CHAMPION P7-30 User Manual

Installation/Operation Manual with Service Replacement Parts

Waste Handling Systems

Close-Coupled Pulper /Water Extractor

Models: P5-24

5HP with 24" Tank P5-27

5HP with 27" Tank P7-30

7.5HP with 30" Tank

Model P5-24

3765 Champion Blvd. Winston-Salem, NC 27105 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

Machine Serial No.

Issue Date: 10.15.13

Manual P/N 114509 rev. D

For machines beginning with S/N J08072511 and above

Printed in the USA

For future reference, record your Remote Waste Handling Systems 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 Waste Handling System model no.,

serial no., voltage, Hz and phase are

needed to identify your machine and to

answer questions.

The Serial No. is located on the front

of the remote-mounted control cabinet

Please have this information on-hand

if you call for service assistance.

The USGBC Member Logo is a trademark owned by the U.S. Green Building Council and is used by permission. The logo signies only that

Moyer Diebel is a USGBC member; USGBC does not review, certify or endorse the products or services offered by its members.

Make sure you are connected to the internet then enter the address below.

In the U.S.A

http://www.championindustries.com/register

In Canada

http://www.championindustries.com/canada/register

PRODUCT REGISTRATION

BY FAX

COMPLETE THIS FORM AND FAX TO:

(336) 661-1660 in the USA

1-(800) 204-0109 in Canada

PRODUCT REGISTRATION CARD

Model

Date of Installation: Company Name:

Address: Telephone #: ( ) ---

Serial #

(Street) Province Postal Code

Contact:

Installation Company: Address: Telephone #: Contact:

FAILURE TO REGISTER YOUR PRODUCT MAY VOID YOUR WARRANTY

IMPORTANT IMPORTANT

Revision History

A revision might be a part number change, a new instruction, or other information that was not available at print time. We reserve the right to make changes to these instructions without notice and without incurring any liability by making the changes. Equipment owners may request a revised manual, at no charge, by calling 1 (800) 858-4477 in the USA or by calling 1 (800) 263-5798 in Canada.

Revision Revised Serial Number Revision Date Pages Effectivity Description

10.10.08 All J08072511 Released First Edition

2.15.10 8 J08072511 Added trough conversion kit instructions

10.11.10 34-35 J08072511 Added Key, P/N 113728 to P/L 49 All Added 2HP 380V/50/3PH to P/L

4.2.12 33 All Changed P/N 111939 description & added P/N 319310 Auger Assembly

10.15.13 49 All Changed Item 9 to P/N 109568

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

Waste Handling Systems: P5-24, P5-27, and P7-30

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

Limited Warranty ...........................................................................................................ii

Model Descriptions ...........................................................................................................iv

Introduction ..........................................................................................1

Theory of Operation ....................................................3

Waste Handling Precautions ......................................6

Recirculating Pump Trough Connections ...................8

Installation ............................................................................................9

Utility Connections ......................................................11

Receiving ....................................................................10

Initial Start-up ..................................................................................................13

Electrical Controls .......................................................15

Mechanical Adjustments .............................................17

Water Fill Adjustments ................................................19

System Operation Checks ..........................................20

Operation .............................................................................................. 23

Cleaning and Maintenance ................................................................. 25

Cleaning ......................................................................26

Maintenance ...............................................................27

Troubleshooting ..........................................................29

Service Replacement Parts ................................................................ 31

Remote Control Cabinet Component Selection Chart ........................ 63

Electrical Schematic ........................................................................................ 64

iii

Model Descriptions

P5-24

24" diameter waste grinding chamber with 5 HP grinder motor 4 stationary cutter blocks and 2 tool-steel cutting blades. Flatware saver Pressure switch water-level control Mounted start/stop station Remote mounted control cabinet Close-coupled water press/extractor with 2 HP motor (700 lb/hr. input capacity)

P5-27 and P5-30

27" or 30" diameter waste grinding chamber with 5 HP grinder motor respectively 4 stationary cutter blocks and 2 tool-steel cutting blades. Flatware saver Pressure switch water-level control Mounted start/stop station Remote mounted control cabinet Close-coupled water press/extractor with 2 HP motor (700 lb/hr. input capacity)

P7-30

30" diameter waste grinding chamber with 7.5 HP grinder motor 4 stationary cutter blocks and 2 tool-steel cutting blades. Flatware saver Pressure switch water-level control Mounted start/stop station Remote mounted control cabinet Close-coupled water press/extractor with 3 HP motor (1000 lb/hr. input capacity)

Optional Equipment

Anti-vibration feet Recirculating pump Flushing systems for pulper and water press Deodorizer injector Remote start/stop station (unmounted) Automatic shut-down timer Spray reel - 30 ft. (unmounted) Feed tray and hood assembly

Trough feed congurations

(consult factory)

Introduction

Theory of Operation

WASTE

Pulp compression

cone

Drain/overflow

Slurry

PULP

OUT

Fresh make-up

water

Grinding

disk

Recirculated

slurry water

Cutters

SLURRY OUT

Slurry auger

and screen

Optional slurry

recirculating

pump

Pulper

motor

Drain

Theory of Operation

Refer to the illustration on the preceding page as you read the theory of operation below. The close-coupled waste handling system is made up of 2 units: a pulper and a water extractor.

