Champion Power Equipment PP-3 User Manual
Technical Manual
Taskmaster
Power Wash Sink System
Model
PP-3
Machine Serial No.
P.O. Box 4149 2674 N. Service Road
Winston Salem, NC 27115-4149 Jordan Station, Ontario, Canada L0R 1S0
336/661-1556 Fax:: 336/661-1660 905/562-4195 Fax: 905/562-4618
www.championindustries.com
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Intentionally
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USER MANUAL
Operation & Installation Guide
Champion Industries
PO Box 4149
Winston Salem, NC 27115
336/661-1556
www.championindustries.com
T ABLE OF CONTENTS
NOTES.......................................................................................ERROR! BOOKMARK NOT DEFINED.
INITIAL START UP...........................................................................................................................6
FILL TANKS WITH WATER...................................................................................................................6
ADD SOAP / CHEMICALS .....................................................................................................................6
APPROVED CHEMICALS.......................................................................................................................7
OPERATION INSTRUCTIONS........................................................................................................8
PRE-SCRAPPING ..................................................................................................................................8
LOADING WASH TANK........................................................................................................................8
Pots and Pans..................................................................................................................................8
Utensils and Silver Ware.................................................................................................................9
Sheet Pans.......................................................................................................................................9
START THE WASH CYCLE....................................................................................................................9
UNLOAD WASH TANK....................................................................................................................... 10
NOTES.............................................................................................................................................11
CONTROL PANELS........................................................................................................................12
IDENTIFYING YOUR CONTROL PANEL ................................................................................................12
STANDARD CONTROL CENTER ......................................................................................................13
Mylar Buttons................................................................................................................................13
Mylar Indicator Lights.................................................................................................................. 14
Basic Operation ............................................................................................................................14
Advanced Operation......................................................................................................................15
Changing Temperature Set Point................................................................................................................15
Supervisor Mode ................................................................................................................ ........................15
Setup Mode – OP.S.......................................................................................................................................15
Configuration Mode –Cn F...........................................................................................................................16
Loading Celsius or Fahrenheit Tables........................................................................................................17
Display Software Version...........................................................................................................................18
Alarms........................................................................................................................................................18
Display Sheath Temperature.......................................................................................................................18
Reset Change Water...................................................................................................................................18
Display Lamp Test......................................................................................................................................18
Temperature Sensor Fault...........................................................................................................................18
Timer Operation.........................................................................................................................................19
Keypad Operation.......................................................................................................................................19
Wire Diagrams..............................................................................................................................20
STANDARD – 208V..................................................................................................................................20
STANDARD – 480V..................................................................................................................................21
Operational Details and Engineering Diagram............................................................................22
Operation Modes...........................................................................................................................23
Fill State .....................................................................................................................................................23
Run State ....................................................................................................................................................23
Drain State..................................................................................................................................................23
Drain State..................................................................................................................................................24
Stop State....................................................................................................................................................24
AL2 State....................................................................................................................................................24
Trouble Shooting...........................................................................................................................25
DELUXE CONTROL CENTER............................................................................................................26
Display.......................................................................................................................................... 26
Mylar Buttons................................................................................................................................26
Cycle Buttons .............................................................................................................................................26
Stop Button.................................................................................................................................................27
Language Buttons .......................................................................................................................................27
Up/Down Buttons.......................................................................................................................................27
Mylar Indicator Lights................................................................................................................................28
Basic Operation ............................................................................................................................28
Time Display.................................................................................................................................29
Wash Cycles.................................................................................................................................. 29
Change Settings..........................................................................................................................................29
Step Duration..............................................................................................................................................30
Step Temperature........................................................................................................................................30
Step Pump Speed........................................................................................................................................30
Step Soap Quantity.....................................................................................................................................31
System States.................................................................................................................................31
Power up State............................................................................................................................................31
Off State .....................................................................................................................................................32
