Champion PP-28 Corner, PP-28 Front Feed, PP-28 Straight Thru General Manual

Technical Manual

Pot, Pan, and Utensil Door-type

Models: PP-28 PP-28 Corner PP-28 Front Feed PP-28 Straight Thru

June, 2004

P. O. Box 4149 Winston-Salem, North Carolina 27115-4149 336/661-1556 Fax: 336/661-1660

Champion Manual P/N 109844 Rev C

2674 N. Service Road

Jordan Station, Ontario, Canada L0R 1S0 905/562-4195 Fax: 905/562-4618

www.championindustries.com

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

Model Number Serial Number

Voltage and Phase

Champion Service Agency Phone

Champion Parts Source Phone

Champion Service:

Champion (USA) Champion (Canada) Phone: 1 (336) 661-1556 Phone: 1 (905) 562-4195

1 (800) 858-4477 1 (800) 263-5798

Fax: 1 (336) 661-1660 Fax: 1 (905) 562-4618

We strongly recommend that you Fax your orders.

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

Machine Data Plate with Model & Serial number located on left side of control cabinet panel.

REVISION HISTORY

Revision Revised Serial Number Comments

Date Pages Effectivity

11/01/02 All First issue of manual and replacement parts 10/13/03 46-47 — Inserted tracks for all models 10/13/03 58-61 J1789 Inserted new piping drawings - moved pressure

gauge after solenoid valve.

06/21/04 48-49 — Corrected part number 314187 to 314185 drain

overflow. Added overflow gaskets and o-rings.

REVISIONS

TABLE OF CONTENTS

CONTENTS

Page

REVISION HISTORY ...................................................................................................................... i

WARRANTY .................................................................................................................................. v

SAFETY SUMMARY...................................................................................................................... vi

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

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

INSTALLATION ............................................................................................................................ 3

Unpacking .......................................................................................................................... 3

Plumbing Connnections ...................................................................................................... 4

Electrical Connections ........................................................................................................ 5

Ventilation Connections ...................................................................................................... 5

Chemical Connections ........................................................................................................ 6

Dishtable Connections ........................................................................................................ 7

Completing Installation ...................................................................................................... 7

OPERATION .................................................................................................................................... 8

Inital Startup ........................................................................................................................ 8

Basic Operation .................................................................................................................. 9

MAINTENANCE ............................................................................................................................ 10

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

Deliming .............................................................................................................................. 12

Lubrication .......................................................................................................................... 12

TROUBLESHOOTING .................................................................................................................. 13

COMPONENTS .............................................................................................................................. 16

Electrical Service ................................................................................................................ 18

Component Replacement .................................................................................................... 25

REPLACEMENT PARTS ................................................................................................................ 35

ELECTRICAL SCHEMATICS ...................................................................................................... 91

LIST OF FIGURES

Figure 1 — Lubrication Points .................................................................................................... 12

Figure 2 — Fuse Blocks .............................................................................................................. 18

Figure 3 — Motor Overload ...................................................................................................... 18

Figure 4 — Wash Pump Timer .................................................................................................... 19

Figure 5 — Final Rinse Timer .................................................................................................... 19

Figure 6 — Dual Float Switch .................................................................................................... 20

Figure 7 — Tank Heat Thermostats ............................................................................................ 21

Figure 8 — Booster Thermostat Locations (Electric) ................................................................ 21

Figure 9 — Booster High Limit Thermostat (Electric) .............................................................. 21

Figure 10 — Vacuum Breaker ...................................................................................................... 25

Figure 11 — Parker Valve Replacement........................................................................................ 26

iii

TABLE OF CONTENTS

Figure 12 — Asco Valve Replacement.......................................................................................... 28

Figure 13 — Line Strainer ............................................................................................................ 29

Figure 14 — Rear View High Limit.............................................................................................. 30

Figure 15 — Tank Element Placement.......................................................................................... 30

Figure 16 — Rear View of Electric Heating Element .................................................................. 30

Figure 17 — Booster High Limit .................................................................................................. 31

Figure 18 Typical 40˚ Rise Booster.......................................................................................... 31

Figure 19 — Typical 70˚ Rise Booster.......................................................................................... 31

Figure 20 — Pump Assembly Breakdown .................................................................................... 33

Figure 21 — Door Switch and Magnet ........................................................................................ 34

Figure 22 — Panels ...................................................................................................................... 36

Figure 23 — Door Assemblies ...................................................................................................... 38

Figure 24 — Cable Pulley Assembly ............................................................................................ 40

Figure 25 — Counterweight System ............................................................................................ 42

Figure 26 — Wash & Rinse Assemblies ...................................................................................... 44

Figure 27 — Track Assembly........................................................................................................46

Figure 28 Drain System............................................................................................................ 48

Figure 29 — Wash Tank Components (Electric Heat) .................................................................. 50

Figure 30 — Steam Coil Tank Heat .............................................................................................. 52

Figure 31 — Steam Coil (Low Pressure) Tank Heat .................................................................... 54

Figure 32 — Scrap Screens & Baskets.......................................................................................... 56

Figure 33 — Piping without Booster ............................................................................................ 58