1. The close-coupled waste handling system is designed to reduce the volume of waste created in the food service operation thereby reducing the expense associated with conventional methods of waste removal and disposal. The waste handling system accomplishes this by combining food, paper and water, removing the water and then compressing the waste for disposal.

2. The waste handling system consists of a grinding tank, (pulper), and a water press, (water extractor). The 2 components are physically connected (close-coupled) and share a common electrical control system.

3. The pulper contains a spinning grinding disk and cutting blocks which shred food waste and paper to a water-laden mixture called slurry. The pulper forces the slurry into the water extractor.

4. The water extractor contains an auger and screen. The auger rotates inside the circular screen moving the slurry upward to the top of the water extractor. Water is gradually removed from the slurry by the action of the auger and screen.

5. A compression cone, located at the top of the water extractor is the nal stage in the water extraction process. The cone compresses the waste into a semi-dry, papery pulp and then pushes it out of the water extractor and into waste containers for disposal.

6. The pulper is lled with fresh water initially. After that, the water-level in the pulper and the water extractor is maintained by the combination of recirculated slurry water and fresh make-up water. Slurry moves from the pulper into the extractor, water is removed from the slurry and then returned

to the pulper via cross-ow piping or via an optional recirculating pump and waste trough system. The cross-ow piping is blocked when the optional recirculating pump is used. A drain/overow

skims excess water from the water extractor during normal operation and is used to drain the system during the clean-up operation.

7. There are 2 methods for feeding waste into the pulper. In the rst method, the operator manually feeds the waste directly into the pulper. In the second method, waste is conveyed into the pulper via a water-fed trough system.

8. The standard electrical controls consist of a common remote-mounted control box , 1 Start/Stop push-button station on the pulper and 1 push-button station on the water extractor. The pulper water level is controlled by a pressure switch mounted on the side of the pulper. Safety switches mounted on the pulper and the water extractor protect the operator from rotating components. An optional deodorizer injector can be mounted on the water extractor.

9. The waste handling system must be cleaned daily after the day's operation. Optional ushing systems in the pulper and the water extractor aid in removing solids that may be present. Foreign matter must be removed manually and the machine interiors must be ushed with fresh water. The machine exteriors must be cleaned as well as the surrounding work areas to prevent odors and reduce the accumulation of debris.

Waste is compressed into a semi-dry, papery pulp.

Theory of Operation

Under-table Feed tray and Hood Congurations

The illustrations below show the standard under-table designs employed to manually feed food and paper waste into the pulper. The feed tray/feed hood components are removable for cleaning and access to the pulper interior.

Direct feed w/cover

Feed tray w/hood

Feed hood w/hinged lid

Theory of Operation

Feed-trough Congurations

Six standard feed-trough congurations for the waste handling system are shown below.

A feed-trough system semi-automates the waste loading operation by providing an alternative to the under-table feed-tray design shown on the previous page.

The operator separates food and paper waste from the wares and places them in the trough.

Slurry water, which ows down the trough, carries the waste into the pulper. The slurry water is

supplied by a recirculating pump mounted on the water extractor.

Waste Handling Precautions

WARNING!

The Remote Waste Handling System contains ROTATING PARTS moving at high speed.

Death or serious injury may result if clothing, jewelry, or body are caught in the machine.

NEVER run the machine unless all safety devices are in good working condition and all safety covers are installed on the machine.

CAUTION:

Damage to the waste handling system will result

if metal objects are fed into the machine. This includes, but is not limited to, box staples, metal foil, steel wool, metal fasteners, wire, coins, and

metal utensils

WHEN IN DOUBT— KEEP IT OUT.

1. The waste handling system is designed to process a wide range of waste products that are water soluble including: food waste, paper (e.g., paper napkins, cardboard).

2. The system will process waxed paper in limited amounts but only if the waxed paper is loaded in conjunction with waste products described above.

