11/01/02AllFirst issue of manual and replacement parts
10/13/0346-47—Inserted tracks for all models
10/13/0358-61J1789Inserted new piping drawings - moved pressure
gauge after solenoid valve.
06/21/0448-49—Corrected part number 314187 to 314185 drain
overflow. Added overflow gaskets and o-rings.
REVISIONS
i
TABLE OF CONTENTS
CONTENTS
Page
REVISION HISTORY ......................................................................................................................i
— Side Mounted Booster Cabinet ................................................................................ 76
iv
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 workmanship 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, 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 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: (1) Damage to the exterior or 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: 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.
SCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY. CHAMPION’S WARRANTY IS ONLY TO
DI
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.
v
SAFETY SUMMARY
SAFETY SUMMARY
Safety Symbols
• The following symbols appear throughut this manual alerting you to potential hazards.
Statements associated with each symbol are printed on italics.
WARNING:
Warning statements indicate any condition or practice that could result in personal injury or
possible loss of life.
CAUTION:
Caution statements indicate any condition or practice which, if not strictly observed or
!
remedied, could result in damage to or destruction of the dishwasher.
NOTE:
Note statements indicate any condition or practice which, if observed, will help in the safe
completion of a task.
General Safety Rules
• The following general safety rules must be observed in addition to the specific cautions
and warnings presented in this manual.
• Your Champion pot and pan washer uses hot water to clean and sanitize a variety of wares.
Machine surfaces and wares become hot during and immediately following normal
operations. Operators should use caution when loading and unloading wares from
the machine.
• Operators must NOT bypass a safety interlock or control(s) to operate unit.
• The service and maintenance instructions contained in this manual are intended for qualified
service personnel. These instructions assume that you are trained in basic electricity and
mechanical theory. If you are not a trained technician, then do not attempt to adjust or
repair the dishwasher as serious personal injury or damage to the dishwasher may result.
vi
INTRODUCTION
INTRODUCTION
Welcome to Champion....
and thank you for allowing us to take care of your dishwashing needs.
This manual covers several models. Model numbers are shown on the front cover.
Your machine has been completely assembled, inspected, and thoroughly tested at our factory
before it was shipped to your installation site.
This manual contains:
•Warranty information
•Operation and cleaning instructions
•Maintenance instructions
•Troubleshooting guide
•Basic service information
•Replacement parts lists
•Electrical schematics
Complete and return your warranty registration card within ten (10) days after the installation of
your machine.
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 obligation.
For your protection, factory authorized parts should always be used for repairs.
Replacement parts may be ordered from your Champion authorized service agency. When
ordering parts, please supply the model number, serial number, voltage and phase of your
machine, the part number, part description, and quantity.
1
GENERAL
GENERAL
This manual covers the Champion pot, pan, and utensil door type washing machine. This
machine is fully automatic and is equipped with a 7.5 Hp wash pump motor. This model is
available for straight-through, corner or front-loading operation.
Standard Features
•Balanced door system•Interchangeable upper and lower
•Detergent/chemical connectionwash and rinse arms
provisions •Door safety switch on each door
•Low water tank heat protection•Enclosure panels (front and sides)
Your dishwasher was completely assembled, inspected, and thoroughly tested at our factory
before shipment to your installation site.
• The pot, pan, and utensil washer is shipped on a single pallet.
• Optional components may have been shipped separately.
• Check your packing list thoroughly.
NOTE:
Care should be taken when lifting the machine. The piping under the base can be damaged.
Remove the dishwasher front panels if lifting from the front with a forklift.
BE SURE TO COMPLETE AND RETURN
INSTALLATION
THE WARRANTY CARD
INCLUDED WITH YOUR MACHINE
NOTE:
The installation of your pot, pan, and utensil washer must meet all applicable health and
safety codes and conform to good trade practice.
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. Check the interior of the dishwasher for the following items stowed inside:
• 1 set of dishracks
• Upper and lower spray arm assemblies
• Warranty information packet
3. Move the dishwasher to its permanent location. Move the machine while on the skid.
Do not lift on any of the piping under the base.
