Moyer Diebel 401-HTM2-PLUS Service Manual

Simply Engineered Better

Technical Manual

Undercounter Dishwasher

Model

401-HTM2 PLUS 401-HTNM2 PLUS 401-LTM2 PLUS

Manual

P/N 0510645

September, 2003

2674 N. Service Road Jordan Station, Ontario, Canada L0R 1S0

Moyer Diebel, Ltd.

Fax: 905/562-4618905/562-4195

Machine Serial No.

CONTENTS

Page

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

WARRANTY .............................................................................................................................................. 2

GENERAL .................................................................................................................................................. 3

INSTALLATION ........................................................................................................................................ 5

Unpacking ............................................................................................................................................ 5

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

Plumbing Connections ......................................................................................................................... 6

Detergent .............................................................................................................................................. 6

Rinse-Aid ............................................................................................................................................. 6

Chemical Sanitizer ............................................................................................................................... 6

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

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

Operation Summary ............................................................................................................................. 8

Operation Procedures ........................................................................................................................... 8

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

Cleaning Schedule................................................................................................................................ 10

Deliming............................................................................................................................................... 11

Deliming Process.................................................................................................................................. 11

Maintenance Schedule.......................................................................................................................... 12

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

REPLACEMENT PARTS........................................................................................................................... 15

ELECTRICAL DIAGRAMS ...................................................................................................................... 39

TIMER CHARTS AND DIAGRAMS........................................................................................................ 44

LIST OF FIGURES

Figure 1—Track and Panel Assembly......................................................................................................... 16

Figure 2—Door and Switch Assembly........................................................................................................ 18

Figure 3—Tank/Drain Assembly ................................................................................................................ 20

Figure 4—Pump Assembly ......................................................................................................................... 22

Figure 5—Wash System Assembly............................................................................................................. 24

Figure 6—Booster Assembly and Water Inlet Piping (HT PLUS Only) .................................................... 26

Figure 7—Water Inlet Piping (HTN PLUS, LT PLUS Only)..................................................................... 28

Figure 8—Fill System ................................................................................................................................. 30

CONTENTS

Figure 9—Detergent Pump Assembly......................................................................................................... 32

Figure 10—Sanitizer/Rinse-Aid Pump Assembly....................................................................................... 34

Figure 11—Control Panel Assembly........................................................................................................... 36

Figure 12—Electrical Diagram, 401-HT PLUS.......................................................................................... 40

Figure 13—Electrical Diagram, 401-HTN PLUS ....................................................................................... 41

Figure 14—Electrical Diagram, 401-LT PLUS .......................................................................................... 42

Figure 15—Timer Chart and Diagram, 401-HT PLUS............................................................................... 43

Figure 16—Timer Chart and Diagram, 401-LT PLUS ............................................................................... 44

INTRODUCTION

Welcome to Moyer Diebel.

Thank you for choosing Moyer Diebel and 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 to eliminate problems at installation before it was shipped to your installation site. This manual provides:

•Warranty information

• Installation and operation procedures

• Maintenance instructions

•Troubleshooting guide

•Replacement parts lists.

Complete and return your warranty registration card as soon as possible.

Moyer Diebel constantly improves its products; therefore, specifications contained in this manual may have changed.

For your protection, factory authorized parts should always be used.

Replacement parts may be ordered from your Moyer Diebel authorized parts distributor or service agency. When ordering parts, supply the model number, serial number, voltage and phase of your machine, the part number, part description, and quantity.

WARRANTY

LIMITED WARRANTY

Champion Industries/Moyer Diebel Limited, P.O. Box 4183, Winston-Salem, North Carolina 27115, and P. O. Box 301, 2674 North Service Road, Jordan Station, Ontario, Canada L0R 1S0 warrants machines, and parts, as set out below.

Warranty of Machines: Champion Industries/Moyer Diebel Limited warrants all new machines of its manufacture bearing

the name “Champion” or "Moyer Diebel" 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/Moyer Diebel, whichever occurs first. [See below for special provisions relating to Model Series DF and SW.] The warranty registration card must be returned to Champion/Moyer Diebel within ten (10) days after installation. If warranty card is not returned to Champion/Moyer Diebel within such period, the warranty will expire after one year from the date of shipment.

