Champion DL-1000 Part Manual

DH-1000
IDH-200
Installation Manual with Service Replacement Parts
Door-type Dishwasher
Models:
DH-1000 IDH-200
Pumped rinse high temperature sanitizing with built-in stainless steel electric booster
Pumped rinse low temperature chemical sanitizing w/3 built-in chemical dispensing pumps
Dishwasher serial no.
DL-1000
Issue Date: 3.14.06
Manual P/N 114157 rev.—
www.championindustries.com
P.O. Box 4149 Winston-Salem, NC 27115 336/661-1556 Fax: 336/661-1660 Toll-free: 800.858.4477
2674 N. Service Road, Jordan Station Ontario, Canada L0R 1S0 905/562-4195 Fax: 905/562-4618 Toll-free: 800.263.5798
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For machines beginning with S/N D2466 and above
File: DTVC0214.6
Printed in the USA
For future reference, record your dishwasher information in the box below.
Model Number__________________________ Serial Number_______________________
Voltage________________Hertz_____________ Phase__________________
Champion Service Agent __________________________________ Tel:______________________
Champion Parts Distributor _________________________________ Tel:______________________
For all models:
The data plate mounts to the right, side of the top-mounted control cabinet,
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 dishwasher model no., serial no.,
voltage, Hz and phase are needed to
identify your machine and to answer
questions.
We support
Please have this information on-hand
if you call for service assistance.
COPYRIGHT © 2006 All rights reserved Printed in the USA
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Revisions to this manual
_____________________ Revisions to this manual
This is where we record changes to the manual. A revision might be a part number change, new instructions, or information that was not available at print time.
We reserve the right to make changes to this manual without notice and without incurring any liability by making the 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 Revised Serial Number Revision Date Pages Effectivity Description
03.14.06 All D2466 Released first edition
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Dear Owner: Thank-you for choosing our dishwasher. We appreciate your business.
This manual covers two models:
DH-1000 Pumped rinse high temperature door-type dishwasher with standard
built-in booster in 40° F/22° C rise or an optional 70° F/39° C rise booster.
DL-1000 Pumped rinse low temperature chemical sanitizing door-type dishwasher
with built-in chemical dispensing pumps for detergent, rinse-aid, and sanitizer.
The
installation, and initial start-up of your dishwasher
must be performed by qualified electricians, plumbers, and authorized service technicians who are trained in commercial dishwashers.
Defects and repairs resulting from the improper installation
of your dishwasher cannot be covered
by the dishwasher warranty.
Mr. or Ms. Installer:
Please read the installation guide before you begin.
Thank you,
Your dishwasher !
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Table of Contents
_____________ Table of Contents
Revisions to this manual _______________________________________________ i
Limited Warranty __________________________________________________ iv
Installation Guide ___________________________________________________ 1
DH-1000: High temperature Door-type Dishwasher ___________ pg.2
;
Unpack and Place ;Water Connection
;
Drain Connection ;Electrical Connection
;
Ventilation ;Chemical Dispensers
Initial Start-up
How to Operate your dishwasher
How to Clean your dishwasher
How to Maintain your dishwasher
DL-1000: Low Temperature Door-type Dishwasher __________ pg.26
Unpack and Place ;Water Connection
;
;
Drain Connection ;Electrical Connection
;
Ventilation ;Chemical Dispensers
Initial Start-up
How to Operate your dishwasher
How to Clean your dishwasher
How to Maintain your dishwasher
All Models
Service Replacement Parts _______________________________________ pg.43
Appendix A: (Specification Sheets)
Electrical Schematics
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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 fifteen (15) months after the date of shipment by Champion, whichever occurs first. [See below for special provisions relating to glasswashers.] The warranty registration card must be returned to Champion within ten (10) days after installation. If warranty card is not returned to Champion within such period, the warranty will expire after one year from the date of shipment.
Champion will not assume any responsibility for extra costs for installation in any area where there are jurisdictional problems with local trades or unions.
If a defect in workmanship or material is found to exist within the warranty period, Champion, at its election, will either repair or replace the defective machine or accept return of the machine for full credit; provided, how ever, as to glasswashers, Champion's obligation with respect to labor associated with any repairs shall end (a) 120 days after shipment, or (b) 90 days after installation, whichever occurs first. In the event that Champion elects to repair, the labor and work to be performed in connection with the warranty shall be done during regular working hours by a Champion authorized service technician. Defective parts become the property of Champion. Use of replacement parts not authorized by Champion will relieve Champion of all further liability in connection with its warranty. In no event will Champion's warranty obligation exceed Champion's charge for the machine. The following are not covered by Champion's warranty:
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:
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:
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 warrants all new machine parts produced or authorized by Champion to be free
(1) Damage to the exterior or
Champion does not authorize any other person, including persons who deal in Champion dishwashing machines to change this warranty or create any other obligation in connection with Champion Dishwashing Machines.
