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Champion P5-24 Installation/Operation Manual With Service Replacement Parts

Waste handling systems
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Installation/Operation Manual with Service Re
3765 Champion Blvd.
Winston-Salem, NC 27105
336/661-1556 Fax: 336/661-1660
Toll-free: 800.858.4477
Model P5-24
2674 N. Service Road, Jordan Station
Ontario, Canada L0R 1S0
905/562-4195 Fax: 905/562-4618
Toll-free: 800.263.5798
placement Parts
Waste Handling Systems
Close-Coupled Pulper /Water Extractor
Models:
P5-24
5HP with 24" Tank
P5-27
5HP with 27" Tank
P7-30
7.5HP with 30" Tank
Machine Serial No.
Issue Date: 10.15.13
Manual P/N 114509 rev. D
For machines beginning with S/N J08072511 and above
Printed in the USA

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Summary of Contents for Champion P5-24

  • Page 1 P5-27 5HP with 27" Tank P7-30 7.5HP with 30" Tank Machine Serial No. Model P5-24 Issue Date: 10.15.13 Manual P/N 114509 rev. D For machines beginning with S/N J08072511 and above 3765 Champion Blvd. 2674 N. Service Road, Jordan Station...
  • Page 2 For future reference, record your Remote Waste Handling Systems information in the box below. Model Number__________________________ Serial Number_______________________ Voltage________________Hertz_____________ Phase__________________ Service Agent __________________________________ Tel:______________________ Parts Distributor _________________________________ Tel:______________________ National Service Department In Canada: In the USA: Toll-free: 800/ 263-5798 Toll-free: 800/ 858-4477 Tel: 905/ 562-4195 Tel:...
  • Page 3 REGISTER YOUR PRODUCT ONLINE Make sure you are connected to the internet then enter the address below. In the U.S.A http://www.championindustries.com/register In Canada http://www.championindustries.com/canada/register...
  • Page 4 PRODUCT REGISTRATION BY FAX COMPLETE THIS FORM AND FAX TO: (336) 661-1660 in the USA 1-(800) 204-0109 in Canada PRODUCT REGISTRATION CARD Model Serial # Date of Installation: Company Name: Address: (Street) Province Postal Code Telephone #: ( Contact: Installation Company: Address: Telephone #: Contact:...

  • Page 5: Revision History

    Revision History Revision History A revision might be a part number change, a new instruction, or other information that was not available at print time. We reserve the right to make changes to these instructions without notice and without incurring any liability by making the changes. Equipment owners may request a revised manual, at no charge, by calling 1 (800) 858-4477 in the USA or by calling 1 (800) 263-5798 in Canada.

  • Page 6: Limited 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;...

  • Page 7: Table Of Contents

    Table of Contents Table of Contents Waste Handling Systems: P5-24, P5-27, and P7-30 Revision History ......................i Limited Warranty ......................ii Model Descriptions ......................iv Introduction ..................1 Theory of Operation ............3 Waste Handling Precautions ........6 Recirculating Pump Trough Connections ....8 Installation ....................9 Receiving ..............10 Utility Connections ............11...

  • Page 8: Model Descriptions

    Model Descriptions Model Descriptions P5-24 24" diameter waste grinding chamber with 5 HP grinder motor 4 stationary cutter blocks and 2 tool-steel cutting blades. Flatware saver Pressure switch water-level control Mounted start/stop station Remote mounted control cabinet Close-coupled water press/extractor with 2 HP motor (700 lb/hr.

  • Page 9: Introduction

    Introduction Introduction...
  • Page 10 Theory of Operation Pulp compression cone Drain/overflow Slurry PULP WASTE Fresh make-up water Recirculated slurry water Slurry auger and screen Cutters Grinding disk Optional slurry recirculating pump SLURRY OUT Pulper Drain motor...