Champion/Moyer Diebel 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/Moyer Diebel, at its election, will either repair or replace the defective machine or accept return of the machine for full credit; provided, however, as to Model Series DF and SW, Champion/Moyer Diebel'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/Moyer Diebel 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/Moyer Diebel authorized service technician. Defective parts become the property of Champion/Moyer Diebel. Use of replacement parts not authorized by Champion/Moyer Diebel will relieve Champion/ Moyer Diebel of all further liability in connection with its warranty. In no event will Champion/Moyer Diebel's warranty obligation exceed Champion/Moyer Diebel's charge for the machine. The following are not covered by Champion/Moyer Diebel'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. Adjustments to chemical dispensing equipment. h. Cleaning of valves, strainers, screens, nozzles, or spray pipes. i. Performance of regular maintenance and cleaning as outlined in operator’s guide. j. Damages resulting from water conditions, accidents, alterations, improper use, abuse,

tampering, improper installation, or failure to follow maintenance and operation procedures.

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/Moyer Diebel warrants all new machine parts produced or authorized by Champion/Moyer

Diebel 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/Moyer Diebel will replace the defective part without charge.

DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY. CHAMPION/MOYER DIEBEL'S WARRANTY IS ONLY TO THE EXTENT REFLECTED ABOVE. CHAMPION/MOYER DIEBEL MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY, OR FITNESS OF PURPOSE. CHAMPION/MOYER DIEBEL 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/MOYER DIEBEL DISHWASHING MACHINES AND CHAMPION/MOYER DIEBEL PARTS, AND ALL OTHER REMEDIES ARE EXCLUDED, INCLUDING ANY LIABILITY FOR INCIDENTALS OR CONSEQUENTIAL DAMAGES.

Champion/Moyer Diebel does not authorize any other person, including persons who deal in Champion/Moyer Diebel dishwashing machines, to change this warranty or create any other obligation in connection with Champion/Moyer Diebel Dishwashing Machines.

rev. 8699

GENERAL

This manual covers the Moyer Diebel 401PLUS undercounter dishwashing machine. This machine is fully automatic and is equipped with a 1/2 H.P. pump motor. All models are available for mounting directly to the floor or on optional stands (see accessories listed on page 4).

Standard equipment includes:

-Automatic tank fill -Upper and lower spray arms

-Common utility connections -Two dish racks (peg and flat)

-120 Volt control circuit -Exclusive vent design for

-Convenient, easy to use controls venting of condensation

-Door latch activated start switch -Stainless steel heavy-gauge construction

-Pumped drain (to 3 ft/1m) (vertical) -Detergent and rinse aid pumps

-Final rinse sentry feature (high temp models only)

This series of dishwahers is available in he following models:

Model Numbers

401-HT PLUS, 401-HTN PLUS, 401-LTPLUS

• The 401-HT PLUS model is a high temperature (82°C/180°F rinse) sanitizing model with booster and the final rinse sentry feature.

• The 401-HTN PLUS model is a high temperature (customer supplied 82°C/180°F rinse water) sanitizing model without booster.

• The 401-LT PLUS model is a low temperature (60°C/140°F rinse) sanitizing model.

Options

• Kit 504 - Top and side panels (P/N 0708756)

• Kit 505 - Top panel only (P/N 0708744)

• Kit 506 - Left side panel only (P/N 0708745)

• Kit 507 - Right side panel only (P/N 0708746)

• Kit 510 - Extended reach pumped drain kit (P/N 0708766)

• Kit 511 - 30°C/70°F temperature rise booster (P/N 0708753)

(for 49°C/110°F supply water).

GENERAL

Accessories

• 17RS - 17" rack stand (raises working height and adds rack storage)

• 17T - 17" cabinet (raises working height and adds storage)

• CST - Combination sink/table (scraping and sorting station)

• 101285 - Dish Rack (Peg Rack)

• 101273 - Silverware Rack (Flat Bottom Rack)

Electrical Power Requirements

Booster Machine Power Requirement

Model Voltage Rise Full Load Amp (125% Service Factor)

401-LT PLUS 115/60/1 N/A 9 15

401-HTN PLUS 115/60/1 N/A 9 15

401-HT PLUS 208/60/1 40 33 42

401-HT PLUS 240/60/1 40 37 47

401-HT PLUS 208/60/1 70 45 57

401-HT PLUS 240/60/1 70 51 64

NOTE:

208-230V/60Hz/1PH electrical supply service must be a 3-wire plus ground for connection as shown.