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Installation Guide
_____________ Installation Guide
;Unpack and Place (DH-1000)
1. Check the corrugated box that protected the dishwasher during shipment for punched holes or impact marks.
2. Inspect the shipping pallet for splintered or broken boards.
3. Inspect the exterior of the dishwasher while still mounted on the pallet for signs of damage.
4. Contact the freight company immediately if damage is found and save all packing for inspection to verify your damage claim.
5. Report the damage to your equipment supplier. They will contact our factory for repair or replacement of damaged components.
6. If no damage is found, proceed with lifting the dishwasher from its pallet. Be careful to lift the dishwasher by the main frame if using a forklift.
7. Make sure the four legs are screwed firmly in place after landing the machine.
8. Check the packing list to ensure all accessories are with the dishwasher.
9. Open the doors and remove the dishracks inside the machine and locate the postpaid warranty cards.
10. Complete the warranty card and drop in the mail immediately.
11. Move the dishwasher close to its permanent location.
12. Locate the Quick Check Installation Card glued on the front door of the dishwasher. The card has a check list to familiarize the installer with the dishwasher installation procedures detailed in this manual.
13. Remove the protective covering from the dishwasher and identify the utility connections. Information cards and stickers must not be removed from the dishwasher until the installation is complete.
14. Locate but do not remove the set of 2 keys attached to the back of the top-mounted control cabinet.
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DH-1000 • Unpack and Place
Installation Guide _____________
;Unpack and Place DH-1000
1. The installation of your dishwasher must be performed by qualified service personnel.
2. Problems due to improper installation are not covered by the Warranty.
3. Compare the utilities at the installation site with the specifications listed on each model's specification sheets ( See Appendix A at the end of this manual)
4. The dishwasher data plate is located on the left, rear-corner of the top-mounted control cabinet.
5. Study the configuration diagrams below. They show the 2 ways that the dishwasher may be positioned.
Corner and straight-through dishwasher configurations
Control Cabinet
Incorrect Corner Configuration
Control Cabinet
Note:
The correct corner installation places the dishwasher so the top-mounted controls are easy to reach.
The minimum distance from wall to dishwasher is 4" [103mm]. The maximum distance is 6" [129].
6" [152] Max. Wall Clearance
Straight-through Configuration
The room ceiling height must be a minimum of 80" [2032mm] so the doors can be removed completely.
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DH-1000 • Unpack and Place
_____________ Installation Guide
;Unpack and Place DH-1000
1. All dishwashers ship in the straight-through configuation.
2. Relocate the tracks and remove the wall-side door link components to convert the dishwasher for corner operation.
1
Move Part 1
Remove Interior Door Bracket
4
2
Move Part 2
3
1
2
Remove Door Linkage
5
wall
Adjust Door Spring Tension
wall
3
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DH-1000 • Unpack and Place
Installation Guide _____________
;Unpack and Place DH-1000
1. Compare the dishwasher and site utility connections.
2. Level the dishwasher by adjusting the bullet feet.
3. Raise the doors and check the door clearance to the ceiling.
4. Move the dishwasher to its permanent location.
Note:
Installers must follow applicable sanitation, safety, plumbing, and electrical codes and regulations; and work in accordance with best practices for dishwasher installation.
Utility Connections - DH-1000
Power: 208-240V Single or Three Phase
Water supply: 3/4" NPT hot water supply (140°F/60°C minimum) for 40° F/22° C rise booster
(35 psi/241 KPa static pressure) 7-10 psi/63-69Kpa flow pressure
3/4" NPT hot water supply (110°F/43°C minimum) for 70° F/39° C rise booster (35 psi/241 KPa static pressure) 7-10 psi/63-69Kpa flow pressure
Drain: 1-7/8" stainless steel, slip-fit hose connection
Max flow: 15 Us gal/min. (13.5 Imperial gal/min) 57liters/min.
Chemicals: Detergent and rinse-aid products are supplied by a chemical supplier
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DH-1000 • Electrical Connection
_____________ Installation Guide
;Electrical Connection DH-1000
Warning:
The dishwasher must be electrically grounded according to all local codes and regulations governing the installation of electrical service.
