Champion I-DHM3 Service Manual

This manual supersedes PIN 112426, April, 1997. Destroy previous edition.

For machines beginning with Technical Manual

serial no. 89519 and above

International Door Dishwasher

Model

I-DHM 3

High Temperature

with Built-in Booster

Machine Serial No.

February, 1998__________________________Manual P/N 112426 Rev.A

P. 0. Box 4149 2674 N. Service Road Winston-Salem, North Carolina 27115-4149 Jordan Station, Ontario, Canada LOR ISO 336/661-1556 Fax: 336/661-1660 905/562-4195 Fax: 905/562-4618

Champion Industries, Inc.

Revision History

Revision

Date 1/30/98 All 89519 Issue of manual and

Revised Pages Serial Number

Effectivity

Comments

replacement parts lists

CONTENTS

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 59

LIST OF FIGURES

Figure 1 - Remove Front Panel 8 Figure 2 - Placement for Comer Operation 9 Figure 3 - Change the Track Assembly 9 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" OD 13

LIST OF FIGURES (Cont'd)

Figure 9 - Detergent Signal Connection Point 14 Figure 10 - Detergent Probe Injection Point, 1/2" 15 Figure 11 - Rinse Aid Injection Point, 1/8" NPT 15 Figure 12 - Doors and Panels 30 Figure 13 - Door Guides, Stops, and Lift Bracket 32 Figure 14 - Door Handle, Spring Assembly and Safety Switch 34 Figure 15 - Track Assembly 36 Figure 16 - Wash/Rinse Spray Piping 38 Figure 17 - Wash/Rinse Spray Arm Assembly 40 Figure 18 - Drain Assembly and Scrap Screens 42 Figure 19 - Wash Tank Heat and Thermostats 44 Figure 20 - Electric Booster Assembly and Thermostats 46 Figure 21 - Fill Piping Assembly 48 Figure 22 - Pump Assembly 50 Figure 23 - Control Panel and Gauges 52 Figure 24 - Control Cabinet 54 Figure 25 - Dishracks and PRV 56 Figure 26 - Electrical Schematic (Electrical Heat 1 & 3 Phase) 59 Figure 27 - Electrical Schematic (Steam Heat 1 & 3 Phase) 60 Figure 28 - Electrical Schematic (Optional Timed Fill) (1 & 3 Phase) 61

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 notice 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.

Model Number

Power Requirement

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

• 1HP 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

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

Booster Rise

Machine Full Load Amps

(125% Service Factor)

INSTALLATION

Unpack the dishwasher

CAUTION:

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

NOTE:

The installation of your machine must meet all applicable health and safety codes.

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.

NOTE:

Refer to: To change from Straight-through Operation to Corner Operation on the next page if

your machine will be placed for comer operation.

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.

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).

Placement for Corner Operation

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 left 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.

Figure3

Change the Track Assembly

INSTALLATION (Cont) Electrical Connections

Warning:

Electrical and grounding connections must comply with all applicable 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 before connecting to the incoming service through a fused disconnect switch.

2. A knock -out 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.

Electrical Connections (Cont.)

3. Remove (2) lower screws from the front panel of the machine to expose the electrical controls. Remove (2) screws on the control panel support. Swing the hinged control panel forward.

4. Three phase or single phase incoming power 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.

INSTALLATION (Cont.)

Plumbing Connections

NOTE:

Plumbing connections must comply with all applicable sanitary and plumbing codes.

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 2022PSI/138-151.8kPa.

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.

3/4" NPT

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

1-1/2" O.D.

INSTALLATION (Cont.)

Chemical Connections

NOTE:

Consult a qualified chemical supplier for your chemical needs.

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.

2. The detergent signal is limited to a maximum

load of 2 Amps. Signal voltage is 120VAC.

Chemical Connections (Cont.)

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

1/2" Plug

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.

1/8" NPT

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.

Install scrap screens. Make sure rubber stopper is secure on the drain-overflow assembly. Make sure the drain-overflow seats securely in the tank bottom.

Make sure all doors are fully closed.

Warning:

During the fill operation, water will spray from the dishwasher if the doors are open.

MAKE SURE DOORS ARE FULLY CLOSED.

Fill the dishwasher with water (Cont.)

The controls are located on the front of the dishwasher.

A- On/Off power switch B- In cycle light C- Fill/Extended wash

switch D-Wash water temperature gauge

E- Final rinse water

temperature gauge

THE POWER SWITCH IS OFF DURING INITIAL FILL. Push the On/Off power switch down to the OFF position. The red indicator light in the center of the power switch is not illuminated when the switch is off.

Push and hold the Fill/Extended wash switch UP to the FILL position to fill the dishwasher with water.

NOTE:

The initial fill primes the booster tank assembly. The booster tank is full when you hear water enter the wash tank of the dishwasher.

Continue to hold the switch UP until water begins to drain out the overflow. Tank is full. Release the Fill/Extended wash switch.

INITIAL START-UP (Cont.)

Check wash and final rinse water temperatures

Push the On/Off power switch "Up" to the on position. The red indicator light in the switch will come on.

The wash tank and booster tank heaters will begin to heat the water in the dishwasher.

Wait approximately 10 minutes for the wash tank water to reach operating temperature.

Check the wash water temperature gauge located on right side of the control cabinet to be sure it indicates the proper temperature.

Open and then fully close the dishwasher doors. The dishwasher will begin a wash cycle automatically.

Note that the amber colored cycle lamp is lit during the automatic dishwasher cycle.

Opening the doors anytime during the cycle will stop the dishwasher.

Closing the doors will resume the automatic cycle where it left off.

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