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Champion D-HBM5 Technical Manual Addendum

Door-type dishwasher
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Download this manual See also: Technical Manual, Installation/operation Manual With Service Replacement Parts
For machines beginning with
Serial no. D3694 and above
March, 2004
P.O. Box 4149
Winston-Salem, North Carolina 27115-4149
336/661-1556
Fax: 336/661-1660
Technical Manual
www.championindustries.com
Door-Type
Dishwasher
Model
D-HBM5
High Temperature
with Built-in Booster
D-H1M5
High Temperature
D-LFM5
Low Temperature
Machine Serial No.
113491
P/N
Manual
2674 N. Service Road
Jordan Station, Ontario, Canada L0R 1S0
905/562-4195
Rev. E
Fax: 905/562-4618

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  • Page 1 Technical Manual For machines beginning with Serial no. D3694 and above Door-Type Dishwasher Model D-HBM5 High Temperature with Built-in Booster D-H1M5 High Temperature D-LFM5 Low Temperature Machine Serial No. 113491 March, 2004 Manual Rev. E P.O. Box 4149 2674 N. Service Road...
  • Page 2 Champion Parts Distributor ___________________________________ Phone ______________ ______________________________________________________________________________ Champion Service Agency ____________________________________ Phone ______________ ______________________________________________________________________________ Champion Industries Service: 1 (800) 858-4477 Champion Service Fax: 1 (336) 661-1660 In Canada: Champion Service: 1 (800) 263-5798 Canada Service Fax: 1 (905) 562-4618 We strongly recommend that you fax your orders.
  • Page 3 REVISIONS Revision History Revision Revised Serial Number Comments Date Pages Effectivity 6/01/02 D3694 Issue new manual with replacement parts lists 6/01/02 — Issue new manual with replacement parts lists 10/18/02 D3858 Revised rated amps listing 10/18/02 D3858 Revised wash and final rinse times 10/18/02 36,37 D3858...

  • Page 4: Table Of Contents

    CONTENTS CONTENTS Page WARRANTY ..........................INTRODUCTION........................GENERAL ..........................Model Numbers ........................Standard Equipment ......................Options..........................Accessories .......................... Electrical Power Requirements.................... INSTALLATION........................Unpacking..........................Changing from Straight-through to Corner Operation............Electrical Connections......................Plumbing Connections......................Water Connections....................... Drain Connections ....................... Chemical Connections......................Model D-HB, D-H1 and D-LF..................Detergent..........................
  • Page 5 CONTENTS CONTENTS Page TROUBLESHOOTING ......................BASIC SERVICE ........................Electrical Service......................... Fuses .......................... Motor Overloads ......................Solid State Control Board ..................... Low Water Tank Heat Protection.................. Heater Element Wiring ....................Motor Connections......................Mechanical Service ......................Pump Seal Replacement ....................REPLACEMENT PARTS LIST....................ELECTRICAL SCHEMATICS ....................
  • Page 6 CONTENTS LIST OF FIGURES (cont’d) Page Figure 26 — D-HB, D-H1 Upper Fill Piping Assembly ............Figure 27 — D-H1, D-LF Lower Fill Piping Assembly............Figure 28 — D-LF Upper Fill Piping Assembly ............... Figure 29 — Pump Assembly ....................Figure 30 —...

  • Page 7: Warranty

    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...

  • Page 8: Introduction

    For your protection, factory authorized parts should always be used for repairs. Replacement parts may be ordered from your Champion authorized parts distributor or from your Champion authorized service agency. When ordering parts, please supply the model number,...

  • Page 9: General

    GENERAL GENERAL This manual covers the Champion door type dishwashing machine. These machines are fully automatic and come equipped with a 1-HP pump motor. The D-series dishwasher is available in the following models: Model Numbers D-H1, D-HB, D-LF The D-H1 model is a high temperature (180°F/82°C rinse) sanitizing model without booster.

  • Page 10: Electrical Power Requirements

    GENERAL Electrical Power Requirements for Electric Heat / Electric Booster Booster Rise Rated Minimum Supply Ckt. Maximum Overcurrent Model Voltage (D-HB Only) Amps Conductor Ampacity Protective Device D-H1/LF 115/60/1 — 46 Amps 55 Amps 55 Amps D-H1/LF 208/60/1 — 35 Amps 40 Amps 40 Amps D-H1/LF...

  • Page 11: Installation

    INSTALLATION INSTALLATION Unpacking CAUTION: Care should be taken when lifting the machine to prevent damage. 1. Immediately after unpacking the 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.

  • Page 12: Plumbing Connections

    INSTALLATION Electrical Connections (cont’d) the main electrical connection block. For single phase machines, motor rotation is changed at the motor connection plate on the rear of the single phase motor. 3. A knock-out is provided at the rear of the top mounted control cabinet for the electrical service connection.

