Champion I-UH Service Manual

Technical Manual

Undercounter Dishwasher

Model I-UH

Manual

P/N 0509635 REV. D

February, 2003

P.O. Box 4149 Winston-Salem, NC 27115-4149

Champion Industries, Inc.

Fax: 336/661-1979336/661-1556

Machine Serial No.

The Dishwashing Machine Specialists

Champion

Complete the information below so it will be available for quick reference.

Model Number __________________________ Serial Number ________________________

Voltage and Phase ______________________________________________________________

Champion Parts Distributor __________________________________ Phone _____________ (if applicable)

_____________________________________________________________________________

Champion Service Agency___________________________________ Phone _____________

_____________________________________________________________________________

Champion Service:

Phone: 1-336-661-1556

1-800-858-4477

Fax: 1-336-661-1660

NOTE: When calling to order parts, be sure to have the model number, serial number, voltage, and phase of your machine, along with your customer account number.

REVISIONS

Revision History

Revision Revised Serial Number Comments

Date Pages Effectivity

02/28/97 All 7791 Issue of manual and replacement parts lists.

02/28/00 38 7791 Revised electrical schematic.

08/22/01 18, 19 — Revised part numbers for hose clamps and hose.

11/04/02 15 — Revised part number for front panel.

11/04/02 21 — Revised part number for pump assembly.

11/04/02 25 — Revised part number for booster tank and tank plug.

11/04/02 35 — Revised part numbers for control cabinet parts.

Added contactor and fuses for control transformer.

2/5/03 35 — Replaced 108391 with 113622 thermometer.

CONTENTS

Page

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

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

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

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

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

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

Detergent .............................................................................................................................................. 5

Rinse-Aid ............................................................................................................................................. 5

Completing Installation ........................................................................................................................ 6

OPERATION .............................................................................................................................................. 7

Operation Summary ............................................................................................................................. 7

Operation Procedures ........................................................................................................................... 7

MAINTENANCE........................................................................................................................................ 9

Cleaning Schedule................................................................................................................................ 9

Deliming............................................................................................................................................... 10

Deliming Process.................................................................................................................................. 10

Maintenance Schedule.......................................................................................................................... 11

TROUBLESHOOTING .............................................................................................................................. 12

REPLACEMENT PARTS........................................................................................................................... 13

ELECTRICAL DIAGRAMS ...................................................................................................................... 37

TIMER CHARTS AND DIAGRAMS........................................................................................................ 39

LIST OF FIGURES

Figure 1—Track and Panel Assembly......................................................................................................... 14

Figure 2—Door and Switch Assembly........................................................................................................ 16

Figure 3—Tank/Drain Assembly ................................................................................................................ 18

Figure 4—Pump Assembly ......................................................................................................................... 20

Figure 5—Wash System Assembly............................................................................................................. 22

Figure 6—Booster Assembly and Water Inlet Piping................................................................................. 24

Figure 7—Water Inlet Piping (No Booster Assembly) ...............................................................................26

Figure 8—Fill System ................................................................................................................................. 28

Figure 9—Detergent Pump Assembly......................................................................................................... 30

Figure 10—Rinse-Aid Pump Assembly...................................................................................................... 32

CONTENTS

Figure 11—Control Panel Assembly........................................................................................................... 34

Figure 12—Electrical Diagram, I-UH (50Hz)............................................................................................. 38

Figure 13—Timer Chart and Diagram, I-UH.............................................................................................. 39

INTRODUCTION

Welcome to Champion.

Thank you for choosing Champion and for allowing us to take care of your dishwashing needs.

This manual covers the I-UH model undercounter dishwasher.

Your machine has been completely assembled, inspected, and thoroughly tested at our factory to eliminate problems at installation before it was shipped to your installation site. This manual provides:

•Warranty information

• Installation and operation procedures

• Maintenance instructions

•Troubleshooting guide

• Replacement parts lists.

Complete and return your warranty registration card as soon as possible.

Champion constantly improves its products; therefore, specifications contained in this manual may have changed.

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

Replacement parts may be ordered from your Champion authorized parts distributor or service agency. When ordering parts, 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 undercounter dishwashing machine. This machine is fully automatic and is equipped with a 1/2 H.P. pump motor. All models are available for mounting directly to the floor or on optional stands (see accessories listed on page 4).