  • Page 11: Theory Of Operation

    Theory of Operation Theory of Operation Refer to the illustration on the preceding page as you read the theory of operation below. The close-coupled waste handling system is made up of 2 units: a pulper and a water extractor. 1. The close-coupled waste handling system is designed to reduce the volume of waste created in the food service operation thereby reducing the expense associated with conventional methods of waste removal and disposal.
  • Page 12 Theory of Operation Theory of Operation Under-table Feed tray and Hood Configurations The illustrations below show the standard under-table designs employed to manually feed food and paper waste into the pulper. The feed tray/feed hood components are removable for cleaning and access to the pulper interior. Direct feed w/cover Feed tray w/hood Feed hood w/hinged lid...
  • Page 13 Theory of Operation Theory of Operation Feed-trough Configurations Six standard feed-trough configurations for the waste handling system are shown below. A feed-trough system semi-automates the waste loading operation by providing an alternative to the under-table feed-tray design shown on the previous page. The operator separates food and paper waste from the wares and places them in the trough.

  • Page 14: Waste Handling Precautions

    Waste Handling Precautions Waste Handling Precautions WARNING! The Remote Waste Handling System contains ROTATING PARTS moving at high speed. Death or serious injury may result if clothing, jewelry, or body are caught in the machine. NEVER run the machine unless all safety devices are in good working condition and all safety covers are installed on the machine.
  • Page 15 Waste Handling Precautions 9. Cellophane wrappers (typically used for saltine crackers, candy or nuts.) 10. Plastic package tape 11. Plastic banding, 12. Cloth rubber, leather, wood, 13. Glass, rocks, dirt 14. Paint, solvents or any other chemicals 15. The pulper is equipped with a powerful magnet in the bottom of the grinding chamber that is intended to attract eating/cooking utensils if they contain a percentage of iron.

  • Page 16: Recirculating Pump Trough Connections

    Recirculating Pump Trough Connection Kit: P/N 407365 P-5 Recirculating Pump Trough Connection Kit: P/N 407365 Form # 900822 A trough connection kit (See No. 1 below) is shipped with each pulper equipped with a recirculating pump. The kit is designed to connect the recirculating pump discharge to a waste trough (supplied by others). Trunk Option A and Trunk Option B (See No.

  • Page 17: Installation

    Installation Installation...

  • Page 18: Receiving

    Receiving • Installation Receiving IMPORTANT: Plan the route used to transport the main components/pallets. Halls and doorways may be to small to travel through to the final site. Follow the steps below to receive the waste handling system at the installation site. Refer to Theory of Operation on page 2 for an illustration of the system.

  • Page 19: Utility Connections

    Installation • Utility Connections Utility Connections WARNING! Electric shock may cause death or serious injury. Do not work on energized circuits. Turn off all main power service disconnects, lock them out and place a tag on the switch and/or breaker to indicate that work is being performed on the circuit.
  • Page 20 Utility Connections • Installation Utility Connections (continued) The Plumbing and Electrical Diagram-P&E (continued) Refer to the P&E and match the utilities at the installation site to the P&E. Contact a supervisor if the installation site does not match P&E. The general utility requirements may include, but are not limited: Cold water supply Electrical supply Drain...
  • Page 21 (supplied by others) National Electrical Code. Refer to the Champion Service Manual, P/N 114509 for complete operating instructions for the machine. Remote Start/Stop Station Wiring Diagram...

  • Page 22: Initial Start-Up

    Initial Start-up - Pulper/Water Extractor WARNING! Death or serious injury may result if hands, clothing, or jewelry are caught in the machine. The Waste Handling System contains ROTATING PARTS moving at high speed. WARNING! Death or serious injury may result if safety devices are not working. NEVER operate the machine unless all safety devices are in good working condition and all safety covers are in place on the machine.

  • Page 23: Electrical Controls

    Pulper/Water Extractor - Initial Start-up Pulper/Water Extractor Electrical Controls POWER MUST BE TURNED OFF UNTIL ALL MECHANICAL CHECKS ARE COMPLETE. The Remote Control Cabinet offers the following controls: START STOP A: ON/OFF manual reset breaker switch. Rotate handle fully CW to turn power ON.

  • Page 24: Initial Start-Up

    Initial Start-up - Pulper/Water Extractor Electrical Controls (continued) Note: The remote control cabinet controls the pulper and the water extractor. 1. Push the STOP push button on the Start/Stop Station located at the top of the water extractor. 2. Turn the Disconnect Breaker Switch located on the Remote Control Cabinet to the RESET/LOCK position.