Warning:
Disconnect the main electric supply and place a tag at the fuse or disconnect switch indicating that work is being performed on that circuit.
1. Locate the control cabinet keys on the rear of the control cabinet.
2. Remove 1 key to unlock the cabinet; do not remove the other key.
3. Unlock the control cabinet and remove the cover.
4. Locate the power cable knock out and main terminal block on the left-side of the cabinet.
5. Locate the Machine Electrical Connection Data Plate mounted near the terminal block.
MACHINE ELECTRICAL CONNECTION DATA PLATE is the certified authority for the
The
dishwasher power requirements.
unless an authorized factory representative instructs you to use other data.
6. Connect the electric service to the dishwasher.
ATTENTION
ELECTRICIAN
DO NOT use electrical data from any other source
Cable knock-out
Machine Electrical Connection Data Plate
Main terminal block
The Model DH-1000 dishwasher must not be turned ON at the dishwasher's power switch located on the front of the top-mounted control cabinet
without performing an Initial Start-up at the same time.
Powering the dishwasher without performing the Initial Start-up
may damage the dishwasher's electrical circuits.
5
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DH-1000 • Water Connection
Installation Guide _____________
;Water Connection DH-1000
1. Locate the built-in stainless steel booster on the left-side of the dishwasher.
Note:
The existing hot water supply lines to the dishwasher must be 3/4" NPT or larger. To the best of your ability inspect, and verify that all supply piping meets the 3/4" NPT requirement.
Note:
The installing plumber must connect a water supply line to the dishwasher that is equal to or greater than 3/4" NPT in size with a 3/4" pressure regulating valve ( not supplied).
Dishwasher temperature and water pressure requirements:
140°F/60°C minimum) for 40° F/22° C rise booster
(35 psi/241 KPa static pressure) 7-10 psi/63-69Kpa flow pressure
(110°F/43°C minimum) for 70° F/39° C rise booster
(35 psi/241 KPa static pressure) 7-10 psi/48-69Kpa flow pressure
2. Connect a 3/4” NPT hot water supply to the dishwasher at the line strainer.
Note: The following components are not required for proper dishwasher operation, but are highly recommended, because they make servicing of the dishwasher much faster.
Install the following components (not supplied) in the hot water supply line:
1) 3/4” or larger water shut-off valve near the machine in the water supply line.
2) ASSE 1010 Water hammer arrestor upstream from the shut-off valve.
3) Pressure gauge 0-60 PSI minimum downstream from the PRV.
4) Temperature gauge 0-180°F/82°C (not supplied) downstream from the gauge.
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Blank Page
This page
intentionally
left blank
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DH-1000 • Drain Connection
Installation Guide _____________
;Drain Connection DH-1000
Continued from page 7
1. Locate the dishwasher drain connection underneath the machine frame.
2. Install a drain line conforming to local plumbing and health regulations.
Drain: 1-7/8" stainless steel, slip-fit hose connection
Max flow: 15 Us gal/min. (13.5 Imperial gal/min) 57liters/min.
;Ventilation DH-1000
1. The factory has no requirements for vent hoods; but, local codes and regulations in your area supersede our suggestions. Consult your local building and health authorities for local requirements.
2. Dishroom ventilation must provide sufficient airflow to prevent excessive humidity in the work area. 200-400cfm/5.6- 11.3 k Liters/min - is sufficient.
3. The dishwasher must not be subjected to continual drafts or cold air.
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DH-1000 • Chemical Dispensers
_____________ Installation Guide
;Chemical Dispensers DH-1000
1. The DH-1000 high temperature dishwasher sanitizes with 180-195° F/82-91° C hot final rinse water.
2. Do not connect a sanitizer chemical dispenser to the DH-1000.
3. You may wish to contact a chemical supplier to supply the chemical dispensers and chemicals for liquid detergent and liquid rinse-aid. (Consult your local listings).
4. The chemical supplier must adjust their dispensers to provide the proper dosages for the installed dispensing system.
5. The factory may have supplied the chemical dispensing system as an option. Your chemical supplier must adjust factory dispensers for the chemicals supplied also.
Note:
Manual dosing of detergent or rinse-aid is NOT RECOMMENDED for the DH-1000 dishwasher. Poor washing results may result if manual dosing is employed..
Note:
Cartridge detergent systems are NOT RECOMMENDED for the DH-1000 dishwasher. Poor washing results may result if installed on this model.
6. The factory recommends that the chemical injectors be installed in the right front corner of the wash tank as shown below.