Wash State..................................................................................................................................................32
Hold/Clean State.........................................................................................................................................33
Additional System Features...........................................................................................................33
Internal Buzzer ...........................................................................................................................................33
Soap Injection Algorithm ...........................................................................................................................33
Soap Level Detection..................................................................................................................................34
Dry Fire Detection......................................................................................................................................34
Change Water Feature................................................................................................................................34
Auto-Drain / Fill.........................................................................................................................................35
Manual Drain..............................................................................................................................................35
Sanitize Tank..............................................................................................................................................35
Diagnostics ...................................................................................................................................35
Temperature Probe Error............................................................................................................................36
External DC Error.......................................................................................................................................36
Omron Messages........................................................................................................................................36
Omron Inverter Control................................................................................................................37
Low Level programming...............................................................................................................37
Temperature Units......................................................................................................................................38
Low Speed Frequency................................................................................................................................38
Medium Speed Frequency..........................................................................................................................38
High Speed Frequency................................................................................................................................38
Hold Pump Speed.......................................................................................................................................38
Hold Temperature.......................................................................................................................................39
Soap Minimum........................................................................................................................................... 39
Soap Intermediate .......................................................................................................................................39
Soap Maximum ..........................................................................................................................................39
Sanitize Soap..............................................................................................................................................39
Sanitize Heater Temperature......................................................................................................................40
Buzzer Time...............................................................................................................................................40
Key Press Buzzer Volume..........................................................................................................................40
Dry Fire Period...........................................................................................................................................40
Dry Fire Duty.............................................................................................................................................40
Dry Fire Threshold.....................................................................................................................................41
Change Water Time....................................................................................................................................41
Drain Time .................................................................................................................................................41
Fill Time.....................................................................................................................................................41
Operational Details and Engineering Diagram............................................................................42
Wire Diagrams..............................................................................................................................43
DELUXE – 208V w/Communications.......................................................................................................43
DELUXE – 480V w/Communications.......................................................................................................43
DELUXE – 480V w/Communications.......................................................................................................44
Wash Cycle Defaults.....................................................................................................................45
NOTES.............................................................................................................................................47
INSTALLATION..............................................................................................................................48
PRE-INSTALLATION........................................................................................................................... 48
PLACEMENT ......................................................................................................................................48
PLUMBING REQUIREMENTS...............................................................................................................49
ELECTRICAL REQUIREMENTS............................................................................................................49
WARRANTY INFORMATION......................................................................................................50
WARRANTY.......................................................................................................................................50
NOTES.............................................................................................................................................51
MAINTENANCE..............................................................................................................................52
ROUTINE MAINTENANCE ..................................................................................................................52
Heater ...........................................................................................................................................52
Wash Tank.....................................................................................................................................52
REPLACING HEATER .........................................................................................................................52
REPLACING THERMOCOUPLE ............................................................................................................53
REPLACING STANDARD ELECTRONICS ..........................................................................................54
REPLACING DELUXE CONTROLLER ................................................................................................55
REPLACING PUMP .............................................................................................................................56
REPLACING SOAP PUMP....................................................................................................................57
PARTS LIST......................................................................................................................................58
Heater / Thermocouple .................................................................................................................58
Soap Pump / STANDARD / DELUXE...........................................................................................59
Water Pump ..................................................................................................................................60
NOTES.............................................................................................................................................64
START UP
p
INITIAL ST ART UP
Fill T anks with Water
¾ WASH TANK – Fill wash tank with hot water to the marked Fill Line. The water
temperature ought to be approximately
110˚ to 120˚ F (43˚ to 49˚ C).
¾ RINSE TANK – If equipped, fill the rinse
tank with hot water to the marked Fill Line.
The water temperature ought to be
approximately 75˚ to 80˚ F (24˚ to 27˚ C).
¾ SANITIZE TANK – If equipped, fill the
sanitize tank with hot water to the marked Fill Line. The water temperature ought to
be approximately 75˚ to 80˚ F (24˚ to 27˚ C).