3
INSTALLATION
PERMANENT PLACEMENT
Special Tools-
• Bubble Level (3ft)
Perform the following steps to place the dishwasher in its permanent location.
1. Before moving the dishwasher into position, inspect the location site to ensure the electrical,
2. Remove the skid.
3. Place a 3ft. level on top of the pot and pan washer or inside the dishwasher on the track
4. Remove the control cabinet cover and the right side panel for the booster cabinet
plumbing, and ventilation services (if required) are provided in the correct locations.
Compare the site connections with the dishwasher to ensure they will match when the
machine is set in its permanent location.
assembly to level the dishwasher front to back. Adjust the level by turning the adjustable
feet. Level side to side with the level place on the top of the unit.
(if applicable), to expose the electrical terminal connection points.
Plumbing Connections
WARNING:
The installation of this unit must conform to local codes or, in the absence of local codes,
to all National Codes governing plumbing, sanitation, safety and good trade practices.
1. Incoming water supply line is 1” for water connections. Connect the hot water supply at the
final rinse piping connection located at the top right rear of machines with boosters.
2. A “Y” line strainer is provided by Champion for machines without boosters. A pressure
reducing valve (PRV) is provided by Champion for machines with built-in boosters.
3. If the incoming hot water supply pressure exceeds 25 psi [173 kPa], a PRV must be installed
and set to 20-22 psi [138-151 kPa] flowing pressure. The PRV may be purchased from
Champion or supplied by others.
4. Install a manual shut-off valve in the steam and water supply lines to accommodate servicing
the machine. The valve should be the same size as or larger than the supply line.
5. Provide a suitable gravity drain to connect to the 1-1/2" NPT machine drain connection.
4
INSTALLATION
Electrical Connections
NOTE:
Electrical and grounding connections must comply with the National Electrical Code and/or
Local Electrical Codes.
WARNING:
When working on the unit, disconnect the electric service and tag it to indicate work is being
done on that circuit.
1. A qualified electrician should compare the electrical specifications on the machine electrical
connection plate (located inside the control cabinet) to the electrical power supply before
connecting to the incoming service at a fused disconnect switch.
2. The unit is phased at the factory. The phasing of the incoming service can be checked by the
rotation of the pump shaft. The pump shaft should rotate in the direction of the discharge,
indicated by an arrow on the casting. If the machine is out of phase, make changes at the
control cabinet main terminal block and not at the motor.
3. A knock-out plug is provided at the rear of the control cabinet for electrical service
connections. Electric booster requires a separate connection.
Ventilation
1. Stainless steel watertight ducting should be installed INSIDE the 6” diameter vent collar on
the top of the machine.
2. There shall be a minimum of 8 air changes per hour of kitchen air.
CAUTION:
Exhaust air should not be vented into a wall, ceiling, or concealed space of a building.
!
Condensation will cause damage.
5
INSTALLATION
CHEMICAL CONNECTIONS
!! ATTENTION POT AND PAN WASHER OWNER!!
Your pot and pan washer is designed to work best with liquid commerchemicals. Detergents must be a commercial non-foaming liquid. Champion strongly
recommends that you contact a qualified chemical supplier to supply these products and to
set-up your machine for the first time.
1. Use a qualified detergent/chemical supplier.
2. Labeled control circuit connection terminals are provided in the control cabinet for detergent
and rinse agent dispensing equipment (supplied by others).
3. Refer to the wiring schematic for connection points. Signal connection points include:
• Detergent signal 120VAC, 1 Amp Max amp load.
• Rinse aid signal 120VAC, 1 Amp Max amp load.
4. A removable black plastic plug is provided on the lower left side of the wash tank, behind
the panel, for the installation of the detergent conductivity cell.
5. The detergent input tube should be located above the conductivity cell and the scrap screens.
6. Liquid product is available in 1 to 30 gallon containers and should be located within the
sight of the operator.
