CHAMPION USN10 User Manual

I

The Source
502 Rotary Street
Hampton, VA 23661
Tel: [phone]
1 [phone]
Fax: [phone]

Website: www.thesource2000.net Email:
Equipment Information HQ - Darlene Ehrenfried [e-mail]
Parts Information HQ - Lori Hicks [e-mail]
Service Information HQ - Jim Luther [e-mail]
U.S. Navy POC - Judy Lowman, HQ [e-mail]
U.S. Navy POC - Nigel Pearce, San Diego, C [e-mail]
U.S. Navy POC - Tony Cox, Mayport, FL [e-mail]
U.S. Navy POC - Janet Searls, Norfolk, VA [e-mail]

The Source (San Diego)
2101 Wilson Ave.
National City, CA 91950
Tel: [phone]
Fax: [phone]

The Source (Mayport)
1840 Mealy Street
Atlantic Beach, FL 32233
Tel: [phone]
1 [phone]
Fax: [phone]

2013

TECHNICAL PUBLICATION SHEET

TECHNICAL PUBLICATION SHEET

i

TECHNICAL MANUAL VALIDATION CERTIFICATE

TECHNICAL MANUAL VALIDATION CERTIFICA TE

ii

APPROVAL AND PROCUREMENT RECORD

APPROVAL AND PROCUREMENT RECORD

iii

TECHNICAL MANUAL DEFICIENCY/EVALUATION REPORT (TMDER)

TECHNICAL MANUAL
DEFICIENCY/EVALUA TION REPORT (TMDER)
(Form - NAVSEA 9086/10, REV. 6/85)

iv

8/25/10 50-51 U2769 Revised illustration added note for

supersession of overflow tube and screen

2/20/13 IFC, 45All Updated contact information

10/3/13 47 All Replaced Items 4-6, switches with Kits 900856, 900857

and 900858 respectively.

10/3/13 61 All Pump motor, seal and impleller no longer available

as separate parts, order Item 2 complete motor assembly.
Changed Item 4 to P/N 108629, Item 7 to P/N 115374

vii

SAFETY SUMMARY

SAFETY SUMMARY

Safety Symbols

• The following symbols appear throughout this manual alerting you to potential hazards. S tatements

associated with each symbol are printed in italics.

WARNING:

CAUTION:

!

Warning statements indicate any condition or practice that could result in
result in personal injury or possible loss of life.

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 dishwasher may be an electric or steam heated machine using hot water
to clean and sanitize a variety of wares. Machine surfaces and wares become hot during and immedi­ately following normal operations. Consult your supervisor and wear protective gear as directed to
avoid possible injury.

• Your dishwasher contains rotating spray arms.
Use caution when working around the dishwasher especially when loading or unloading wares.

• Operators must NOT bypass a safety interlock or control to operate the dishwasher.

• 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.

YLLL

SAFETY SUMMARY

Warning and Caution Statement Listing

• The following listing gives the page number and text of all the warning and caution statements that appear
in this manual.

Warning Statements

Pg. 6- The installation of this unit must conform to local codes or, in the absence of local codes, to the National

Electrical Code and all National Codes governing plumbing, sanitation, safety and good trade practices.

Pg. 8- The installation of water supplies must conform to local codes or, in the absence of local code, all National

Codes governing plumbing, sanitation, safety and good trade practices.

Pg. 8- The installation of steam supplies must conform to local codes or, in the absence of local code, all National

Codes governing plumbing, sanitation, safety and good trade practices.

Pg. 10- The installation of drains must conform to local codes or, in the absence of local code, all National Codes

governing plumbing, sanitation, safety and good trade practices.

Pg. 10- The installation of ventilation must conform to local codes or, in the absence of local code, all National Codes

governing plumbing, sanitation, safety and good trade practices.

Pg. 11- The installation of electrical supplies and controls must conform to local codes or, in the absence of local

codes, the National Electrical Code and good trade practices.

Pg. 11- Dangerous voltages are present at the local electrical distribution system.

Dangerous voltages are present at the dishwasher when it is connected to the local electrical distribution
system.