Add Soap / Chemicals
¾ WASH TANK – If your unit is equipped
with the soap injection option, then make
sure that the soap pump pick up tube is
inserted into the soap container. The soap
will automatically be injected into the
wash tank. Otherwise, manually add the
soap into the wash tank.
¾ SANITIZE TANK – If equipped, add
the appropriate sanitizing chemical to the
sanitize tank. Consult your local health
code.
Soap Pum
6
START UP
Approved Chemicals
It is recommended that chemicals that are low to non foaming, metal safe, and noncaustic be used in the wash and sanitize tank.
Caustic chemicals are capable of burning, corroding, or destroying living tissue and
should not be used. If you plan on using caustic chemicals, then a rolling lid is required.
If your unit did not come with a rolling lid, one can be ordered from the factory.
Contact information is provided on the inside cover of this manual.
WARNING
- Chemicals used in the wash tank that do not have de-foaming
capabilities will not run properly and could damage the machine. Consult your chemical
manufacturer before use.
WARNING
– Chemical Hazard - could result in serious injury or death. Always consult
with your chemical manufacturer and read all warning labels before handling new
chemicals.
7
OPERATION INSTRUCTIONS
OPERA TION
INSTRUCTIONS
Pre-Scrapping
It is recommended that any loose or excess soils be
removed from the item to be washed prior to
placing it into the wash tank. This will ensure a faster
and more efficient cleaning operation and will also
cut down on the number of times that the water will
have to be changed.
This pre-scrapping process should be done in the
scrapping sink. If your unit does not include a
scrapping sink, then you can typically scrap into a
waste area close to the wash tank.
Loading Wash T ank
Pots and Pans
Pots, pans, mixing bowls, etc. can be placed into the
wash tank in any order.
NOTE – Pots and Pans that are stacked or nested
together during the wash cycle will not be cleaned
properly. Pause the cycle and move them apart from
one another.
8
OPERATION INSTRUCTIONS
Utensils and Silver Ware
Utensils and Silver Ware must be placed in a utensil basket.
If your unit was not supplied with a utensil basket, one can
be ordered from the factory. Contact information is
provided on the inside cover of this manual.
To use the utensil basket, simply hang the basket over the
side of the wash tank, place the utensils and silver ware in
the basket, and run a wash cycle.
WARNING
– Never load sharp objects or silver ware into
the machine. This could cause serious bodily injury.
Sheet Pans
Some simple steps must be followed when washing sheet pans to ensure that proper
cleaning can be achieved.
If your unit was supplied with a sheet pan rack, place the rack into the wash tank in a vertical
position (opening on top). Load the rack with sheet pans, and then pivot the rack to a
horizontal position.
To load sheet pans without the rack, insert the sheet pans into the wash tank one at a time
with the baking side up. Place the pans in an opposite or alternating crisscross pattern, so as
not to have them stacked inside of each other.
It is recommended that 10 to 12 pans be placed in the wash tank during a wash cycle.
If your unit did not come with a sheet pan rack, one can be ordered from the factory.
Contact information is provided on the inside cover of this manual.
Start the Wash Cyc le
After the wash tank has been loaded, press the cycle start button. Which button you press
will be determined by which controller that has been installed on your unit. See the section
on controllers for more details.
9
OPERATION INSTRUCTIONS
Unload Wash T ank
The display will indicate that the items are clean when a
wash cycle has been completed. At this time the system
will switch to a holding cycle. This cycle has slower water
movement that will keep grease and soiled sediments
from falling back onto the items that were just cleaned.
Remove the clean items from the wash tank and dip into
the rinse tank to rinse off any soap or soiled residue.
Place items into the sanitize tank. When done soaking in
the sanitize tank, remove item and allow to air dry.