  • Page 13: Water Connections

    A PRV is standard equipment on Model D-HB. A PRV is not standard equipment on Models D-H1 and D-LF. The PRV may be obtained locally or direct from Champion. Drain Connections 1. Models D-HB, D-H1, and D-LF are GRAVITY DRAIN machines equipped with a 2"...

  • Page 14: Chemical Connections

    INSTALLATION Chemical Connections NOTE: Consult a qualified chemical supplier for your chemical needs. Models D-HB, D-H1 and D-LF Refer to Figure 3. 1. Labeled chemical signal connection points are provided inside the control cabinet for chemical dispensing equipment (supplied by others). Signal connection points include: •...

  • Page 15: Rinse Aid/Sanitizer

    INSTALLATION Chemical Connections (cont’d) Detergent (cont’d) 2. Detergent may be added manually if dishwasher is not equipped with dispensing equipment. Consult your chemical supplier for recommended amounts. Rinse Aid/Sanitizer Model D-HB and D-H1 Refer to Figure 5. 1. A rinse aid injection point is provided via a 1/4" NPT plug located in the final rinse piping.
  • Page 16 INSTALLATION Chemical Connections (cont’d) Rinse Aid/Sanitizer (cont’d) Model D-LF Refer to Figure 6. 1. A rinse aid injection point is provided via a 1/4" NPT plug located in the final rinse piping. The plug is located in a cross fitting on the outlet side of the vacuum breaker. The vacuum breaker is located behind the control cabinet at the top of the machine.

  • Page 17: Initial Start-Up

    8. Check pump motor rotation. Rotation is CW when viewed from rear of motor. 9. If machine checks okay, flip the power switch to OFF and machine will drain for ten minutes. Main power switch Pressure gauge circuit breaker Green pushbutton Champion start switch POWER WASH RINSE START CYCLE...

  • Page 18: Operation

    OPERATION OPERATION Model D-HB, D-H1 and D-LF 1. Close the door and flip power switch ON Power light illuminates. Drain valve closes. Tank fills automatically and tank heat comes on. 2. Monitor wash tank temperature gauge Wait for temperature reading to reach Min.

  • Page 19: Maintenance

    MAINTENANCE MAINTENANCE Cleaning your machine is the best maintenance that you can provide. Components that are not regularly flushed and cleaned do not perform well. The Maintenance intervals shown in the following schedules are the minimum requirements necessary for the proper performance of your machine. Maintenance intervals should be shortened whenever your machine is faced with abnormal working conditions, hard water, or multiple shift operations.

  • Page 20: Deliming

    MAINTENANCE DELIMING Your dishwasher should be delimed regularly depending on the mineral content of your water. Inspect the machine interior for mineral deposits and use a deliming solution for the best cleaning results. NOTE: Consult your chemical supplier for an appropriate deliming solution. WARNING: Deliming solutions or other acids must not come in contact with household bleach (sodium hypochlorite) or any chemicals containing chlorine, iodine, bromine, or...

  • Page 21: Operation Checks

    MAINTENANCE OPERATION CHECKS • Daily 1. Check temperature gauges for proper readings. 2. Check pressure gauge for proper reading (D-H1, D-HB ONLY). 3. Check for leaks. 4. Check chemical supplies and refill as necessary. • Weekly 1. Inspect all water lines for leaks. 2.
  • Page 22 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 .

  • Page 23: Basic Service

    Troubleshooting Schematics Champion places an electrical schematic in the control cabinet of every machine before it is shipped. Schematics are included at the back of this manual as well. Be aware that these schematics include options that may not apply to your machine. Options are enclosed in dashed lines with the words (IF USED) next to them on the schematic.

  • Page 24: Fuses

    BASIC SERVICE Fuses Refer to Figure 9. There are two fuse blocks, located in the center of the main control cabinet. The (A) fuses protect the main control transformer. The (B) fuses protect the wash tank heater circuit. Fuses are marked FU on the electrical schematic.
  • Page 25 BASIC SERVICE ELECTRICAL SERVICE (cont’d) 6. Run machine through several cycles or wait 10 minutes for temperature to stabilize. 7. Open door, insert rack of dishes. 8. Close doors. Push the GREEN push button to start cycle. 9. Machine cycle is: WASH = 40 seconds DWELL = 1 second RINSE = 10 seconds...

  • Page 26: Solid State Control Board

    BASIC SERVICE 2. Place the NEGATIVE (Black) test probe on the “HOT” terminal: • T2, marked “H”. 3. Place the POSITIVE (Red) test probe on the input terminal to be tested: • T7, marked “START SW” (for the Start Switch). •...