3. DO NOT FEED THE FOLLOWING MATERIALS INTO THE PULPER:

4. Metal (e.g., box staples, metal foil, steel wool, metal fasteners, wire, coins, and metal

utensils

5. Styrofoam

6. Plastic spoons, forks, knives, cups, plates, or bowls

7. Condiment packages (e.g., ketchup, mustard, etc.)

8. Plastic bottles/bottle caps

Waste Handling Precautions

9. Cellophane wrappers (typically used for saltine crackers, candy or nuts.)

10. Plastic package tape

11. Plastic banding,

12. Cloth rubber, leather, wood,

13. Glass, rocks, dirt

14. Paint, solvents or any other chemicals

15. The pulper is equipped with a powerful magnet in the bottom of the grinding chamber that is

intended to attract eating/cooking utensils if they contain a percentage of iron. The magnet will

not attract high quality stainless steel nor sterling silver.

The waste handling system can process a wide

range of waste products; but plastic products

should not be fed into the system.

A powerful magnet is in the pulper grinding chamber.

The magnet will attract utensils and other metal objects

if they contain enough iron in their composition.

Recirculating Pump Trough Connection Kit: P/N 407365

P-5 Recirculating Pump Trough Connection Kit: P/N 407365

A trough connection kit (See No. 1 below) is shipped with each pulper equipped with a recirculating pump. The kit is designed to connect the recirculating pump discharge to a waste trough (supplied by others).

Trunk Option A and Trunk Option B (See No. 2 below) are two suggested methods of making the trunk connection to the trough which is supplied by others.

Recirculating Pump Trough Connection Kit: P/N 407365

Form # 900822

Recirculating Pump Trough Connection Kit P/N 407365

Item No. Part No. Qty.Description

1 102448 Elbow, 1" x 90° Brass 1 2 100585 Locknut, 1" NPT Brass 1 3 111557 Nipple RTOE 1" x 2-12" Brass 1 4 111079 Tee, Red. 1-1/2" x 1-1/2" x 1" Brass 1 5 111080 Plug 1-1/2" Brass 1 6 204731 Stub End, Recirc Pump 1 7 107340 Clamp, Hose SST w/CS Screw 2 8 111117 Hose, 1-5/8" I.D. 1 9 104889 Compound, Grey Sealing 1 ft.

Trough (supplied by others)

Trunk Option A

Trunk Option B

(supplied by others)

Suggested Trough Bafﬂe (supplied by others)

1½" Pipe

½" Critical Gap

Slurry Water Recirculating Pump

!! ATTENTION !!

A splash bafﬂe (supplied by others) must be fabricated and installed in the discharge end of the trough to create the proper water ﬂow. See No. 3 at left for a suggested design for the bafﬂe.

The splash bafﬂe must extend across the entire length of the trough and maintain a 1/2" gap between the bafﬂe and the trough bottom. The trough must be removable for cleaning.

Form # 900822

Installation

Receiving • Installation

Receiving

IMPORTANT:

Plan the route used to transport the main components/pallets. Halls and doorways may be to small to travel through to the nal site.

Follow the steps below to receive the waste handling system at the installation site. Refer to Theory of Operation on page 2 for an illustration of the system.

NOTE: The waste handling system may require parts and materials that are not supplied by the factory. The scrapping station water trough is an example of an item typically supplied by others.

NOTE:

Observe all safety regulations and procedures when moving and placing the machine.

CAUTION:

To prevent damage to the machine, do not lift the machine by any of its piping or electrical conduit.

1. The waste handling system is shipped on a single pallet. The system consists of a pulper,

water extractor, and remote control cabinet.

2. If specified, optional fasteners, trough gaskets, and anti-vibration feet are stored inside the

pulper tank.

3. Inspect the installation site before moving the machine, then place the machine and the

remote control cabinet at their permanent locations.

4. Complete the Warranty Registration Card located at the front of this manual and mail it

immediately to validate the machine warranty.

5. Level the pulper and water extractor front-to-back and side-to-side.

The legs are fitted with adjustable feet to level the machine.

Legs are tted with adjustable feet.

2" [51mm]

6. Follow the instructions (supplied by others)

to permanently attach the machine to the floor.

7. A rubber gasket and mounting hardware is

supplied with the pulper if the installation includes a feed trough system. The feed trough system is supplied by others.

Rubber gasket for a trough connection is

supplied with the pulper.

Installation • Utility Connections

Utility Connections

WARNING!

Electric shock may cause death or serious injury.

Do not work on energized circuits. Turn off all main power service disconnects, lock them out and place a tag on the switch and/or breaker to indicate that work is being performed on the circuit.

WARNING!

Death or serious injury may result if hands, clothing, or jewelry are caught in the machine.

The Waste Handling System contains ROTATING PARTS moving at high speed.

WARNING!

Death or serious injury may result if safety devices are not working.

NEVER operate the machine unless all safety devices are in good working condition and all safety covers are in place on the machine.

ATTENTION!

Utility connections must be performed by authorized installers who will follow all electrical, plumbing, sanitary, safety procedures and regulations.