Pg. 11- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch

to indicate work is being done on that circuit.

Pg. 12- The installation of electrical supplies and controls must conform to local codes or, in the absence of local

codes, the National Electrical Code and good trade practices.

Pg. 12- Dangerous voltages are present at the local electrical distribution system.

Dangerous voltages are present at the dishwasher when it is connected to the local electrical distribution
system.

Pg. 12- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch

to indicate work is being done on that circuit.

Pg. 19- Dangerous voltages are present at the local electrical distribution system.

Dangerous voltages are present at the dishwasher when it is connected to the local electrical distribution
system.

Pg. 19- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch

to indicate work is being done on that circuit.
Pg. 20- Perform the following checks before placing the machine into service for normal operation.
Pg. 20- Never bypass a safety device in order to operate the dishwasher for normal operation.
Pg. 22- Perform the following checks before placing the machine into service for normal operation.

L[

SAFETY SUMMARY

SAFETY SUMMARY (Cont.)

Warning Statements (Cont.)

Pg. 22- Never bypass a safety device in order to operate the dishwasher for normal operation.
Pg. 23- Dishwasher surfaces, dishracks and wares become hot during and immediately after washing operations.

Wear protective gear per your supervisor's directions.

Pg. 24- Dishwasher surfaces, dishracks and wares become hot during and immediately after washing operations.

Wear protective gear per your supervisor's directions.

Pg. 27- Deliming solutions or other acids must not come in contact with household bleach (sodium hypochlorite) or

any chemicals containing chlorine, iodine, bromine, or fluorine.
Mixing will cause hazardous gases to form.

Skin contact with deliming solutions can cause severe irritation and possible chemical burns.
Pg. 27- Consult your chemical supplier for an appropriate deliming solution, protective gear and safety procedures.
Pg. 28- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch

to indicate work is being done on that circuit.
Pg. 29- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch

to indicate work is being done on that circuit..
Pg. 35- When working on the dishwasher, disconnect the electric service and place a red tag at the disconnect switch

to indicate work is being done on that circuit
Pg. 35- Use Extreme Caution when performing tests on energized circuits.

[

SAFETY SUMMARY

SAFETY SUMMARY (Cont.)

Caution Statements

Pg. 5- Check piping mounted underneath dishwasher before lifting to avoid damaging the machine.
Pg. 6- Check piping mounted underneath dishwasher before lifting to avoid damaging the machine.
Pg. 18- Perform the following checks before placing the machine into service.
Pg. 26- Do not hose down the exterior of the machine with water.
Pg. 28- Only qualified service personnel should perform preventive maintenance on the dishwasher.
Pg. 29- Only qualified service personnel should perform preventive maintenance on the dishwasher.
Pg. 35- Only qualified service personnel should perform preventive maintenance on the dishwasher.

-

[L

LIMITED WARRANTY

UNITED STATES NAVY LIMITED WARRANTY

Champion Industries Inc. (herein referred to as Champion), P.O. Box 4149, Winston-Salem, North Carolina 27115,
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 to be free from defects in material and workman
ship 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, how
ever, 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 at a ship's homeport located within the continental
United States. 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.

DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY. CHAMPION'S WARRANTY
IS ONLY TO THE EXTENT REFLECTED ABOVE. CHAMPION MAKES NO OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED, TO ANY WARRANTY OF
MERCHANTABILITY, OR FITNESS OF PURPOSE. CHAMPION SHALL NOT BE LIABLE FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES. THE REMEDIES SET OUT ABOVE ARE
THE EXCLUSIVE REMEDIES FOR ANY DEFECTS FOUND TO EXIST IN CHAMPION DISHWASHING
MACHINES AND CHAMPION PARTS, AND ALL OTHER REMEDIES ARE EXCLUDED,
INCLUDING ANY LIABILITY FOR INCIDENTALS OR CONSEQUENTIAL DAMAGES.

[LL

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.