Factory installed injection points
○○○○
Recommended locations for chemical injectors for dispensing systems supplied by others.
Continued on page 10
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DH-1000 • Chemical Dispensers
Installation Guide _____________
;Chemical Dispensers DH-1000
Continued from page 9
115VAC Power Connections for Chemical Dispensers
FOR QUALIFIED INSTALLERS ONLY
Warning:
Chemical dispensers must be electrically grounded in compliance with applicable electric codes.
Warning:
Disconnect the main electric supply and place a tag at the fuse or disconnect switch indicating that work is being performed on that circuit.
Caution:
Connecting chemical dispensers at points other than those recommended by the factory may damage the dishwasher electrical system.
Damage caused by the installation of chemical equipment will not be covered by our WARRANTY.
1. Unlock the top-mounted control cabinet with the key. two keys should be stowed behind the control cabinet. The installing electrician used one key during their installlation.
2. Locate the cycle timer mounted in the right-rear corner of the control cabinet.
3. Refer to the DH-1000 electrical schematic located at the end of this manual.
4. Find the following components shown on the electrical schematic at end of this manual.
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DH-1000 • Chemical Dispensers
_____________ Installation Guide
;Chemical Dispensers DH-1000
Main terminal block Detergent dispensing pump & cycle Rinse-aid dispensing pump & cycle and ground lug Timer cam No.6 with timer microswitch timer cam No.7 with timer microswitch
Earth
Ground
also called
Chassis
Ground
Continued on page 12
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DH-1000 • Chemical Dispensers
Installation Guide _____________
;Chemical Dispensers DH-1000
Continued from page 11
7. The main terminal board is the termination point for the incoming power and earth ground which is also called the chassis ground.
Chemical dispensers (not supplied by
8.
Factory) must be grounded to chassis to protect the dishwasher circuits if possible.
9. The detergent signal and the rinse-aid signal terminals for your chemical dispensing pumps are provided on the common terminal of each Timer Cam microswitch (See diagrams above).
Cam No.6 operates the detergent microswitch
Cam No.7 operates the rinse-aid microswitch.
10. Look to the right for the photo of a timer cam microswitch. Note the configuration of the switch, do you see how the common terminal is different than the Normally Closed (N.C.) and the Normally Open (N.O.) terminals?
11. Look again at the Cycle Timer and locate the Detergent Cam No.6 and the Rinse-aid cam No.7.
12. There are 7 Cams on the cycle timer. They are numbered 1-7 starting at the timer motor side of the assembly.
13. Look at the underside of the detergent and the Rinse-aid timer microswitches and identify the common terminals.
14. Connect the hot lead for the detergent pump to the common terminal of Cam Switch No. 6. Make the connection using a 12-14 slip-on terminal. Do the same for the rinse-aid switch.
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DH-1000 • Chemical Dispensers
_____________ Installation Guide
;Chemical Dispensers DH-1000
Caution:
The NEUTRAL RETURN (#2 white wires) and Chassis Ground are not the same point electrically. Improper wiring to these points may result in unusual voltage readings and damage to the dishwasher's electrical circuits.
STOP WORKING ON THE DISHWASHER AT ONCE, if you do not know the difference between a neutral return and chassis ground.
Note:
You may void the dishwasher warranty if you connect the neutral wire of your dispensing system anywhere else than at the main power transformer.
15. Now you must connect your pumps to the dishwasher neutral return. All white wires marked with No. 2 are neutral wires; however, you are not authorized to connect to any #2 wire that you may identify.
16. Run a 12 gauge white wire with spade terminal connector (not supplied) from your chemical dispensing pumps to the neutral #2 white wire located on the main power transformer in the control cabinet.
ATTENTION
DO NOT TURN ON the dishwasher power switch
located on the front of the top-mounted control cabinet
before the Initial Start-up is completed
Powering the dishwasher as described above, without knowing for
certain that the Initial Start-up was performed, may make you liable for any damages
stemming from your actions.
INSTALLER
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DH-1000 • Chemical Dispensers
Installation Guide _____________
;Chemical Dispensers DH-1000
Priming the chemical dispensers (Factory dispensers only)
1. Factory dispensers are optional equipment; however, an automatic dispenser must be installed by someone in lieu of the factory.
2. The dispensers are mounted on the right-hand side of the lower wash tank.
3. Chemical pick-up tubes are inserted into their respective containers.
4. Detergent and Rinse-aid chemical containers can be placed a maximum of 11" [280 mm] above the finished floor, (ABF).
5. Place the chemical containers as close to the dishwasher as possible.
Each day check the detergent and
6. rinse-aid chemical containers to make sure they are at least 1/2 full.