CAUTION:
Never use residential nonautomatic dishwashing detergents such as JOY™ or DAWN™, or
!
any other liquid designed for the handwashing of wares, in your machine. Extreme foaming
inside your Champion pot and pan washer will cause operation problems.
cial dishwashing
Rinse Aid Connections
1. Rinse aid injection system should be installed by a qualified detergent/chemical company.
2. A removable plug in the fill line on top of the machine, at the rear, will be the rinse
iI
N
6
injection point.
3. Since the final rinse is controlled by the machine timer, rinse aid is only introduced during
this cycle.
4. Refer to the wiring schematic for the connection points in the form of two terminal screws.
3. The reservoir should be placed within sight of the operator with machine doors in the open
position. The liquid product is available in 1 to 6 gallon containers.
INSTALLATION
Installation of Dish Tables
1. Load and unload machine openings are 28-7/8”, therefore, table width should be 29” with a
3/4” turned down lip. (33-1/2” max entry).
2. The formed down lip of the dishtable should be placed inside the machine. The dishtable
should be pitched toward the dishwasher for proper draining by adjusting its leveling feet.
The dishtable should be sealed to the dishwasher.
Completing Installation
WARNING:
Do not insert racks into machine before tanks fill with water. Operating pumps dry will cause
pump seal damage and leakage that can result in a motor failure.
1. Remove any foreign material from inside the machine.
2. Check to ensure that drains and overflow pipes are operational and sealed.
3. Position scrap screens on supports above the tanks.
4. After plumbing and electrical connections are completed, fill the tank and wait 10
minutes. Check all plumbing connections for leaks.
5. Drain the tank and check the drain lines for leaks.
7
OPERATION
INITIAL START-UP
Check your site to ensure that all plumbing and electrical connections have been properly made by
qualified personnel. Check the installation of chemical dispensing systems. Perform the following
steps to prepare your machine for operation.
1. Check the exterior of the machine for any foreign material and remove.
2. Check the interior of the machine for any foreign material and remove.
3. Remove the lower spray arms and the scrap screens.
4. Make sure that all loose tape, nut, bolts and paper have been removed from the interior.
5. Replace the scrap screen and clean if required.
6. Make sure that the upper and lower spray arms are in place and that the nozzles are clean. The
arms are held in place by knurled retaining screws. The arms are interchangeable.
7. Check the chemical supply containers and fill as required. Detergent may be introduced by hand,
for the first initial start up, on the top of the screens (follow chemical supplier’s directions).
8. Open the water supply valve. Check for leaks and take any corrective action that may be
needed.
9. Open the final rinse pet cock under the pressure gauge.
10. Check the drain and/or drain connections to ensure that drains are functional.
11. Turn the main power on at the breaker panel or fused disconnect switch.
8
BASIC OPERATION
Perform the following steps to prepare and load your wares for washing.
1. Scrap and rinse wares to remove any heavy food particles and other debris.
2. Place wares into rack.
3. Place rack into the machine and close all doors.
4. Flip the power toggle switch, located on the control cabinet, to ON.
5. The power ON red light will glow and the machine should begin to fill.
6. Wait until the machine has stopped filling. Check for leaks and observe the wash
temperature gauge. The minimum wash temperature is 150˚F.
7. Turn the wash cycle timer face counterclockwise to stop (2 minutes). Push the GREEN start
button, machine will start. The GREEN in-cycle light will remain on. During the final rinse
(15 seconds) check the rinse temperature gauge. The minimum temperature for the final
rinse is 180˚F.
8. If for any reason the doors are opened during the cycle, the machine will stop. Closing the
doors will restart the machine where the cycle was stopped at timewise.
OPERATION
9. Check the Detergent/Rinse Aid feed during the machine operation.
10. For best results, clean the scrap screens and scrap baskets after each meal period. REPLACE
the tank water every 8 hours of operation.
11. Check the chemical supply. Replenish any chemicals as needed.
12. Follow the Maintenance section of this manual for DAILY and WEEKLY maintenance.
CAUTION:
!
DO NOT leave water in tank overnight.
9
MAINTENANCE
MAINTENANCE
The efficiency and life of your machine is increased by regularly scheduled preventive maintenance.