10
OPERATION INSTRUCTIONS
NOTES
11
CONTROL PANELS
Control Panels
Identifying your control panel
There are two types of control panels used, the STANDARD and the DELUXE. Your
control box type is printed on the front cover. Use the diagrams below to determine which
control box you have.
control box you have.
the diagrams below to determine which
STANDARD CONTROL CENTER
DELUXE CONTROL CENTER
Champion
12
CONTROL PANELS
ST ANDARD Co ntrol Center
Mylar Buttons
115
¾
Temp Button
, press to set or display the wash tanks
running temperature. When pressed, the display will
toggle between sp and 115 (115 represents a temperature
set point value and may be different from your display),
at this time you can press the Up and Down Arrow keys
to change the set point temperature. Once changed, press
the Temp button again to lock in the new value.
¾
Down Arrow Button
, pressing this button, while not in
the temperature set point mode, will display the time
remaining before a mandatory water change. Pressing this
button while in the temperature set point mode, will
lower the temperature set point setting.
UP Arrow Button
¾
, pressing this button, while in the
temperature set point mode, will raise the temperature set
point value. Pressing this button while in the wash mode
will display the heaters sheath temperature.
¾
Start / Stop Button
and off the circulation pumps.
13
, pressing this button will toggle on
CONTROL PANELS
Mylar Indicator Lights
The heater light will illuminate whenever the wash
tank’s heater is powered on.
The alarm light will illuminate whenever an alarm has
occurred.
The change water indicator light will flash when it is
time to change water. The display will show drn.
The soap indicator light will illuminate whenever the
soap pump is powered on.
Basic Operation
When you first power up to use your wash tank, the display will show fil, fill the wash tank
to the water fill line (see the INITIAL START UP section).
Once the tank has been filled, press the Start/Stop button to start the continuous wash cycle.
Soap will be dispensed automatically into the wash tank.
During the wash operation, the display will show current water temperature and the heater
light will cycle on and off as the heater is maintaining the preset water temperature.
The Start/Stop button can be used to toggle on and off the circulation pumps. During a
pause state, the heater is still in operation and maintaining the water temperature.
After a certain amount of time, the water is considered dirty and the circulation pumps will
turn off, the display will show drn, and the change water indicator light will flash.
Note
: Pressing the down arrow key will display the time remaining before a water change is required.
After the water has been drained, the display will show fil. You are now ready to start
another wash cycle.
14
CONTROL PANELS
Advanced Operation
Changing Temperature Set Point
The temperature set point is the water temperature setting for the wash tank and is the only
parameter that can be set by the operator. If the TEMP button is pressed once, the display
will switch back and forth from sp and 115 (115 represents the temperature setting and may
be different from your display).
Use the UP or DOWN buttons to change the temperature setting. Once set, press the
TEMP button to lock in the new value.
NOTE:
If no key is pressed within three seconds, then your display will revert back to the way it was before
the TEMP button was pressed. If the temperature setting was changed and the TEMP button was not
pressed, then the temperature setting will remain unchanged.
Supervisor Mode
The supervisor mode can be accessed by holding the TEMP and START/STOP buttons
simultaneously for 3 seconds. The display will toggle opr and op.b. Pressing the UP or
DOWN buttons will toggle between “op.b”, “op.s”, “cpi.”, and “cnf.”.
To exit the supervisor mode, press the UP or DOWN buttons until op.b is displayed, then
press the TEMP button.
NOTE
: You may need to hold the TEMP and START/STOP buttons in
for 3 seconds to get to the menu.
Setup Mode –
ΟΠ.Σ
Enter the supervisor mode and press the UP or DOWN buttons until op.s is displayed. Press
the TEMP button to select.
When prompted for a password (pss), use the UP and DOWN buttons to select 55. Press
the TEMP button to enter in the value.
Press the TEMP button to toggle between the parameters that are available, see parameter
table below.
The parameter name and its value will be swapped in and out of the display. Press the UP
and DOWN button to change the parameters value. Once a value has been changed, press
the TEMP key to lock in this value and move on to the next parameter. If you do not press
the TEMP key within three seconds after changing a parameters value, the new value will
not be saved.
Exit the supervisor mode when done with the setup mode.
NOTE:
See Supervisor Mode section
on how to exit.