7. Push and hold the 2-position prime switch located on the front of the top-mounted control cabinet. Push UP to prime the detergent and DOWN to prime the rinse-aid.
8. Watch the chemical as it travels up the tube to the injection point sight-glass located on the right­hand side, top-rear corner of the machine.
Factory installed sight-glass
9. Release the switch when the chemical enters the sight-glass.
10. Chemicals should reach the sight-glass within 2 minutes of prime.
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DH-1000 • Initial Start-up
_____________ Installation Guide
;Initial Start-up DH-1000
Caution:
DO NOT flip the dishwasher power switch "ON" until you read the instructions below.
1. The built-in stainless steel electric booster
was shipped without water.
2. A manila card located above the power switch explains how to turn the machine on for the first time.
See step No. 10 on the next page for the first DISHWASHER POWER UP procedure.
Let's begin the Initial Start-up:
1. Check the placement of the dishwasher:
;Compare the machine location with the
building plan or consult the owner or the General Contractor for approval.
;Check that the dishwasher configuration
straight-through or corner operation is correct (See page 2 for details).
2. Check that all options and/or accessories are installed.
3. Remove protective white wrapping, tape, and other packing materials and discard.
4. Remove any foreign materials from the interior of the machine.
Continued on page 16
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DH-1000 • Initial Start-up
Installation Guide _____________
;Initial Start-up DH-1000
Continued from page 15
5. Check that the following utilities are connected: to the dishwasher and ready for use:
;Electrical service
;Hot water supply
;Drain
;Ventilation (if required by local regulations).
6. Check the chemical connections and chemical containers to ensure that enough chemical supplies are available.
7. Turn on the water supply to the dishwasher.
8. Turn on the main power switch at the service disconnect switch.
9. Open the dishwasher doors fully.
10. Check upper and lower spray arms are in place and spin freely.
11. Check that the drain-overflow and pump screen are in place.
10
12. Check that the lower scrap screen is clean and in place.
11b11a
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_____________ Installation Guide
;Initial Start-up DH-1000
POWER UP THE DISHWASHER:
As stated on page 15, the dishwasher power switch must not be turned without reading the instructions below.:
DH-1000 • Initial Start-up
FILL
DRAIN
POWER
CYCLE
ON
OFF
13. Turn on the main power switch at the service disconnect switch.
14. Flip the dishwasher power switch UP to turn on the dishwasher.
15. Immediately, push the fill switch up and hold it in the up position until the water flows out of the wash tank and into the lower scrap screen.
16. Release the fill switch.
17. Open the dishwasher door fully and check the water level inside the tank. The proper water level is just below the overflow tube and 3" [76 mm] from the lower sprayarm support. Measure from the back of the support up the tank toward the rear wall of the dishwasher.
8
9
10
3" [76mm]
Water line
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DH-1000 • Initial Start-up
Installation Guide _____________
;Initial Start-up DH-1000
18. Operate the dishwasher for 10 cycles. Monitor the wash and final rinse gauges located on the
lower front panel of the dishwasher to ensure the machine is maintaining the proper temperatures.
In the USA, the NSF standards are:
150° F/66° C minimum wash temperature 180° F/82° C minimum final rinse temperature
Note: In Canada, sanitary standards are regulated by each province.
Consult your provincial authorities for temperature requirements and other sanitary standards.
19. Check the green cycle light. It should illuminate throughout the 90-second cycle, then go out at the end of the cycle. When the doors are raised, the cycle light should again illuminate for 3-seconds and then go out. The 3-second light indicates the timer is resetting. DO NOT CLOSE the doors until the cycle light goes out.
20. Check the dishwasher piping for leaks.
21. Check the drain connection and make sure the house drain piping handles the dishwasher drain flow. Max flow is 15 USgpm/58 lpm or 1.7 US gals/6.6 Liters per rack.
22. Check the operation of the doors. They should go up and down smoothly. Check the white door guides to ensure they move with the doors.
23. Inspect the table connections to the dishwasher making sure they are secure and sealed with 100% silicon sealant on the mating flanges. The soiled table must slope away from the dishwasher and the clean table must slope toward the dishwasher.
24. Remove the upper and lower sprayarms and check the condition of the sprayarm bearing O-rings.
25. The initial start-up is complete. Turn off power to the dishwasher.
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