Electrical Power Requirements (Steam Heat)

Connections Between Dishwasher and Booster (Steam Only)

Steam and Condensate Connections (Steam Heat Only)

3.2.1 Control Cabinet

Final Rinse (Steam) Thermostat Adjustment and Replacement

Fuses and Fuse Block Replacement

Electric Tank Heat Assembly (Prior to S/N G3599)
Electric Tank Heat Assembly (After S/N G3600)
Electric Tank Heat Assembly (After S/N U2769)

Control Cabinet (Prior to S/N G3599)

No.180 Steam Booster and Steam Piping Assembly

TABLE OF CONTENTS

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xvi

PART 1: GENERAL SPECIFICATIONS

PART 1: GENERAL SPECIFICATIONS

Welcome to Champion...

and thank you for allowing us to take care of your dishwashing needs.

1.1 About this Manual

All information, illustrations and specifications contained in this manual are based upon the
latest product information available at the time of publication. Champion constantly im­proves its products and reserves the right to make changes at any time or to change specifica­tions or design without notice and without incurring any obligation.

Manual Organization

This manual is divided into eight parts:

→ Part 1, General Specifications, introduces this manual and the dishwasher in general.

→ Part 2, Installation, discusses the installation of the dishwasher and describes the

connection of utilities and services.

→ Part 3, Operation, discusses theory of operation, operator controls, initial start up and

shutdown procedures.

→ Part 4, Maintenance and Cleaning, discusses lubrication, preventive maintenance,

cleaning and deliming.

→ Part 5, discusses basic troubleshooting and service procedures.

→ Part 6, discusses replacement parts procurement and provides parts diagrams and

parts lists.

→ Part 7, contains the dishwasher electrical schematic.

→ Part 8, contains special inserts and late breaking information.

1.2 Model Numbers
USN-10

The USN-10 series is a undercounter high temperature (180°F/82°C rinse) sanitizing dish­washer. This model features electric or steam heat with booster.

The USN-10 is as front loading door model.

The USN-10 comes in the following model::

USN-10: 440V/60/3 Electric heat or Steam heat @ 15 PSI flow pressure

1

Two electrical connections

Single Point Electrical Connection:
USN-10 440/60/3 70°F (E) 26 Amps 40 Amps

Two-Point Electrical Connection: Machine
USN-10 440/60/3 6 Amps 15 Amps
Two-Point Electrical Connection: Booster
USN-10 440/60/3 70°F (E) 20 Amps 25 Amps

PART 2: INSTALLATION

PART 2: INSTALLA TION

In This Part—

• Unpacking the dishwasher

• Making Utility Connections

2.1 Unpack the Dishwasher

NOTE:

The installation of your dishwasher must meet all applicable health and safety codes
and conform to good trade practice.

Your USN-10 was completely assembled, inspected, and thoroughly tested at our factory
before shipment to your installation site.

• The dishwasher with booster are shipped on a single pallet.

• The booster is connected to the dishwasher.

Perform the following steps to unpack the dishwasher:

1. Remove protective wrap and hold downs from the pallet.

2. Inspect for any shipping damage. If damage is found, save the packing material
and contact the carrier immediately.

3. Check the interior of the dishwasher for the following items stowed inside:

- 1 set of flanged feet

- 1 set of dishracks

- Warranty information packet

CAUTION:

!

Check piping mounted underneath dishwasher before lifting to avoid damaging the
machine.

5

PART 2: INSTALLATION

2.2 Permanent Placement

Perform the following steps to place the dishwasher in its permanent location.

1. Before moving the sections into position, inspect the location site to ensure the electrical,
plumbing, and ventilation services 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.

!

2. Lift the dishwasher and replace the adjustable legs with flanged mounting feet provided.

3. Position dishwasher in its permanent location.

4. Level the dishwasher front to back and side to side by turning the adjustable feet.

5. Position the external booster heater at the unload end of the dishwasher.

6. Mount control cabinet to location nearest machine (if applicable).

7. Install deck plates and bolt dishwasher and booster to deck per standard procedures.

CAUTION:

Check piping mounted underneath dishwasher before lifting to avoid damaging the machine.

Make sure the load and unload openings align with the table system height.

Check alignment of common plumbing connections between booster and dishwasher.

