordance with all local codes and regulations or in the absence of local codes in accordance with the National Electrical Code.

1. A knockout is provided at the lower right rear corner (machine viewed from the front) for the electrical service connection. A fused disconnect switch or circuit breaker (supplied by others) is required to protect the power supply circuit.

2. Remove two screws on the control panel support and swing the panel forward to gain access to the main terminal block.

Electrical knockout lower rear corner

MACHINE ELECTRICAL CONNECTION

!!ATTENTION!!

Electrical and grounding connections must comply with the National Electrical Code or in the absence of a National Code then all Local Electrical Codes.

A qualified electrician MUST compare the electrical power supply with the machine electrical specifications stamped on the MACHINE ELECTRICAL CONNECTION PLATE located on the base of dishwasher near the main terminal block.

Installation

Electrical Connections

3. Three phase or single phase incoming power connections are made at the bottom of the main terminal block. The main terminal block is located on the right front post of the dishwasher.

Main Terminal Block

Electrical Power Connection

Installation

Hot Water Connections

NOTE:

Only qualified personnel should make dishwasher plumbing connections. Connections must meet local plumbing and sanitary codes. Improper installation is not covered by the dishwasher warranty.

Hot Water Requirements:

1. Connect a 3/4" NPT hot water supply line to the line strainer located above the base of the dishwasher. Refer to the illustrations below.

2. For a dishwasher without a booster heater, the hot water connection must supply a minimum of 180°F/82°C measured at the dishwasher.

3. For a 40°F/22°C rise booster heater, the hot water connection must supply a minimum of 140°F/60°C measured at the dishwasher.

4. For a 70°F/39°C rise booster heater, the hot water connection must supply a minimum of 110°F/43°C measured at the dishwasher.

5. For a wash tank hot water coil heated dishwasher, the hot water connection must supply a minimum of 185°F/85°C measured at the dishwasher

6. Install a pressure regulating valve (PRV) before the dishwasher supply connection to maintain a flowing pressure of 20-25 PSI/137.8-172.4 kPa. (Sold separately for DH1T).

7. Install a service shut-off valve in the supply line, as close to the dishwasher as possible. The size of the valve must be the same size or larger as the supply line.

8-7/8"

[225 mm]

FLOOR

DHBT, DHBTC 3/4" NPT Hot Water

Connection

[225 mm]

FLOOR

DH1T, DH1TC 3/4" NPT Hot Water

Connection

Installation

Drain Connections

1. All models are GRAVITY DRAIN machines equipped with a 2" O.D. hose connection.

2. The maximum flow rate is 15 U.S. gpm/56.8 Lpm.

3. Drain height for all models must not exceed 8-7/8" [225mm] above the finished floor.

4. The drain connection is made to the dishwasher from underneath the machine. An access hole is provided in the machine base.

Vent

2" O.D.

Hose Fitting

Ventilation Connections

NOTE:

DO NOT VENT THE DISHWASHER INTO WALLS, CEILINGS OR ENCLOSED PLACES.

1. The dishwasher is equipped with a vent stack at the rear of the machine.

2. Typical venting requires a vent hood for the machine.

3. DO NOT CONNECT A VENT STACK TO THE DISHWASHER VENT.

Installation

Steam Coil Tank Heat and Steam Booster Heater

The illustration below details a steam heated machine consisting of a tank heat steam coil and a mounted steam booster for the final rinse. Contact the factory for steam injector tank heat details.

NOTE:

Only qualified personnel should make dishwasher steam connections. Connections must meet local plumbing and sanitary codes. Improper installation is not covered by the dishwasher warranty.

Steam Requirements: 2A: 3/4" NPT hot water supply (140˚F/60˚C) at 68 GPH at 20 PSI flowing pressure.

3A: 1/2" NPT cold water tempering (85˚F/30˚C) max 25 PSI if equipped.

4A: 3/4" NPT final rinse hot water (180-195˚F/82-91˚C) at 324 GPH at 20 PSI flowing pressure.

5A: 2" O.D. drain hose connection.

5B: 3/4" NPT booster relief to open drain.

6A: 1" NPT Booster 50 Lb/Hr / Tank Heat 25 Lb/Hr consumption. 7-10 PSI, 11-14 PSI, 15-30 PSI flowing pressure.

7A: 3/4" NPT condensate return to boiler (no back-pressure).

1'-4

12"

1'-4

10"

12"

87"

DOOR

5'-7

1'-0

11"

2 HP

1'-1

2'-1

FRONT VIEW

27"

CLEARANCE

34"

20"

13"

1'-2

Installation

Single Source Gas Booster Heater

The illustration below details a single source gas heated machine consisting of a tank heat hot water coil and a gas-powered booster heater for the final rinse. The gas-powered booster provides hot water for the hot water coil and the final rinse. The booster will run on natural gas or propane which is specified at the time of order.

NOTE:

Only qualified personnel should make dishwasher gas connections. Connections must meet local gas and sanitary codes. Improper installation is not covered by the dishwasher warranty.

Single Source Requirements: 1A: Gas booster electrical requirements are 15A @ 120V/60/1

2A: 3/4" NPT hot water supply 140˚F/60˚C for 40˚F/22˚C rise and 110˚F/43˚C for 70˚F/39˚C rise at 20-22 PSI flowing pressure.

3A: 2" O.D. machine drain hose connection, 3B: 3/4" NPT relief valve to open drain, 3C: 1/2"NPT vent to open drain.