  • Page 27: Low Water Tank Heat Protection

    BASIC SERVICE Models D-HB, D-H1, and D-LF use a float switch and circuit board to control tank fill and tank heat. For Model D-HB only, the built-in booster heat circuit is also controlled by the float switch. Operation: 1. When dishwasher main power switch is turned on (wash tank empty), the drain valve closes allowing cycle time to run for a minimum of 110 seconds to fill the tank.

  • Page 28: Heater Element Wiring

    BASIC SERVICE Heater Element Wiring – Booster Tank and Wash Tank Heater Elements Refer to the illustrations and follow 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.

  • Page 29: Motor Connections

    BASIC SERVICE Motor Connections 1. Models D-HB, D-H1, and D-LF are available in either single phase or 3 phase voltages. 2. Motor rotation was set at the factory. For three phase machines, reversing the motor direction is done in the control cabinet by reversing the wires L1 and L2 on the disconnect side of the main electrical connection block.

  • Page 30: Mechanical Service

    REPLACEMENT PARTS MECHANICAL SERVICE Pump Seal Replacement 1. Disconnect the power to the machine at the main breaker panel or fuse box. 2. Drain the machine. 3. Remove the front and side panels. 4. Remove drain plug on the pump volute and drain the pump. 5.
  • Page 31 REPLACEMENT PARTS Figure 16 – D-HB/D-H1/D-LF Doors, Panels and Gauges...

  • Page 32: Replacement Parts List

    REPLACEMENT PARTS D-HB/D-H1/D-LF DOORS, PANELS AND GAUGES Fig. 16 Part Item No. Part Description Qty. 325405 Side Door, Right ........325407 Side Door, Right (Corner Machine) .
  • Page 33 REPLACEMENT PARTS FRONT OF HOOD Fig. 17 – D-HB/D-H1/D-LF Door Guides, Stops, and Lift Bracket...

  • Page 34: Figure 17 - Door Guides, Stops, And Lift Bracket

    REPLACEMENT PARTS D-HB/D-H1/D-LF DOOR GUIDES, STOPS, AND LIFT BRACKET Fig. 17 Part Item No. Part Description Qty. 108053 Plug, Cornerpost ........107966 Nut, Grip 10-32 w/Insert .
  • Page 35 REPLACEMENT PARTS Fig. 18 – D-HB/D-H1/D-LF Door Handle and Spring Assembly...

  • Page 36: Figure 18 - Door Handle And Spring Assembly

    REPLACEMENT PARTS D-HB/D-H1/D-LF DOOR HANDLE AND SPRING ASSEMBLY Fig. 18 Part Item No. Part Description Qty. 112723 Bolt 5/16-18 x 15 Hex Head ......108066 Spring, Extension .
  • Page 37 REPLACEMENT PARTS Fig. 19A – D-HB/D-H1/D-LF Straight Track Assembly Fig. 19B – D-HB/D-H1/D-LF Corner Track Assembly...

  • Page 38: Figure 19A - Straight Track Assembly

    REPLACEMENT PARTS D-HB/D-H1/D-LF STRAIGHT TRACK ASSEMBLY Fig. 19A Part Item No. Part Description Qty. 0309472 Track, Rear ......... . . 100073 Screw (1/4-20 x 1/2 Truss Head) .
  • Page 39 REPLACEMENT PARTS Fig. 20 – D-HB/D-H1/D-LF Wash/Rinse Spray Piping...

  • Page 40: Figure 20 - Wash/Rinse Spray Piping

    REPLACEMENT PARTS D-HB/D-H1/D-LF WASH/RINSE SPRAY PIPING Fig. 20 Part Item No. Part Description Qty. 324526 Rinse Manifold Weldment ....... 113027 Connector, Rinse Arm .
  • Page 41 REPLACEMENT PARTS AFTER S/N D3858 PRIOR TO S/N D3857 Fig. 21 – D-HB/D-H1/D-LF Wash/Rinse Spray Arms...

  • Page 42: Figure 21 - Wash/Rinse Spray Arms

    REPLACEMENT PARTS D-HB/D-H1/D-LF WASH/RINSE SPRAY ARMS Fig. 21 Part Item No. Part Description Qty. 0507443 Spindle, Rinse Arm ........0508376 Nozzle, Rinse Arm (DHB, D-H1 Only) (Prior to S/N D3857) .
  • Page 43 REPLACEMENT PARTS Fig. 22 – D-HB/D-H1/D-LF Drain Assembly and Scrap Screens...
  • Page 44 REPLACEMENT PARTS D-HB/D-H1/D-LF DRAIN ASSEMBLY AND SCRAP SCREENS Fig. 22 Part Item No. Part Description Qty. 305164 Screen 10"..........324582 Filler Plate.
  • Page 45 REPLACEMENT PARTS Fig. 23 – D-HB/D-H1/D-LF Wash Tank Heat, Thermostats, and Float Switch...