2.3 Connections between the dishwasher and booster
(Steam Only)

WARNING:

The installation of this unit must conform to local codes or, in the absence of local codes,
to the National Electrical Code and all National Codes governing plumbing, sanitation,
safety and good trade practices.

Connect the plumbing and electrical connections between the dishwasher and booster heater.

1. Connect the 1/2" condensate union from the dishwasher to the booster.

2. Connect the 3/4" steam union from the dishwasher to the booster. .

3. Connect the 3/4" water line from the booster to the top of the dishwasher at the
vacuum breaker.

4. Pull the electrical conduit and harness from the junction box located on the lower
rear corner of the dishwasher to the booster junction box located on the lower left rear leg
of the booster stand.

5. Match the harness wire numbers to the booster junction box wiring.

6

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PART 2: INSTALLATION

2.4 Water Connections

Perform the following steps to connect the water supply

WARNING:

The installation of water supplies must conform to local codes or, in the absence of local
code, all National Codes governing plumbing, sanitation, safety and good trade practices.

1. Connect a 3/4" NPT hot water supply line (140°F minimum) to the water inlet valve located
at the booster.

2. Connect a 3/4" NPT hot water line (140°F minimum) to the water inlet valve located at the
rear of the dishwasher.

2.5 Steam and Condensate Connections (Steam heat only)

Perform the following steps to connect the steam supply and condensate return.

WARNING:

The installation of steam supplies must conform to local codes or, in the absence of local
code, all National Codes governing plumbing, sanitation, safety and good trade practices.

NOTE

A manual shut-off valve for steam (supplied by others) should be installed in the supply
lines to allow for servicing of the machine. The shut-off valve should be the same size or l
larger than the supply line.

1. Connect a steam supply line to the line strainer located at the booster.

2. Connect a steam condensate line to the tee fitting located at the booster.
Condensate must be gravity return to the boiler or to a pumping trap.

8

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1. The USN-10 undercounter dishwasher does not require a ventilation connection.

2.8 Electrical Connections

Perform the following steps to connect the electrical supply.

WARNING:

The installation of electrical supplies and controls must conform to local codes or, in the

absence of local codes, the National Electrical Code and good trade practices.

WARNING:

Dangerous voltages are present at the local electrical distribution system.
Dangerous voltages are present at the dishwasher when it is connected to the
local electrical distribution system.

WARNING:

When working on the dishwasher, disconnect the electric service and place a tag at the
disconnect switch to indicate work is being done on that circuit.

PART 2: INSTALLATION

1. A qualified electrician must compare the electrical power supply with the machine electrical
specifications stamped on the MACHINE ELECTRICAL CONNECTION PLATE located
inside the control cabinet before connecting to the incoming service through a fused disconnect

switch.

2. Locate the dishwasher main electrical junction box for the machine.
The box is located either to the left or right of the dishwasher (depending on how the machine
was originally ordered from the factory).

3. Controls must be easily accessible to the operator.

4. Install the power supply wires from the local distribution panel to the control cabinet
at the incoming power terminal block.

5. Refer to Part 3.3, Start up procedure to test the installation.

11

PART 2: INSTALLATION

2.9 Chemical Connections

Perform the following steps to connect the chemical dispensing equipment (supplied by others).

WARNING:

The installation of electrical supplies and controls must conform to local codes or, in the
absence of local codes, the National Electrical Code and good trade practices.

WARNING:

Dangerous voltages are present at the local electrical distribution system.
Dangerous voltages are present at the dishwasher when it is connected to the
local electrical distribution system.

WARNING:

When working on the dishwasher, disconnect the electric service and place a tag at the
disconnect switch to indicate work is being done on that circuit.

1. Chemical dispensing signal connection points are provided in the control cabinet.

2. The detergent signal is limited to a maximum load of 1 Amp. Signal voltage is 120VAC.

3. The Rinse aid signal is limited to a maximum load of 1 Amp. Signal voltage is 120VAC.

4. Sanitizer is not required for the USN-10 dishwasher.

5. The rinse aid injection point is located in the upper final rinse piping of the dishwasher.

6. The chemical equipment installer must cut a hole in the wash tank for a detergent
sensor and a detergent injection point.

12