Figure 34 — Piping with Steam Booster ...................................................................................... 60

Figure 35 — Steam Booster (Mounted under Tank) .................................................................... 62

Figure 36 — Side Mounted Steam Booster ................................................................................ 64

Figure 37 — Low Pressure Steam Booster .................................................................................. 68

Figure 38 — Electric Booster (Mounted under Tank) .................................................................. 70

Figure 9 — Electric Booster 70˚ Rise (Side Mounted) .............................................................. 74

Figure 41 — Pump Assembly........................................................................................................ 78

Figure 42 — Machine Control Panel ............................................................................................ 80

Figure 43 — Machine Control Cabinet ........................................................................................ 82

Figure 44 — Booster Control Cabinet ........................................................................................ 84

Figure 45 — Vent Fan Control Cabinet (Optional) ...................................................................... 86

Figure 46 — Racks ........................................................................................................................ 88

CONTENTS (CONT.)

LIST OF FIGURES

Page

— Side Mounted Booster Cabinet ................................................................................ 76

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.

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.

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.

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 connection wash and rinse arms

provisions • Door safety switch on each door

• Low water tank heat protection • Enclosure panels (front and sides)

• Recessed, front-mounted controls • External lift-out refuse basket

• Six-inch diameter vent connections • Fully automatic wash and rinse cycle

• Hold-down grid • Tank heater (choice of electric, steam

• Ten-inch shelf on front-loading coils or steam injectors)

machines

• Field convertible to corner model

Options & Accessories

• Stainless Steel Booster (interplumbed and intewired)

Steam: 40˚F/23˚C-70˚F/39˚C rise (built in booster) (externally mounted with cover for corner model)

Electric: 40˚F/23˚C rise (built-in)(externally mounted with cover for corner model) 70˚F/39˚C rise (externally mounted with cover)

NOTE:

ALL electric boosters require separate electrical connection.

• Exhaust Fan, 1/3Hp

• Stainless steel rack

Basket Rack P/N 109584 Pan Rack P/N 109585 Utility Rack P/N 109586 Bake Sheet Rack P/N 109587

INSTALLATION

Unpacking

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.

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.

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.

• The machine requires 200 CFM @ 1/4" (SP), [95 Liters/sec].

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.

INSTALLATION

CHEMICAL CONNECTIONS

!! ATTENTION POT AND PAN WASHER OWNER!!

Your pot and pan washer is designed to work best with liquid commer chemicals. 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

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.

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.

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.

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.

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.

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

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.

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

CONDITION CAUSE SOLUTION

Machine will not start Door 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 water Main 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 filling Stuck 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 running Overload protector tripped ................ Reset overload in control box

Defective motor ................................ Contact your service agency

Wash tank water temperature Incoming water temperature

is low when in use at 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

Low steam pressure .......................... Check steam supply pressure

Defective steam trap .......................... Check or replace

Defective solenoid valve.................... Check or replace

TROUBLESHOOTING

CONDITION CAUSE SOLUTION

Insufficient pumped spray Clogged pump intake screen.............. Clean

pressure Clogged spray pipe ............................ Clean

Scrap screen full ................................ Must be kept clean and in place

Low water level in tank...................... Check drain and overflow tube

Pump motor rotation incorrect .......... Reverse connection between L1

and L2 in control cabinet (3 phase only)

Defective pump seal .......................... Contact service agent

Insufficient final rinse or no Faulty pressure reducing valve .......... Clean or replace

final rinse Improper setting on pressure

reducing valve.................................... Set flowing water pressure to 20-22 psi

............................................................ [138-151 kPa]

Clogged rinse nozzle and/or

pipe .................................................... Clean with paper clip/delime

Improper water line size .................... Have installer change to proper size

Clogged ‘Y’ strainer .......................... Clean or replace

Low final rinse temperature Low incoming water ........................ Check the booster (if supplied with machine)

be sure the thermostat is set to maintain 180˚F/82˚C temperature. Check valve to be sure it is clean and operating.

Defective thermometer ...................... Check for proper setting or replace

Poor washing results Detergent dispenser not

operating properly.............................. Contact detergent supplier

Insufficient detergents ...................... Contact detergent supplier

Food Soil concentration too

high in wash tank .............................. Drain tank, clean and refill every 2 hours of

operation or after each meal period. Wash water temperature

too low .............................................. See condition “Wash Tank

Water Temperature” above

Wash arm clogged.............................. Clean

Wash arm not rotating........................ Clean arm. Check bearing, replace if necessary.

Improperly scraped dishes ................ Check scraping procedures

Ware improperly

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

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.

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.

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

• 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

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.

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

ELECTRICAL SERVICE

31L3

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

480V/3 Phase

208-240V/3 Phase

Delta Connection

575V/3 Phase

Delta Connection

Terminal Connections view of element

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

480V/3 Phase

208-240V/3 Phase

Delta Connection

575V/3 Phase

Delta Connection

Terminal Connections view of element

480V/3 Phase

208-240V/3 Phase

Delta Connection

575V/3 Phase

Delta Connection

Terminal Connections view of element

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

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

208-240V/3 Phase

Wye Connection for

380-415V/3 Phase

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