  • Page 25: Mechanical Adjustments

    Pulper - Initial Start-up Pulper Mechanical Adjustments 1. Refer to the illustrations below and check the clearance between the stationary cutter blocks and rotating cutter blades. 2. Slowly rotate the cutting disk to make sure that the rotating blades do not hit any of the blocks. 3.

  • Page 26: Initial Start-Up

    Initial Start-up - Pulper/Water Extractor Water Extractor Mechanical Adjustments 1. The water extractor Compression Cone (A) should be adjusted to 3⅞" from the top of the water extractor housing and the top of Compression Cone. The main components of the water 3⅞"...

  • Page 27: Water Fill Adjustments

    Pulper/Water Extractor - Initial Start-up Water Fill Adjustments 1. Make sure all access doors, panels and safety devices are in place, secure and operating. 2. Turn the Main Circuit Breaker Switch on the remote control cabinet to the ON position. Turn the Main Circuit Breaker Switch Push the START push button located on to the ON position.

  • Page 28: Initial Start-Up

    Initial Start-up - Pulper/Water Extractor System Operation Tests The Waste Handling System is the following operating state: Doors and panels are closed. Safety switches are closed. Drain valves are closed Water supply is on. Main power supply is on. Pulper and water extractor are filled to preset water level. Pulper drive motor is running.

  • Page 29: Initial Start-Up

    Pulper/Water Extractor- Initial Start-up System Operation Tests Test Delay Stop Option (if equipped) Note: The adjustable timer located inside the control cabinet is preset at the factory for 6-minutes. 1. While the system is running, push the Delay Stop Switch. The system should run for 6-minutes then shut off.
  • Page 30 Initial Start-up - Pulper/Water Extractor System Operation Tests Waste Processing and System Balancing Drain Closed Attention: Waste processing adjustments are best performed under normal loading conditions. Note: A water level fill adjustments and/or the condition of the Drain Open water extractor pulp usually requires some time before the system responds to a change.

  • Page 31: Operation

    Pulper/Water Extractor - Operation Operation...
  • Page 32 Pulper/Water Extractor - Operation Operation Refer to the Theory of Operation and Waste Handling Precautions beginning on page 1 of this manual prior to operating the waste handling system. Turn on main power supply and water supply. Make sure all drain valves are closed. Inspect the interior of the pulper tank for metal or other debris.

  • Page 33: Cleaning And Maintenance

    Pulper/Water Extractor - Cleaning and Maintenance Cleaning and Maintenance...

  • Page 34: Cleaning

    Pulper/Water Extractor - Cleaning and Maintenance Cleaning WARNING! Make sure that power is turned off and the main circuit breaker switch on the remote control cabinet is in the RESET/LOCK position. Install a lock on the Breaker Switch to prevent the switch from being operated.
  • Page 35 Pulper/Water Extractor - Cleaning and Maintenance Cleaning DO NOT HOSE THE EXTERIOR OF THE MACHINE WITH WATER Drain...

  • Page 36: Maintenance

    Pulper/Water Extractor - Cleaning and Maintenance Maintenance Daily Maintenance Checks 1. Check the general cleanliness of the waste handling system and the room. Deodorizers are not a substitute for daily cleaning procedures. Do not hose the exterior of the machine with water. 2.

  • Page 37: Troubleshooting

    Troubleshooting The following troubleshooting guide can help identify a problem and provide a solution. Inspect your waste handling system before you contact an authorized service representative. Problem Cause(s) Solution(s) System will not turn ON. Turn on or reset breaker. Main Power Supply OFF Push to reset 3A breaker Remote Control Cabinet 3A push button breaker tripped.
  • Page 38 Blank Page This Page Left Intentionally Left Blank...

  • Page 39: Service Replacement Parts

    Service Replacement Parts Service Replacement Parts Illustrations Water Extractor Assembly - Inner View ....................Pulper Assembly - Inner View ......................... Water Extractor / Pulper Assembly - Front Outer View................Water Extractor / Pulper Assembly - Rear Outer View ................Under-table Feed Trays - Pulper Assembly .................... Feed Tray with Hinged Lid - Pulper Assembly ..................