A well maintained machine gives better results and service. An investment of a few minutes of
daily maintenance will be worthwhile.
The best maintenance you can provide is to keep your machine clean. Components that are not
regularly cleaned and flushed will clog and become inoperative.
Intervals shown in the following schedules represent an average length of time between necessary
maintenance. Maintenance intervals should be shortened whenever your machine is faced with
abnormal working conditions, hard water, or multiple shift operations.
CLEANING
Daily-Every 8 Hours of Operation
1. Turn power switch to OFF.
2. Drain the tank and flush with water.
2. Remove all scrap screens, scrap baskets and pull drain lever to drain water. Clean inside of
tank and flush with clean water. Backflush scrap screens and basket until clean. Do not strike
screens or basket against solid objects.
3. Remove the spray pipes. Remove the end plug from each spray pipe. Flush pipe and nozzles
until clean. Do not strike spray pipes against solid objects. Check bearings in arms to
ensure that they are clean of any debris and do not need replacing. Reinstall spray pipes.
At the End of Day
1. Drain the machine.
2. Check and clean scrap screens, scrap basket and pump suction screen.
3. Clean the spray arms.
4. Wash inside of machine with fresh water (tank, sides and top).
CAUTION:
!
Do not hose down the exterior of the machine with water.
5. Leave the doors open to aid in drying the interior of the machine.
6. Clean the exterior of machine with a mild soap solution.
6. Check detergent and rinse aid additive, replenish if necessary.
7. Report any unusual conditions to your supervisor.
10
PREVENTATIVE MAINTENANCE SCHEDULES
Daily Maintenance Requirements
1. Check the chemical supply containers and replenish as needed.
2. Inspect the scrap screens and baskets for bent or damaged parts.
3. Check the spray arm bearings and make sure that arms turn freely.
4. Check pump motor for leaks around shaft.
5. Check thermometers for proper readings.
Weekly Maintenance Requirements
1. Inspect for leaks including all piping and supply connections. Tighten or repair as needed.
2. Inspect the door for proper fit and ease of operation.
3. Check the operation of door safety switches.
MAINTENANCE
4. Thoroughly clean any residue from the exterior of machine.
5. Check drain/overflow tube for leaks.
Semi-Annual Maintenance Requirements
1. Inspect all chemical connections and supply tubing for leaks.
2. Check the building drain system and clean as needed.
Yearly Maintenance Requirements
1. Inspect the installation site for cleanliness and any foreign material around the machine. Clean
as required.
2. Check the overall condition of the machine. Replace any worn or damaged parts.
11
MAINTENANCE
DELIMING
Your dishwasher should be delimed regularly as required. This will depend on the mineral
content of your water. Inspect your machine interior for lime deposits. If deliming is required, a
deliming agent should be used for best results. Consult your chemical supplier for proper type
and procedures.
DANGER:
Deliming solution, rinse agents, or other acids must not come in contact with household
bleach (sodium hypochlorite) or any chemicals containing chlorine, iodine, bromine, or
fluorine. Mixing may cause hazardous gases to form. Consult your chemical supplier.
1. Remove all racks and wares from the machine.
2. Remove chemical pick-up tubes from the containers and place in a catch pan on the floor.
3. Place each tube in a container of fresh water and prime the chemical lines for several minutes
to throughly flush chemical from the lines. Leave pick-up tubes out of their containers.
4. Drain the machine and refill with fresh water.
5. Spray interior walls with deliming solution and let stand for 5 or 10 minutes depending on
the amount of buildup.
6. Open door and add deliming solution (per chemical supplier’s instructions) directly in
wash tank.
• PP-28 holds 24 US gallons (90.8 Liters) of water.
7. Close doors.
8. Push start button and run an automatic cycle.
9. Repeat steps 3 and 4 if necessary.
10. Drain machine.
11. Open door and inspect interior for mineral deposits. Repeat steps 3-10 if required.
12. Run two (2) additional cycles to flush all deliming chemicals from machine.
13. Drain and refill machine.
14. Replace chemical pick up tubes in containers and prime chemical dispensing system.
15. Deliming process is complete.
Grease
LUBRICATION
Fittings
12
There are two lubrication points on the pump assembly
motor. The pump motor should be greased every 100
hours of running time with a high temperature and
high pressure bearing grease. DO NOT over
lubricate. One to two pumps of the grease gun is
sufficient.
