Champion I-DH Service Manual

Champion

The Dishwashing Machine Specialists

Technical Manual

International Door
Dishwasher

Model
I-DH

High Temperature with
Built-in Booster

January, 1996 Manual P/N 0509190

P. 0. Box 4149 Winston-Salem, North Carolina 27115-4149 2674 N. Service Road Jordan Station, Ontario, Canada LOR ISO
910/661-1556 Fax: [phone] Fax: [phone]

Champion Industries, Inc.

CONTENTS

2

INTRODUCTION 6

Model Number 7
Standard Equipment 7
Options 7
Electrical Power Requirements 7

INSTALLATION 8

Unpack the Dishwasher 8
To Change from Straight-through Operation to Comer Operation 9
Electrical Connections 10
Plumbing Connections 12
Water Connections 12
Drain Connections 13

Chemical Connections 14
INITIAL START-UP 16
OPERATION 21
MAINTENANCE 23

Maintenance Schedule 23

Deliming Schedule 23

Troubleshooting 24
REPLACEMENT PARTS LIST 29
ELECTRICAL SCHEMATICS 56

LIST OF FIGURES

Figure 1 - Remove Front Panel 8
Figure 2 - Placement for Comer Operation 9
Figure 3 - Change the Track Assembly 9

a - Straight-Through Configuration

b - Comer Configuration
Figure 4 - Electrical Connection Location 10
Figure 5 - Hinged Control Panel 11
Figure 6 - Main Terminal Block 11
Figure 7 - Hot Water Connection, 3/4" NPT 12
Figure 8 - Drain Connection, 1-1/2" O.D. 13

LIST OF FIGURES

3

(Cont.d)

Figure 9 - Detergent Signal Connection Point 14
Figure 10 - Detergent Probe Injection Point, 1/2" NPT 15
Figure 11 Rinse Aid Injection Point, 1/8" NPT 15
Figure 12 - Door Assemblies and Panels 30
Figure 13 - Door Safety Switch and Instrument Panel 32
Figure 14 - Door Handle Assembly and Springs 34
Figure 15 - Track Assembly 36
Figure 16 - Fill Piping Assembly 38
Figure 17 - Wash/Rinse Spray Arm Assembly 40
Figure 18 - Wash/Rinse Spray Piping Assembly 42
Figure 19 - Scrap Screens and Drain Assembly 44
Figure 20 - Pump Assembly 46
Figure 21 - Wash Tank Heater and Thermostats 48
Figure 22 - Electric Booster Assembly and Thermostat 50
Figure 23 - Control Cabinet 52
Figure 24 - Dishracks 54
Figure 25 - Electrical Schematic (Single Phase) 56
Figure 26 - Electrical Schematic (Three Phase) 57

INTRODUCTION

Welcome to Champion...
and thank you for allowing us to take care of your

dishwashing needs.

This manual covers the international door -type
dishwasher, Model I-DH. Your machine was
completely assembled, inspected, and thoroughly
tested at our factory before it was shipped to your
installation site.

This manual contains:

• Installation Instructions

• Operation Instructions

• Maintenance Instructions

• Replacement Parts Lists

• Electrical Schematics

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 noti ce and
without incurring any obligation.

For your protection, factory authorized parts should
always be used for repairs.

Replacement parts may be ordered directly from
your Champion authorized parts distributor or
authorized service agency. When ordering parts,
please supply the model number, serial number,
voltage, and phase of your machine, the part number,
part descriptions and quantity.

6

Model Number

7

The I-DH is a high temperature (180°F/82°C)
sanitizing dishwasher with booster.

Standard Equipment includes:

• Manual tank fill

• Built-in (40°F/23°C rise) electric or steam
booster heater.

• Field convertible for comer operation

• Electric tank heat (3 KW)

• Balanced door lift system

• Automatic start on close of doors

• Low -water tank heat protection

• 1 HP drip-proof pump motor

• Door safety switch

• Splash-proof control console

• Interchangeable upper & lower spray arms

• Stainless steel front and side panels

• Detergent/chemical connection provisions

• Fill solenoid valve

• 3/4" line strainer

• Common utility connections

• Two dish racks (peg and flat bottom)

Options

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

Pressure reducing valve, (PRV) 3/4" - P/N 107550
Water pressure gauge (0-60 PSI) - P/N 100135

Electrical Power Requirements

Voltage Booster Rise Machine Full Load Amps

220/60/1 40°F/23°C 56A 70A
220/50/1 40°F/23°C 56A 70A
220/60/3 40°F/23°C 32A 40A
220/50/3 40°F/23°C 32A 40A
380/60/3 40°F/23°C 19A 24A
380/50/3 40°F/23°C 19A 24A
220/60/1 N/A
220/50/1 N/A — —
220/60/3 70°F/39°C 41A 52A
220/50/3 70°F/39°C 41A 52A
380/60/3 70°F/39°C 24A 30A
380/50/3 70°F/39°C 24A 30A

Power Requirement

(125% Service Factor)

INSTALLATION

Unpack the dishwasher

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. Move the
machine to its permanent location.