Standard equipment includes:

-Automatic tank fill -Wash/rinse arm

-Common utility connections -Two dish racks (peg and flat)

-120 Volt control circuit -Exclusive vent design for

-Convenient, easy to use controls venting of condensation

-Door latch activated start switch -Stainless steel heavy-gauge construction

-Pumped drain (to 3 ft/1m) (vertical)

This series of dishwashers is available in the following model:

Model Number

I-UH

• The I-UH model is a high temperature (82°C/180°F rinse) sanitizing model with booster.

• The I-UH model is available as a high temperature (82°C/180°F rinse) sanitizing model without booster.

Options

• Kit 512 - Detergent pump (P/N 0709624)

• Kit 504 - Top and side panels (P/N 0708756)

• Kit 505 - Top panel only (P/N 0708744)

• Kit 506 - Left side panel only (P/N 0708745)

• Kit 507 - Right side panel only (P/N 0708746)

• Kit 508 - Rinse aid pump kit (P/N 0708754)

• Kit 510 - Extended reach pumped drain kit (P/N 0708766)

• Kit 511 - 30°C/70°F temperature rise booster (P/N 0708753)

(for 49°C/110°F supply water).

GENERAL

Accessories

• 17RS - 17" rack stand (raises working height and adds rack storage)

• 17T - 17" cabinet (raises working height and adds storage)

• CST - Combination sink/table (scraping and sorting station)

• 101285 - Dish Rack (Peg Rack)

• 101273 - Silverware Rack (Flat Bottom Rack)

Electrical Power Requirements

Booster Machine Power Requirement

Model Voltage Rise Full Load Amp (125% Service Factor)

I-UH 115/50/1 N/A 7 15

(without booster)

I-UH 208/50/1 40 31 39

I-UH 240/50/1 40 34 43

I-UH 208/50/1 70 42 53

I-UH 240/50/1 70 48 60

NOTE:

208-230V/50Hz/1PH electrical supply service must be a 2-wire plus ground for connection as shown.

—2-Wire Plus Ground Diagram

208-230V

GND

L2L1

INSTALLATION

Unpacking

WARNING:

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

1. Immediately after unpacking your 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 the machine and adjusting the feet. Level the machine front-to-back and side-to-side.

CAUTION:

After locating your machine, the installation must meet local health codes. An example may be to seal your machine to the floor using a good grade of silicone sealant.

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 tag it to indicate work is being done on that circuit.

1. The electrician should compare the electrical specifications on the machine electrical rating label (located on the lower left front panel) to the electrical power supply before connecting the machine to the incoming service at a fused disconnect switch.

NOTE:

The 208-240V/50Hz/1PH electrical supply service for this machine must be a 2-wire plus ground service.

2. On the 208V-240V models, a terminal block is provided on the left front side of the machine (located behind the front panel) for electrical service connections. A fused disconnect switch or circuit breaker (supplied by user) is required to protect each power supply circuit.

!!!

INSTALLATION

Plumbing Connections

CAUTION:

Plumbing connections must comply with local sanitary and plumbing codes.

Water Connections

1. Connect the hot water supply (60°C/ 140°F Min) to the 1/2" I.D. fill hose provided. The fill solenoid valve is equipped with a flow control that will accept water pressures from 172

kPa/25 psi to 665 kPa/95 psi.

2. Install a manual shut-off valve with 3/4" garden hose connection in the water supply line close to the machine to accommodate installation and servicing the machine. The shut-off valve should be the same size or larger than the supply line.

3. The fill solenoid valve is equipped with a built-in strainer to protect from particles in the water supply.

Drain Connections

1. All Models are supplied with a flexible 5/8" I.D. drain hose, which must be connected to a 1-1/2" drain using a wye (Y) fitting close to the machine.

Detergent/Chemicals

Use a qualified detergent/chemical supplier for your detergent, rinse aid, and chemical sanitizer needs.

1. Your machine may be fitted with an optional liquid detergent dispensing pump. Insert the labeled detergent pickup tube into the detergent container. The pickup tube has a strainer on the end to prevent crystallized chemical from clogging the supply lines.

2. The cycle timer located in the main control cabinet is equipped with adjustable cams for the chemical dispensing pump(s). The cams control the length of time that the pumps operate. A qualified person may adjust the cam settings if necessary. Refer to the timer chart diagram(s) at the end of the manual for timer cam locations. Factory time settings are only approximate. Have your chemical supplier check the concentration and make the necessary adjustments.