Plumbing and Electrical Connection Diagram (P&E)

The plumbing and electrical specications and connection locations are detailed in a P&E diagram. This diagram is supplied for the installation prior to shipment. Contact a supervisor if you do not have the P&E at the time of installation.

Utility Connections • Installation

Utility Connections (continued)

The Plumbing and Electrical Diagram-P&E (continued)

1. Refer to the P&E and match the utilities at the installation site to the P&E.

2. Contact a supervisor if the installation site does not match P&E.

3. The general utility requirements may include, but are not limited:

Cold water supply Electrical supply Drain

Cold Water Supply

1. Connect a 1/2" NPT cold water supply line to the pulper.

2. If the incoming water pressure is greater than 25 PSI/172 kPa, then install a pressure regulating

valve (PRV) in the cold water supply.

3. Install a 3/4" NPT shut-off valve in the 1/2" NPT water supply line as close to the machine as

possible.

Drain

1. Connect a 1-1/2" NPT gravity drain line to the pulper.

2. Drain discharge must comply with local sanitary codes and regulations.

Electrical

1. Refer to the Machine Electrical Connection Data Plate located inside the Remote Control Cabinet

2. Make sure the installation site power supply matches the data recorded on the connection plate.

3. Install the Remote Control Cabinet adjacent to or in sight of the waste handling system.

The control cabinet location should make the operation of the system practical for the operator and service technician.

MACHINE ELECTRICAL CONNECTION

FOR SUPPLY CONNECTION, USE COPPER OR COPPER-CLAD ALUMINUM CONDUCTORS

IN ACCORDANCE WITH LOCAL ELECTRIC CODE, RATED MINIMUM 90°C(194°F)

MINIMUM SUPPLY CONDUCTOR AMPACITY

MAXIMUM SUPPLY OVERCURRENT PROTECTION DEVICE

OVERCURRENT PROTECTION DEVICE

VOLTAGE

TIME DELAY FUSE OR INVERSE TIME CKT BREAKER

PHASE HERTZ

AMPS

4. The 3-phase motor rotation was checked at the factory. The pulper disk must rotate CCW and the

water extractor auger screw must rotate CCW. If it is necessary to reverse the motor rotation, reverse L1 and L2 main incoming power supply wires in the remote control cabinet. DO NOT REVERSE L1 and L2 at the motors.

Optional Remote Start/Stop Station Installation

Model P5-24, P5-27, P7-30 Pulper Remote Start/Stop Station Option Installation Instructions

An optional remote start/stop station may have shipped inside the pulper tank for remote installation by others. The remote station consists of two push buttons in a metal enclosure.

Mounting hardware, ﬂexible1/2" sealtite, wiring and connectors are supplied by others. Wire size must be 14 AWG. THHN (90ºC). Refer to the wiring diagram below which shows how the start/stop station is connected in the pulper control circuit.

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.

&,5&8,7%5($.(5

2))

'(2'25,=(5

'(/$<6723

Remote Start/Stop Station

67$57

6723

5(6(7

2))

/2&.

75,3



32:(521

)/86+,1*9$/9(

2)) 21

The installation of the remote start/stop station should be performed by qualiﬁed personnel who will observe all local safety, sanitary, and electrical codes or in the absence of local electrical codes then personnel should follow the

1/2" Sealtite

(supplied by others)

National Electrical Code.

Refer to the Champion Service Manual, P/N 114509 for complete operating instructions for the machine.

Remote Start/Stop Station Wiring Diagram

DELAY STOP

TIMER (IF USED)

CLUTCH

1 7

OFF DELAY

4 2

6 5

START

Remote

Start

1CR

2CR

4CR

3 32

67$57

STOP

Remote

Stop

6723

Initial Start-up - Pulper/Water Extractor

WARNING!

Death or serious injury may result if hands, clothing, or jewelry are caught in the machine.

The Waste Handling System contains ROTATING PARTS moving at high speed.

WARNING!

Death or serious injury may result if safety devices are not working.

NEVER operate the machine unless all safety devices are in good working condition and all safety covers are in place on the machine.

Pulper • Initial Start-up

1. The steps below describe the initial start-up procedure for the close-coupled pulper and water extractor. The Remote Control Cabinet controls both units.

2. Make sure the waste handling system matches the specifications detailed in the P&E.

3. Make sure the pulper and the water extractor are securely mounted to the finished floor.

4. Review the Theory of Operation beginning on page 2.

5. Make sure the main power supply is disconnected. Lock-out the circuit and place a tag on the switch and/or breaker to indicate that work is being performed on the circuit.

WARNING!

Electric shock may cause death or serious injury.

Do not work on energized circuits. Turn off all main power service disconnects, lock them out and place a tag on the switch and/or breaker to indicate that work is being performed on the circuit.

+ 50 hidden pages