—3-Wire Plus Ground Diagram

00036

115v

N G

208-230

INSTALLATION

Unpacking

WARNING:

Care should be taken when lifting the machine to prevent damage.

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. Remove the dishwasher from the skid. Adjust the feet if required, then move the machine to its permanent location.

3. Level the machine (if required) by placing a level on the top of the machine and adjusting the feet. Level the machine front-to-back and side-to-side.

CAUTION:

After locating your machine, the installation must meet local health codes. An example may be to seal your machine to the floor using a good grade of silicone sealant.

Electrical Connections

WARNING:

Electrical and grounding connections must comply with the National Electrical Code and/or Local Electrical Codes.

WARNING:

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

1. The electrician should compare the electrical specifications on the machine electrical rating label (located on the lower left front panel) to the electrical power supply before connecting the machine to the incoming service at a fused disconnect switch.

NOTE:

The 208-240V/60Hz/1PH electrical supply service for this machine must be a 3-wire plus ground service.

2. On the 208V-240V models, a terminal block is provided on the left front side of the machine (located behind the front panel) for electrical service connections. A fused disconnect switch or circuit breaker (supplied by user) is required to protect each power supply circuit.

3. On 115V models, your machine is already equipped with a 4-foot power cord and plug suitable for 115V-15A service.

!!!

INSTALLATION

Plumbing Connections

CAUTION:

Plumbing connections must comply with local sanitary and plumbing codes.

Water Connections

1. Connect the hot water supply (60°C/ 140°F Min) to the 1/2" I.D. fill hose provided. The fill solenoid valve is equipped with a flow control that will accept water pressures from 172

kPa/25 psi to 665 kPa/95 psi.

2. Install a manual shut-off valve with 3/4" garden hose connection in the water supply line close to the machine to accommodate installation and servicing the machine. The shut-off valve should be the same size or larger than the supply line.

3. The fill solenoid valve is equipped with a built-in strainer to protect from particles in the water supply.

Drain Connections

1. All Models are supplied with a flexible 5/8" I.D. drain hose, which must be connected to a 1-1/2" drain using a wye (Y) fitting close to the machine.

2. Drain connections height should be a maxium of 3 feet from the from the floor.

Detergent/Chemicals

Use a qualified detergent/chemical supplier for your detergent, rinse aid, and chemical sanitizer needs.

1. Your machine has a liquid detergent dispensing pump. Insert the labeled detergent pickup tube into the detergent container. The pickup tube has a strainer on the end to prevent crystallized chemical from clogging the supply lines.

2. The cycle timer located in the main control cabinet is equipped with adjustable cams for the chemical dispensing pump(s). The cams control the length of time that the pumps operate. A qualified person may adjust the cam settings if necessary. Refer to the timer chart diagram(s) at the end of the manual for timer cam locations. Factory time settings are only approximate. Have your chemical supplier check the concentration and make the necessary adjustments.

NOTE:

A nonchlorinated detergent is recommended for your dishwasher.

Rinse Aid

1. A rinse aid pump is included on all models. Insert the labeled Rinse Aid pickup tube into the rinse aid container. Contact your chemical supplier for adjustment to ensure proper dosage.

Chemical Sanitizer

1. Model 401-LT PLUS is supplied with chemical sanitizer dispensing pump. Insert the labeled Chemical Sanitizer pickup tube into the chemical sanitizer container. Have your chemical supplier set chemical dosage according to local code.

2. Contact your chemical supplier for adjustment of the chemical sanitizer to ensure proper dosage.

INSTALLATION

Completing Installation

1. Remove any foreign material from inside the machine.

2. Center the scrap screen over the sump opening.

3. Prime the booster using the following procedure (if applicable).

CAUTION:

To prime the booster, the folowing procedure must be followed AFTER the electrical and plumbing connections have been made.

a. Remove the front panel. b. Locate the Installation and Service toggle switch on the extreme left side of

of the control box.

c. Press the toggle switch to the Booster Fill position and hold it approximately

1 minute (or until water enters wash tank). d. Release the toggle switch to stop the water flow. e. You have complete the booster priming process.

NOTE:

Push the Installation and Service toggle switch to the ON position. Electrical power is now supplied to the machine.

WARNING:

Failure to prime the booster may cause damage to the booster elements and other electrical components and will void the warranty,

4. After plumbing and electrical connections are completed, check the machine for water leaks

by depressing the ON/FILL/OFF/DRAIN to the ON/FILL position, then close and latch the door. This allows the tank to fill and complete the rinse cycle. Check for leaks.