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

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

5. Refer to Fig. 1. Remove (2) screws that hold the
front panel. Remove the front panel in
preparation for service connections.

8

To Change from
Straight-through Operation to
Corner Operation

The I-DH dishwasher is shipped from the factory for
straight-through operation. The following instructions
explain how to change the dishwasher for comer
operation. Refer to Fig. 2

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

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

Refer to Fig. 3a-3b and perform the steps below.

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

2. Move front rack guide (A) to the right side of the
rack tracks. (See Fig. 3b) Use existing hardware.

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

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

5. Bolt (B) and (C) as shown in Fig. 3b.

9

INSTALLATION (Cont.)
Electrical Connections

1. A qualified electrician must compare the electrical
power supply with the machine electrical
specifications before connecting to the incoming
service through a fused disconnect switch.

Refer to Fig. 4

2. A knockout is provided at the lower right rear comer
for the electrical service connection. A fused
disconnect switch or circuit breaker (supplied by
others) is required to protect the power supply circuit.

10

Electrical Connections (Cont.)

3. Remove (2) lower screws from the front panel of the
machine to expose the electrical controls. Loosen (1)
screw on the control panel support post. Slide the
support post up to disengage the post from the machine
base. Swing the hinged control panel forward.

4. Three phase or single-phase incoming powers wiring
connections are made at the bottom of the machine's
main terminal block. The main terminal block is located
on the side of the front right post of the dishwasher.

11

INSTALLATION (Cont.)
Plumbing Connections

Water Connections

1. The I-DH dishwasher requires a single, hot water
supply. The following minimum water temperatures
are recommended:

I-DH with built-in 40° rise electric booster

(Minimum 140°F/60°C)
(Min./Max. flow pressure 20-22 PSI/138 kPa)

I-DH with built-in 70° rise electric booster

(Minimum 110°F/43°C)
(Min./Max. flow pressure 20-22 PSI/138 kPa)

2. Install a pressure-reducing valve, (PRV), in the water
supply line if flow pressure exceeds 20-22 PSI/138-

151.8 kPa.

3. The hot water connection to all I-DH dishwashers is
3/4" NPT. The connection is made from underneath
the dishwasher up to the hot water solenoid valve
located on the left side of the booster tank.

12

Water Connections (Cont.)

4. A manual shut-off valve (supplied by others)
should be installed in the supply line in order to
service the machine.

5. A pressure reducing valve, (PRV), (supplied by
others) should be installed in the water supply
line.

6. A pressure gauge (supplied by others) should be
installed in the water supply line on the machine
side of the PRV.

Drain Connections

1. The model I-DH is a GRAVITY DRAIN machine
equipped with a 1-1/2" O.D. hose connection
point.

2. Drain height for model I-DH must not exceed 11"
(280mm) above floor level.

3. The drain connection is made to the dishwasher
from underneath the machine through an access
hole in the machine base.

Refer to Fig. 8

13

INSTALLATION (Cont.) Chemical

Connections

1. An electrical detergent signal connection point for
detergent dispensing equipment is provided on the
control voltage terminal block located in the top left
comer of the hinged control panel.

Refer to Fig. 9

2. The detergent signal is limited to a maximum load of
2 Amps. Signal voltage is 220VAC.

(Chemical Connections continued on next page)

14

Chemical Connections (Cont.)

15

3. A 1/2"NPT detergent probe injection point is provided
at the rear of the dishwasher.

Refer to Fig. 10

4. A 1/8" NPT rinse aid injection point is provided in the
final rinse manifold of the booster piping. The manifold
is located on the right side of the booster assembly. It can
be accessed from the front of the dishwasher.

Refer to Fig. 11

INITIAL START-UP

Complete the installation

After plumbing and electrical connections are made, follow the
steps below to complete the installation of your dishwasher.

1. Remove the white protective covering from the exterior of
the machine.

2. Remove any foreign material from inside the machine.

3. Make sure dishwasher power switch is off.

4. Turn main water supply on.

5. Turn main power on at the main power service
disconnect switch.

Fill the dishwasher with water

Follow the steps below to fill your machine for the first
time and each time the machine is completely drained.

16

Leave the switch UP until water

Fill the dishwasher

with water (Cont.)

begins to drain out the overflow.
Tank is full. Push the Fill/Extended

wash switch to the center position.

17