NOTE:

A nonchlorinated detergent is recommended for your dishwasher.

Rinse Aid

1. An optional rinse aid pump may be added for all models. Insert the labeled Rinse Aid pickup tube into the rinse aid container. Contact your local chemical supplier for adjustment to ensure proper dosage.

INSTALLATION

Completing Installation

1. Remove any foreign material from inside the machine.

2. Center the scrap screen over the sump opening.

3. Prime the booster using the following procedure (if applicable).

CAUTION:

To prime the booster, the following procedure must be followed AFTER the electrical and plumbing connections have been made and water has been turned on.

a. Open the dishwasher door.

b. Make sure the On-Fill/Off-Drain switch is in the Off-Drain position.

c. Push the Detergent/Rinse prime switch “down” to the Rinse position.

d. Hold the prime switch in the Rinse position until you observe water entering the wash

tank. The water inlet port is on the lower right side of the tank interior.

e. Release the switch. You have completed the booster priming process.

WARNING:

Failure to prime the booster may cause damage to the booster elements and other electrical components and will void the warranty.

4. Check the machine for water leaks by depressing the ON/FILL switch on the front panel, then close and latch the door. This allows the tank to automatically fill by using the rinse cycle. Check for leaks.

5. Open the door and check the water level. The water level should be 1/2" over the scrap screen.

6. Depress the OFF/DRAIN switch, close and latch the door to drain the machine. This allows the machine to complete the 105-second wash and drain cycle. Check the drain plumbing for leaks or kinks in drain hose.

7. Replace the front panel. Installation is now complete.

CYCLE

OFF

DRAIN

FILL

DET

RINSE

00034

OPERATION

Operation Summary

The following is a summary of your Undercounter Dishwashing Machine operating cycle:

1. The cycle begins when you close and latch the door.

2. The green cycle lamp lights and the wash pump starts.

3. The pump runs during the wash cycle for approximately 80 seconds.

4. The wash pump stops, and the drain valve is opened.

5. After a 2-3 second pause, the pump drain cycle begins and continues for approximately 30 seconds.

6. After a 2-3 second pause, the fill valve opens, and the pump starts for the rinse cycle.

7. Within approximately 25 seconds, the rinse cycle is complete. The pump stops, the green cycle lamp turns off, and the cycle is complete.

8. Open the door and remove the rack of clean ware. The door must remain open for 5

seconds to allow the timer to reset before starting another cycle.

Daily Operation Procedures

The operation of your dishwasher will be more efficient when these procedures are followed:

1. Check that the spray arm and scrap screen are in place.

2. Close and latch the door. Push the ON/FILL switch to the ON position. The tank will begin filling with water. This procedure is followed only when the tank is empty.

3. When the tank is full, check the wash tank temperature gauge. Minimum wash temperatures are:

• I-UH – 66°C/150°F

CAUTION:

If the wash water temperature falls below the minimums listed above, you must run an empty cycle to refill with fresh hot water.

4. Scrap and preflush all items to be washed, and load the items into the rack. DO NOT OVERLOAD the rack. Wash only one layer of silverware in a rack.

5. Open the door and insert the rack into the machine.

6. Close and latch the door. This will start the wash cycle. The green cycle lamp located on the front control panel will light. This lamp will remain on until the entire wash and rinse cycle are completed.

OPERATION

NOTE:

The machine may be stopped at any time by opening the door. When restarted, the cycle does not start over. It will continue from the point at which it was interrupted.

7. Check the rinse temperature during the final rinse (120 seconds into cycle). The rinse temperature must be 82°C/180°F minimum for model I-UH.

8. The pump will automatically stop and the green cycle light will turn off indicating the cycle is completed.

9. Open the door and remove the rack.

10. Repeat steps 4-9 for additional cycles. Machine operation is automatic.

11. CLEAN the scrap screen after every meal period. During heavy usage, the scrap screen should be cleaned more frequently.

CAUTION:

Poor machine performance and/or damage to the machine can occur if the scrap screen becomes clogged with soil or waste particles.

12. To drain water out of the tank at the end of each day. Flip OFF/DRAIN switch to DRAIN position. Close and latch door. Machine will drain completely in approximately 105 seconds.

CAUTION:

DO NOT LEAVE WATER IN THE TANK OVERNIGHT. Water left in the tank overnight will allow harmful chemicals to deteriorate the tank.

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