4. Open the door and check the water level. The water level should be 1/2" over the scrap screen.

5. Depress the ON/FILL/OFF/DRAIN switch to the OFF/DRAIN position, close and latch the door to drain the machine. This allows the machine to complete the 105-second wash and drain cycle. Check the drain plumbing for leaks or kinks in drain hose.

6. Replace the front panel. Installation is now complete.

OPERATION

Operation Summary

The following is a summary of your Undercounter Dishwashing Machine operating cycle:

1. The cycle begins when you close and latch the door.

2. The green cycle lamp lights and the wash pump starts.

3. The pump runs during the wash cycle for approximately 80 seconds. The wash cycle

duration is extended if the booster is not up to temperature.

4. The wash pump stops, and the drain valve is opened.

5. After a 2-3 second pause, the pump drain cycle begins and continues for approximately 30 seconds. Just before this cycle ends the fill valve will come on for 2-3 seconds to flush the wash tank of any remaining detergent.

6. After a 2-3 second pause, the fill valve opens, and the pump starts for the rinse cycle.

7. Within approximately 25 seconds, the rinse cycle is complete. The pump stops, the green cycle lamp turns off, and the cycle is complete.

8. Open the door and remove the rack of clean ware.

Daily Operation Procedures

The operation of your dishwasher will be more efficient when these procedures are followed:

1. Check that the spray arm and scrap screen are in place.

2. Close and latch the door. Push the ON/FILL switch to the ON position. The tank will begin filling with water. This procedure is followed only when the tank is empty.

3. When the tank is full, check the wash tank temperature gauge. Minimum wash temperatures are:

• 401-HT PLUS, 401-HTN PLUS - 66°C/150°F.

• 401-LT PLUS - 60°C/140°F.

CAUTION:

If the wash water temperature falls below the minimums listed above, you must run an empty cycle to refill with fresh hot water.

4. Scrap and preflush all items to be washed, and load the items into the rack. DO NOT OVERLOAD the rack. Wash only one layer of silverware in a rack.

5. Open the door and insert the rack into the machine.

6. Close and latch the door. This will start the wash cycle. The green cycle lamp located on the front control panel will light. This lamp will remain on until the entire wash and rinse cycles are completed.

OPERATION

NOTE:

The machine may be stopped at any time by opening the door. When restarted, the cycle does not start over. It will continue from the point at which it was interrupted.

7. Check the rinse temperature during the final rinse (120 seconds into cycle). The rinse temperature must be 82°C/180°F minimum for models 401-HT PLUS, 401-HTN PLUS and 60°C/140°F for model 401-LT PLUS.

8. The pump will automatically stop and the green cycle light will turn off indicating the cycle is completed.

9. Open the door and remove the rack.

10. Repeat steps 4-9 for additional cycles. Machine operation is automatic.

11. CLEAN the scrap screen after every meal period. During heavy usage, the scrap screen should be cleaned more frequently.

CAUTION:

Poor machine performance and/or damage to the machine can occur if the scrap screen becomes clogged with soil or waste particles.

12. To drain water out of the tank at the end of each day. Flip ON/FILL/OFF/DRAIN switch to DRAIN position. Close and latch door. Machine will drain completely in approximately 105 seconds.

CAUTION:

DO NOT LEAVE WATER IN THE TANK OVERNIGHT. Water left in the tank overnight will allow harmful chemicals to deteriorate the tank.

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 Schedule

• Daily-Every 8 Hours

1. Depress the ON/FILL/OFF/DRAIN switch to OFF/DRAIN position and close and

latch the door to drain the tank.

2. Open the door and remove the upper and lower spray arms by unscrewing the knurled fastener.

3. Remove the scrap screen carefully to keep soil or waste particles from falling into the sump. Remove any material caught in pump intake.

4. Clean inside the tank with clean water. Backflush the scrap screen until it is clean. Do not strike the screen against solid objects.

5. Clean the wash arms to remove any debris from spray openings. Do not strike the spray arms against solid objects.

6. Reinstall the scrap screen and spray arms.

7. Leave the door open overnight to allow drying.

8. Report any unusual conditions to your supervisor.

• Meal Periods

1. Clean the scrap screen after every meal period and more frequently during heavy usage. Do not allow the scrap screen to become clogged with soil or waste particles.

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