  • Page 46: Figure 23 - Wash Tank Heat, Thermostats, And Float Switch

    REPLACEMENT PARTS D-HB/D-H1/D-LF WASH TANK HEAT, THERMOSTATS, AND FLOAT SWITCH Fig. 23 Part Item No. Part Description Qty. 107440 Thermometer 8 ft........109069 Thermostat w/Cap 110-220°F .
  • Page 47 REPLACEMENT PARTS Fig. 24 – D-HB Only Electric Booster and Thermostat...
  • Page 48 REPLACEMENT PARTS D-HB ONLY ELECTRIC BOOSTER AND THERMOSTAT Fig. 24 Part Item No. Part Description Qty. 100740 Bolt 5/16-18 x 1 Hex Head ......102376 Washer, Flat 5/16 x 3/4 x 1/16 .
  • Page 49 REPLACEMENT PARTS TO UPPER PIPING CUSTOMER WATER INLET Fig. 25 – D-HB ONLY Lower Fill Piping Assembly...
  • Page 50 REPLACEMENT PARTS D-HB ONLY LOWER FILL PIPING ASSEMBLY Fig. 25 Part Item No. Part Description Qty. 107550 Valve Pressure Red. 3/4" ....... . 102444 Street Ell 3/4"...
  • Page 51 REPLACEMENT PARTS WATER IN FROM LOWER PIPING Fig. 26 – D-HB/D-H1 Upper Fill Piping Assembly...
  • Page 52 REPLACEMENT PARTS D-HB/D-H1 UPPER FILL PIPING ASSEMBLY Fig. 26 Part Item No. Part Description Qty. 100156 Locknut 3/4" NPT Brass....... . . 100571 Union, 3/4"...
  • Page 53 REPLACEMENT PARTS TO UPPER PIPING CUSTOMER WATER IN Fig. 27 – D-H1/D-LF Lower Fill Piping Assembly...
  • Page 54 REPLACEMENT PARTS D-H1/D-LF LOWER FILL PIPING ASSEMBLY Fig. 27 Part Item No. Part Description Qty. 102444 Street Ell 3/4" NPT Brass....... . 0309340 Plumbing Support Bracket .
  • Page 55 REPLACEMENT PARTS WATER IN FROM LOWER PIPING FINAL RINSE THERMOMETER BULB Fig. 28 – D-LF Upper Fill Piping Assembly...
  • Page 56 REPLACEMENT PARTS D-LF UPPER FILL PIPING ASSEMBLY Fig. 28 Part Item No. Part Description Qty. 100548 Locknut 3/4" NPT SST ....... . . 102554 Union, 3/4"...
  • Page 57 REPLACEMENT PARTS Fig. 29 – D-HB/D-H1/D-LF Pump Assembly...

  • Page 58: Pump Assembly

    REPLACEMENT PARTS D-HB/D-H1/D-LF PUMP ASSEMBLY Fig. 29 Part Item No. Part Description Qty. 324580 Stainer ..........107966 Nut, Grip 10-32 w/Nylon Insert .
  • Page 59 FLOAT SW. LAMP OUTPUT EXT. WASH FILL RINSE WASH Champion POWER WASH RINSE START CYCLE W A R N I N G ! T U R N O F F P O W E R B E F O R E S E R V I C I N G M A C H I N E Fig.
  • Page 60 REPLACEMENT PARTS D-HB/D-H1/D-LF CONTROL CABINET Fig. 30 Part Item No. Part Description Qty. 111833 Terminal Block, 1& 3 phase......103310 Wire Lug, Ground.
  • Page 61 REPLACEMENT PARTS Fig. 31 – D-HB/D-H1/D-LF Dishracks and PRV...
  • Page 62 REPLACEMENT PARTS D-HB/D-H1/D-LF DISHRACKS AND PRV Fig. 31 Part Item No. Part Description Qty. 101273 Rack (Flat Bottom) ........101285 Rack (Peg).

  • Page 63: Appendixes

    APPENDIXES APPENDIX A DRAIN TIMER/VALVE CIRCUIT Models D-HB, D-H1, and D-LF uses a drain circuit consisting of a 3cr relay, 10 minute timer, and a drain valve. OPERATION: 1) When the power switch is pushed to the OFF posistion, the 3CR relay coil is then energized, closing the 3CR contacts.
  • Page 64 IF USED TANKS EMPTY SUPPLIED BY OTHERS COIL END OF CYCLE COMMON CHANGED TANK HEAT KW AND ADDED HEAT LIMIT 8/30/02 CHAMPION DOOR MACHINE CUSTOMER TO SUPPLY RATED VOLTAGE/PHASE/Hz, REV. DESCRIPTION DATE REV. DESCRIPTION DATE AS SPECIFIED PER ORDER,TO DISCONNECT SWITCH.

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