Figure 1
Lubrication Points
TROUBLESHOOTING
OPERATOR TROUBLESHOOTING
The first step in troubleshooting your dishwasher is knowing how it works under normal
conditions. Review the Operation section in this manual for a description of proper loading,
operator controls and basic operating procedures. Check the general condition of dishwasher:
• Does the machine appear to be level?
• Are the spray arms and screens clean and in place?
• Are the doors fully closed?
Some problems may be resolved by double-checking the supply connections to your dishwasher.
Perform the following steps to double-check your dishwasher service connections.
• Push the POWER button on the pot and pan washer OFF, then turn the main power OFF at the
main service disconnect switch or fused circuit breaker. Turn the main power ON and recheck
the pot and pan washer operation.
• Turn the dishwasher water supply valve off and back on again.
• Check the water temperature supplied to the dishwasher. Are the building’s water heaters
operating properly.
• Check the flow of the building drain system. Are any drains clogged or running slow?
• Check the chemical dispensing supplies. Are the strainers clean? Are the pick-up tubes in the
correct containers?
Proceed to the next page if the above checks did not
resolve the trouble condition.
13
TROUBLESHOOTING
OPERATOR TROUBLESHOOTING (CONT.)
Troubleshooting Guide
In order to find the cause of a breakdown or abnormal operating condition in your dishwasher
please ensure that:
1. All switches are ON
2. Drain and overflow tube are in place and seated
3. Wash and rinse nozzles are clean
4. Scrap screen(s) and scrap basket are properly positioned
5. Spray arms are in their proper positions
6. Thermostat(s) are at their correct setting
7. Sanitizer, detergent, and rinse additive dispensers are adequately filled
8. Doors are fully closed.
If a problem still exists, use the following table for troubleshooting
CONDITIONCAUSESOLUTION
Machine will not startDoor not closed.................................. Make sure doors are fully closed
Door safety switch faulty .................. Contact your service agency
Start switch faulty.............................. Contact your service agency
Main switch off.................................. Check disconnect
No rack inserted ................................ Place rack in unit
Overload protector tripped ................ Reset overload in control box
Low or no waterMain water supply is turned off ........ Turn on house water supply
Drain/overflow tube is not
in place and seated ............................ Place and seat drain tube
Machine doors not fully closed ........ Close doors securely
Faulty fill valve.................................. Contact your service agency
Stuck or defective float...................... Check floats and clean
Clogged ‘Y’ strainer .......................... Clean or replace
Continuous water fillingStuck or defective float...................... Check floats and clean
Fill valve will not close...................... Clean or replace
Drain tube not in place ...................... Look for drain tube in tank
Motor not runningOverload protector tripped ................ Reset overload in control box
Defective motor ................................ Contact your service agency
Wash tank water temperatureIncoming water temperature
is low when in useat machine too low ............................ Raise temperature to 140˚
Defective thermometer ...................... Check or replace
Defective thermostat.......................... Check for proper setting or replace
Defective heater element .................. Check or replace
placed in rack .................................... Use proper racks. Do not overload racks
Improperly cleaned
equipment .......................................... Unclog wash sprays and rinse nozzles
to maintain proper pressure and flow
conditions. Overflows must be open.
Keep wash water as clean as possible.
Electric elements or steam
coils has soil/lime buildup ................ Clean and delime
15
BASIC SERVICE
BASIC SERVICE
This next section provides photos, illustrations and basic instructions for the electrical service
and replacement of the main components. It does not cover all components such as the wash arm
supports, hoses or panels. These repairs require simple observation and basic mechanical skill
and therefore are not included in this manual.
WARNING:
Machine surfaces are hot during and after normal operation.
WARNING:
When working on the pot and pan washer, disconnect the electrical service and place a red
tag at the disconnect switch to indicate work is being done on the circuit.