4A: Natural gas,40˚F/22˚C rise requires 58,000 BTU/HR., 70˚F/39˚C rise requires 105,000 BTU/HR. Hatco Model PMG-60 requires 1/2" NPT, Hatco Model PMG-100 requires 3/4" NPT

5A: Gas flue connection is 4" diameter at the rear of the booster. Refer to the Hatco Gas Booster Installation and Operating Instructions.

CLEARANCE

2 HP

11"

27"

34"

87"

DOOR

FRONT VIEW

Installation

Purging Air from the Dishwasher/Booster Heater System

CAUTION:

PERMANENT DAMAGE to the hot water recirculating pump can

occur if the air is not purged from the dishwasher/booster heater system prior to placing the dishwasher into service.

Follow the instructions carefully to prevent damage to the dishwasher hot water recirculating pump.

Follow the procedure below to purge the air from the system. Plumbing and electrical service connections must be completed before purging the system.

To purge the air:

1. Make sure the dishwasher main power switch is OFF.

The dishwasher recirculating pump is

located on the base of the machine.

The air purge petcock is

located behind the dishwasher

lower front panel.

2. Make sure the main water supply valve located at the booster heater is OFF.

3. Open petcock (A) on the inlet side of the dishwasher hot water heater coil.

4. Remove the silver plug located in the center of the recirculating pump.

5. Turn the main water supply valve ON. Water

will begin to ll the booster heater and the

dishwasher heater coil.

6. Water and air will begin to ow out of the purge petcock and the recirculating pump and eventually only water will be observed.

7. Turn the booster heater power switch ON.

8. Turn the dishwasher power switch ON. The

dishwasher wash tank will begin to ll with water.

9. Continue to observe the petcock and the recirculating pump and make sure that there is a steady

stream of water is owing from (A) and (B).

10. Replace the silver plug (B) in the center of the recirculating pump then close the petcock (A).

11. Turn the dishwasher power switch OFF.

12. Purging is complete.

Installation

1/4" NPT Rinse aid Injection Point

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 dispensing equipment (supplied by others).

3. The illustration below shows the terminal board for the machine.

4. The signal connection points include:

• Detergent signal 120VAC, 1A max load.

• Rinse aid/Sanitizer signal 120VAC, 1A load.

• Vent Fan 120VAC, 1Amp max amp load

5. A 1/2" detergent probe injection point is provided at the rear and left side of the dishwasher.

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

7. A 1/4" NPT rinse-aid injection point is provided in the final rinse piping located at the top rear of the dishwasher. Consult a chemical supplier for the proper liquid rinse-aid.

A chemical connection terminal board is provided to

RINSE

COMMON

supply chemical dispenser signal voltages.

DETERGENT

A rinse-aid injection point is provided at

the top of the dishwasher.

Two detergent injection fittings are

provided in the wash tank.

Installation

Door Safety Switch

Dishwasher access doors are equipped with a door safety switch that automatically stops the dishwasher pump if a door is raised while the dishwasher is running. In addition, the dishwasher will not start if a door is left open.

1. If the dishwasher is running and a door is raised, then lighted in-cycle light goes out and the pump stops.

2. Check the interior of the dishwasher for a dish rack still in the machine. This dish rack must be washed again to ensure it is washed and sanitized completely.

3. To restart the dishwasher, make sure all doors are closed.

Pump Intake Screen and Float Switch

Refer to the photo below and note the location of the pump intake screen and dual float switch.

1. Make sure the pump intake screen is installed by sliding it on the bracket located above the wash pump intake.

2. Make sure the float ball on the float switch moves freely on the float stem.

3. Check the interior of the tank for any foreign objects and make sure the drain screen is clean.

Make sure tank is clean, the pump intake screen is installed and the float switch

moves freely.

4. Make sure the scrap screen support is positioned across the wash tank and installed in the brackets at the front and rear of the tank.

Installation

Scrap Screens and Screen Support

5. Install the scrap screens.

Initial Start-Up

20-22 PSI

150°F/66°C

180-195°F

Check list

1. Remove white protective film from the dishwasher exterior.

2. Install lower panels to the dishwasher.

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

4. Check dishwasher drain/overflows are closed and in securely seated.

5. Install scrap screens, spray arms.

6. Turn main utilities to the dishwasher ON. (Power, water).

7. Make sure doors are closed.

8. Turn dishwasher power switch ON.

9. Check that the wash tank water temperature reaches a minimum of 150˚F/60˚C.

10. Open and close the door to start an automatic wash and final rinse cycle.

11. During the final rinse check that the final rinse water temperature reaches a minimum of 180˚F/82˚C during the final rinse.

12. Make sure that the final rinse pressure gauge indicates 20-22 PSI during the final rinse.

13. Check for leaks.

14. Push the Power Switch OFF. The dishwasher should drain for 10 minutes.

15. Check that floor drain handles the water volume leaving the dishwasher.

82-91°C

100

Wash

Temperature

120

140

160

180

100

200

220

120

100

Final Rinse

Temperature

140

160

180

100

200

220

CHAMPION INDUSTRIES, INC.

WINSTON-SALEM,NC

PSI

Final Rinse

Pressure

Operation

Control Panel

Refer to the illustration below and the explanation of the control panel controls located at the lower front of the dishwasher.

A: ON/OFF power switch

B: In-cycle light

C: Wash cycle selector for dishes

D: Wash cycle selector for pots and pans

E: Wash water temperature gauge

F: Final rinse water pressure gauge

POWER

OFF

WASH TEMPERATURE

CYCLE

WASH CYCLE

RINSE PRESSURE

1 MIN

6 MIN

2 MIN

3 MIN

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