15
CONTROL PANELS
Parameter
Mnemonic
sp
t
t2
t3
Al.1
Hs.1
Al..2
Hs..2
hs
rl
rh
Setup Mode Parameter Table
Parameter
Name
Setpoint Temperature Set Point
Timer 1
Timer 2
Timer 3 Soap Dispensing Time
Alarm 1 Alarm 1 Set Point
Hysteresis Alarm 1 Hysteresis
Alarm 2 Alarm 2 Set Point
Hysteresis
Hysteresis On/Off Hysteresis
Range
Low
Range
High
Description
Change Water Cycle
Time
Soap Dispensing Delay
Time
Alarm 2 Hysteresis
Set Point Low Limit
Set Point High Limit
Table 1 Default
Value
(Celsius)
Table 2 Default
Value
(Fahrenheit)
46ºc 115 ºF
4.00 4.00
2.00 2.00
0.30 0.30
107 ºc
225
ºF
0.1 0.1
72 ºc 160 ºf
0.1 0.1
0.1 0.1
38 ºc 100 ºf
52 ºc 125 ºf
Units
Degrees
H:MM
M:SS
M:SS
Degrees
%
Degrees
%
%
Degrees
Degrees
Configuration Mode –
cnf
Enter the supervisor mode and press the UP or DOWN buttons until cnf is displayed.
Press the TEMP button to select.
When prompted for a password (p55), use the UP and DOWN buttons to select 415. Press
the TEMP button to enter in the value.
Press the TEMP button to toggle between the parameters that are available, see parameter
table below.
The parameter name and its value will be swapped in and out of the display. Press the UP
and DOWN button to change the parameters value. Once a value has been changed, press
the TEMP key to lock in this value and move on to the next parameter. If you do not press
the TEMP key within three seconds after changing a parameters value, the new value will
not be saved.
Exit the supervisor mode when done with the setup mode.
NOTE:
See Supervisor Mode section
on how to exit.
16
CONTROL PANELS
Parameter
Mnemonic
P 1
P 2
P 3
P 4
P 5
P 6
P 8
P11
P1 2
P22
P23
P25
P33
P35
P36
Configuration Mode Parameter Table
Description
Input table
Low scale range of sensors
High scale range of sensors
Output 1 control action
Output 2 function
Output 2 alarm type
Alarm 1 standby function
Auto-ranging display
Filter sensor values
Output 3 function
Output 3 alarm type
Alarm 2 standby function
Access to op.5 mode
Access to cnf mode
Access to I .cl mode
Table 1
Default
Value
(Celsius)
Table 2 Default
Value
(Fahrenheit)
2 10
0 ºc 0 ºf
282 ºc 540 ºf
reu reu
1 1
h.r. h.r.
Off Off
Off Off
On On
1 1
h.r. h.r.
Off Off
55 55
415 415
415 415
Units
Degrees
Degrees
Loading Celsius or Fahrenheit Tables
The controller contains two default parameter tables. Table 1 is used for Celsius operation,
and Table 2 is used for Fahrenheit.
To load one of the default tables, enter the configuration mode (See instructions listed in the
Configuration Mode – cnf section listed above). When cnf is displayed, press both the UP
and DOWN buttons simultaneously. The display will show d l.f. Press the UP or DOWN
buttons to display d l.1 for table 1 (Celsius), or d l.2 for table 2 (Fahrenheit).
Press the TEMP key to enter in your selection. The display will show d l.t . This indicates
that the loading procedure has been initiated and after approximately 1 second, the loading
will be finished and the display will revert back to cnf.
Exit the supervisor mode when done.
NOTE:
See Supervisor Mode section on how to exit.
17
CONTROL PANELS
Display Software Version
To display the software version, enter the configuration mode (See instructions listed in the
Configuration Mode – cnf section listed above). When cnf is displayed, press the DOWN
button. The software version number will be displayed and should look something like
d.17.
Press the DOWN arrow key again to return back to the cnf display.
Exit the supervisor mode when done.
Alarms
NOTE:
See Supervisor Mode section on how to exit.