WARNING:
Use extreme caution when testing circuits while power is applied to the machine.
Fill/Rinse Solenoid Valves
There are two different types of valves used on the PP-28; Hot Water and Steam valves, both of
which are rated 120VAC. The steam booster and steam fill valves come with a four screw pattern
on the body. In all cases these valves must be installed with the coil above the valve body. Repair
kits include spring, piston, and diaphragm. The electrical solenoid coil is replaceable as well.
When ordering the replacement components as well as the complete valves, specify the size and
type needed.
Vacuum Breaker
The vacuum breaker is located on the top of the machine providing a anti-siphoning protection.
The diaphragm is replaceable by removing the bell shaped top and unscrewing the body.
Dual Float Switches
The tank has a dual float switch assembly. The float switch is on a 24 VAC circuit. When the tank
is empty and both floats are down, the switch for the float will be in a NO (Normally Open)
position calling for the tank to fill with no heat. When both floats rise to the top the switch will
be in a NC (Normally Closed) position. The tank heat will be activated and the fill will stop.
Tank Heat
The tank heat can be electric, steam coils or steam injectors.
Electric: Uses 10KW elements that are coated with a special alloy to protect against detergents
in the tank. The element circuit is protected by a thermostat and a HI-Limit switch in the tank.
16
Steam Coils: Use a 120 volt power to a steam solenoid in a closed loop coil heat exchanger
using a diaphragm trap. The coil circuit is protected by a thermostat in the tank.
Steam Injectors: Use a 120 volt power to a steam solenoid valve that injects steam through a
two muffler system. A one-way check valve prevents back-siphoning should the valve fail.
This circuit is also controlled by a thermostat located in the tank.
COMPONENTS
BASIC SERVICE (CONT.)
Hi-Limit Switch
On machines with electric tank and boosters, a separate thermostat is installed that interrupts the
power if the temperature exceeds a preset limit. When the over temperature condition is resolved,
the red button located on top of the switch, must be pushed to reset the power to the elements.
Pressure Reducing Valve (PRV)
A 3/4” PRV for the water supply or 1-1/4” for steam booster, is required if the incoming water
supply exceeds 20-22 PSI(138-151kPa) for water or 30 PSI for steam flowing pressure. The
PRV’s should be installed in the incoming supply lines before the machine connection.
Water Hammer Arrestor
Whenever a booster heater is installed in the final rinse line a water hammer arrestor shall be
installed between the booster outlet and the final rinse inlet valve. This helps to prevent the
knocking or hammering sound of the water as it flows through the pipes.
Wash Pump/Motor
The wash pump/motor is a closed centrifugal pump that is rated 7-1/2 HP running at 3600 RPM.
The motor is rated 3 phase, 60 hertz, and is multi-voltage.
17
ELECTRICAL SERVICE
ELECTRICAL SERVICE
Fuse Blocks—120VAC Control Voltage
Two fuse blocks, located in the lower front corner of the main control
cabinet protect the main control transformer. Each fuse block holds a fuse.
The fuses are marked 1FU and 2FU on the electrical schematic.
To Replace the fuse:
• Disconnect power to the machine at the main service switch.
• Flip the tab on the top of the fuse block to open the block.
• Remove the fuse and replace it.
• Close the fuse block and turn the main power on.
• If the fuse blows again, DO NOT INCREASE THE FUSE SIZE.
• DETERMINE THE CAUSE OF THE OVERLOAD.
ÊFig. 2 shows the fuse block opened and the fuse exposed.
Motor Overloads
Motor overloads are located to the left of the fuse blocks inside
the control cabinet. The motor has an overload to protect it from line
voltage electrical overloads. In addition, an auxilary set of switch
contacts are built into the overload. The switch contacts
disconnect 120VAC power to the motor contactor coils in the
event of an overload condition.
Note the Switch Lever on the Overload.
• If the switch lever is off with the “0” showing then the
overload has tripped on an overload.
To Reset the Motor Overload:
• Flip the starter switch to the On position.