Alarm 1 is associated with the heater’s sheath temperature, and is triggered when the
temperature rises above the value set in al.1 (see chart above).
Alarm 2 is associated with the wash tanks water temperature, and is triggered when the
temperature rises above the value set in al.2 (see chart above).
When one of these alarms is activated, the circulation pump will turn off and the alarm
indicator light will be illuminated. The controller will enter the fil state.
Display Sheath Temperature
During normal operation, pressing the UP button will display the heater’s sheath
temperature. The sheath temperature will be displayed for about six seconds and then switch
back to the original display that was shown before the UP button was pressed.
Reset Change Water
The Change Water flag is cleared whenever the heaters sheath temperature rises above its set
point. In the case of a heater failure this flag cannot be reset automatically. To manually reset
this flag you will need to hold down the UP button and START/STOP button
simultaneously for approximately 15 seconds. The controller will then enter the fil state.
Display Lamp Test
A lamp test can be started by pressing the DOWN and TEMP buttons simultaneously.
During the lamp test, the controller functions normally, but all display segments and status
lights flash. Pressing the DOWN and TEMP buttons again will return back to the normal
operation display.
Temperature Sensor Fault
If the water or heater sheath temperature sensors should fail, the controller will indicate the
fault by taking the controller to the fil state. The alarm light will be on, the heater will be
disabled, and the circulation pump will be off.
After the sensor(s) have been replaced, normal operation is resumed by exiting the fil state.
18
CONTROL PANELS
N
:
Timer Operation
The change water timer (t) will retain its current count when the washer is stopped or when
power has been disconnected from the controller.
The soap delay timer (t2) allows for a delay before soap is dispensed into the wash tank.
This will allow the soap to be added to a wash tank when it is full of water and the
circulation pumps are running.
The soap dispensing timer (τ3) determines the time for soap dispensing. A time of 0.00 will
bypass the soap dispensing process.
Keypad Operation
Used to decrement or modify a parameter value, or to show the software version when in configuration/calibration mode.
Used to decrement or modify a parameter value, or to show the software version when in configuration/calibration mode.
Used to increment or modify a parameter value, or to show the heater sheath temperature
Used to scroll the display to the next parameter and to store a modified parameter value
Used to cycle the circulation pumps and to restart the washer after a change water cycle has been completed
+
+
+
Used to bypass the change water status, this resets the change water timer and advances the controller
to the fil state.
Used to enable / disable the display lamp test.
Used to access the supervisor mode.
Note
: Buttons must be pressed in the order shown, and held for roughly 15 seconds.
OTE
Buttons must be pressed in the order shown.
NOTE
: Buttons must be pressed in the order shown, and held for roughly 3 seconds.
19
CONTROL PANELS
Wire Diagrams agrams
STANDARD – 208VSTANDARD – 208V
INCOMING POWER
208 VOLT 3 PHASE
LINE 3
30 AMP
LINE 1
LINE 2
30 AMP
GROUND
30 AMP
Pump
2T1
4T2
1L1
3L2
2T1
4T2
15 AMP
15 AMP
#2
Pump
#1
Soap Pump
2T1
4T2
6T3
L3
A1
5
T3
A2 A2
6
6T3
MT03M
1L1
2T1
MT03M
L3
A1
5
3L2
T3
A2 A2
4T2
6
Heater
MC1A 10E
L3
A1
1L1
3L2
5
1
2
POWER
100/240VAC
3
SUPPLY
OUTPUT 2
1L1
4
CIRCULATION
PUMPS
MC1A 10E
1
K1A Z361403GE
2
SSR
3+
TYPE K
THERMOCOUPLE
RVDA/6V25
4-
Water T emp. Sensor
Temp. Sensor
Heater Sheath
9
11
10
- (RED)
+ (YELLOW)
+ (YELLOW)
INPUTS
L3
A1
3L2
5
1 AMP
7
5
6
SOAP
OUTPUT 3
8
-
+
DISPENSER
OUTPUT 1
HEATER
20
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