• Run the dishwasher and test the AMP draw of the motor in
question. If the motor checks okay then there may be a
wiring problem or the overload may be defective.
To Replace a Motor Overload:
• Disconnect the wires to the overload.
• Release the mounting catch on the front side of the overload,
push forward and lift out.
Figure 2
Fuse Blocks
Figure 3
Motor Overloads
18
• Snap the new overload into place and reconnect the wires.
To adjust the overload setting:
The screwdriver in Fig.3 is positioned
to adjust the motor overload AMP setting.
• Read the FLA motor amps that applies for the
machine voltage on the Motor Nameplate.
• Turn the setting to 125% over the FLA .
ELECTRICAL SERVICE (CONT.)
Pump Timer
Refer to Fig.4 and Fig. 5
ELECTRICAL SERVICE
There are two timers in control cabinet of the PP-28,
one is located on the face of the cabinet panel and
controls the pump time, while the other one is
located inside the top of the control cabinet and
controls the final rinse time.
The Pump Timer controls the amount of time that the
pump will run during the wash cycle. This time is set
from the factory and pegged for the minimum time of
2 minutes. You are able to select the time settings from
2 minutes to 5 minutes depending on the amount of
soiled product. (See Fig. 4 for timer position).
The Final Rinse Timer controls the amount of time
for sufficient final rinse sanitizing. This timer is an
adjustable timer for 0 to 30 seconds. The factory
presets this timer for 16 seconds. (See Fig. 5 for
timer in cabinet).
The final rinse timer has the following user defined settings:
1. Adjustable timer range
2. Timer knob setting
3. Indicator light (ON when timer is counting)
4. 50 Hz or 60 Hz setting on the back/bottom of the timer
Image unavailable
at time of printing.
Figure 4
Wash Pump Timer
To Replace a Timer:
• Disconnect power to the machine at the main service switch.
• Remove the defective timer and install the replacement.
• Adjust the new timer setting to match the setting
of the original timer.
Figure 5
Final Rinse Timer
19
ELECTRICAL SERVICE
ELECTRICAL SERVICE (Cont.)
Automatic Fill/Low Water Heat Protection
Dual Float Switches –
Refer to F
Each tank contains a dual float. The device consists of
an angled stem containing two reed switches.
Two stainless steel ball floats slide over the
stem and are free to move up and down.
The floats contain magnets. When the float moves on the
stem, it opens and closes its associated reed switch inside the
stem. The reed switches control relays. The relays control the
automatic fill and heat for different parts of the machine.
Float switches and their relays operate on 24VAC.
Circuit Explanation –
The following is a general explanation of the float switch circuit.
Refer to the electrical schematic on your machine for a detailed description
of the individual floats, relays, and wiring.
Bottom Float and Reed Switch:
• The bottom float controls the heat.
• When the bottom float is down, the bottom reed switch contacts are open.
• When the bottom float is up, the bottom reed switch contacts close.
Top Float and Reed Switch:
• The top float controls a fill valve.
• When the top float is down, the top reed switch contacts are open.
• When the top float is up, the top reed switch contacts are closed.
ig. 6
Figure 6
Dual Float
Switch
Initial Fill –
• When the tank is completely empty, both floats are down and their reed switch contacts
are open.
• The control relay for the float switch is de-energized.
• The fill valve for the tank is energized and the tank begins to fill with water.
• As the water level in the tank rises, the bottom float begins to move up.
• When the bottom float is completely up, its NO reed switch contacts close.
• This prepares the heat circuit, but the heat Does Not energize at this time.
• The tank continues to fill until the top float is completely up.
• The top float’s NO reed switch contacts close. Its control relay energizes.
• The fill valve de-energizes.
• The heat circuit energizes through the float switch and the contacts of the control relay.
During Normal Operation –
• If the water level in a tank falls below the level of the top float, the top float moves down and
its reed switch contacts open.
• When the water level falls below the level of the bottom float, the bottom float moves down
and its reed switch opens.
• The control relay de-energizes. The fill valve energizes and refills the tank.
• The heat circuit will de-energize until the water level in the tank raises the top float again.
• The bottom float keeps the heat circuit ready as long as the water level is above the level of the
bottom float.
20
ELECTRICAL SERVICE (Cont.)
Thermostat Locations and Adjustments
Refer to Fig. 7
Electric tank heat is controlled by two thermostats.
1. The control thermostat which regulates the
temperature.
2. The high limit thermostat which protects from
overheating.
Location:
Both thermostats are located on front of tank, inside
a black enclosure box behind the front access panel.
ELECTRICAL SERVICE
Control Thermostat
Adjustment:
The Control Thermostat has an adjustment screw
on one side.
• The thermostat is wired Normally Closed.
• Turn the adjustment screw clockwise to increase
the temperature in the tank and counterclockwise
to decrease the temperature in the tank.
The High Limit Thermostat is not adjustable.
It contains a red reset button in its center.
• The red button pops out if the temperature
in the tank exceeds 210˚F/99˚C.
• Press the red button in to reset the high limit.
Determine the cause of the high temperature condition.
Refer to Fig. 7 and Fig. 8
Electric Booster Heat is controlled by two thermostats.
1. The control thermostat which regulates the
temperature.
2. The high limit thermostat which protects from
overheating.
3. The tank(s) have a control and a high limit thermostat.
Location:
The control thermostat is enclosed in a black box mounted
on the front of the wash tank behind the front access panel.
The high limit thermostat is enclosed in a box mounted
on top of the booster tank.
High limit
Thermostat
Figure7
Tank Heat Thermostats
High Limit
Thermostat
Control
Thermostat
Figure 8
Booster Thermostat Locations
Adjustment:
The control thermostat has an adjustment screw on one side.
• The thermostat is wired Normally Closed.
• Turn the adjustment screw clockwise to increase the booster
tank temperature and counterclockwise to decrease the booster
tank temperature.
The high limit thermostat is a bimetal snap design.
It is not adjustable.
• A button with a red dot in the center pops out when
the temperature exceeds 210˚F/99˚C.
• Press the red reset button in to reset the high limit.
Determine the cause of the high temperature condition.
Figure 9
Booster – High Limit
Thermostat
21
ELECTRICAL SERVICE
3
3
3
3
3
3
31L3
3
31L3
3
ELECTRICAL SERVICE (Cont.)
Heater Element Wiring – Booster Tank and Wash Tank Heater Elements
Refer to the illustrations and follo
w the steps below to properly install terminal jumpers and
to make line power connections to a replacement element.
Step 1. Hold the element assembly with the calrod coils facing toward you.
Step 2. Match your element coil to Configuration A, B, C, or D.
Step 3. Rotate your element coils to match the correct configuration.
Step 4. Flip the element over and match your element to the correct terminal configuration.
Step 5. Install terminal jumpers according to the illustration for your voltage requirement.
Step 6. Install the element and make your line connections 1L1, 1L2, or 1L3 per the illustration.
Configuration A
Terminal Connections view of element
Booster tank element
View of calrod coils
Configuration B
1L
1L
480V/3 Phase
208-240V/3 Phase
Delta Connection
575V/3 Phase
Delta Connection
Terminal Connections view of element
1L
208-240V/3 Phase
Wye Connection for
380-415V/3 Phase
Booster tank element
View of calrod coils
Configuration C
Booster tank element
View of calrod coils
Configuration D
Wash tank element
View of calrod coils
1L
1L
480V/3 Phase
208-240V/3 Phase
Delta Connection
575V/3 Phase
Delta Connection
Terminal Connections view of element
1L
480V/3 Phase
208-240V/3 Phase
Delta Connection
575V/3 Phase
Delta Connection
Terminal Connections view of element
1L
480V/3 Phase
208-240V/3 Phase
Delta Connection
575V/3 Phase
Delta Connection
208-240V/3 Phase
Wye Connection for
380-415V/3 Phase
1L
208-240V/3 Phase
Wye Connection for
380-415V/3 Phase
208-240V/3 Phase
Wye Connection for
380-415V/3 Phase
22
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