  • Page 40: Water Extractor Assembly - Inner View

    Water Extractor Assembly - Inner View...
  • Page 41 Inner View - Water Extractor Assembly Item Part Description Qty. 100007 SCREW, TRUSS HEAD, 10-32 X 3/8” SST 100028 ELBOW, STREET, 1-1/2 NPT X 90° GALV. 100034 NIPPLE, 1-1/2 NPT X 5-1/4” LG. GALV. 100036 TEE, 1-1/2” NPT GALV. 100043 NIPPLE, 1-1/2 NPT, X CLOSE GALV.

  • Page 42: Pulper Assembly - Inner View

    Pulper Assembly - Inner View...
  • Page 43 Inner View - Pulper Assembly Item Part Description Qty. 100153 BOLT, HEX HD., 3/8-16 X 1" SST 100736 BOLT, HEX HD., 1/4-20 X 3/4" SST 100746 BOLT, HEX HD., 3/8-16 X 1-1/4" SST 100747 BOLT, HEX HD., 1/2-13 X 1" SST 102409 COUPLING, 1/8"...

  • Page 44: Water Extractor/Pulper Assembly - Front Outer View

    Water Extractor/Pulper Assembly - Front Outer View...
  • Page 45 Front Outer View - Water Extractor/Pulper Assembly Item Part Description Qty. 100007 SCREW, TRUSS HD. 10-32 X 3/8" SST 100194 HEX GRIP NUT, 10-32 SST 100734 BOLT, HEX HD., 1/4-20 X 1/2" SST 100754 SCREW, FLAT HD., 10-32 X 1/2 SST 102442 ELBOW, 3/4"...

  • Page 46: Water Extractor/Pulper Assembly - Rear Outer View

    Water Extractor/Pulper Assembly - Rear Outer View...
  • Page 47 Rear Outer View - Water Extractor/Pulper Assembly Item Part Description Qty. 100003 HEX PLAIN NUT, 1/4-20 SST 100007 SCREW, TRUSS HD., 10-32 X 3/8" SST 100073 SCREW, TRUSS HD. 1/4-20 X 1/2" SST 100123 PETCOCK, 1/4" NPT FEMALE, BRASS 100194 HEX GRIP NUT, 10-32 SST 100209 NIPPLE, 1/2"...

  • Page 48: Under-Table Feed Trays - Pulper Assembly

    Under-table Feed Trays - Pulper Assembly...
  • Page 49 COTTER PIN, CIRCLE 309753 BRACKET, UC DRIVE SWITCH 312475 FEED TRAY 313228 ROD, CURTAIN FEED TRAY W/HOOD 24" PULPER 313229 FEED TRAY W/HOOD 24" PULPER 314187 COVER, MAGNET 316145 FEED TRAY P5-24 316147 MANHOLE, COVER P5-27 320985 ALIGNMENT PIN, MANHOLE COVER...

  • Page 50: Feed Tray With Hinged Lid - Pulper Assembly

    Feed Tray with Hinged Lid - Pulper Assembly...
  • Page 51 Pulper Assembly - Feed Tray with Hinged Lid Item Part Description Qty. 107654 SCREW, TRUSS HD., 6-32 X 1" SST 100194 HEX GRIP NUT, 10-32 SST 104985 HEX PLAIN NUT, 10-32 SST 106486 WASHER, LOCK #10 SPLIT SST 107033 WASHER, FLAT SST 107966 HEX GRIP NUT 10-32 SST W/NYLON 108954...

  • Page 52: Two-Piece Feed Tray With Flushing Nozzles - 30" Pulper Assembly

    Two Piece Feed Tray with Flushing Nozzles - 30" Pulper Assembly...
  • Page 53 CLAMP, HOSE M28 SST GEAR-TYPE 107525 SCREW, ROUND HD. 10-32 X 1/2" SST 108954 HEX GRIP NUT, 6-32 SST W/NYLON 109158 NAMEPLATE, CHAMPION 110110 SCREW, ROUND HD. 4-40 X 1/2" SST 110593 LATCH ASSY. PULPER FEED TRAY 113489 COTTER PIN, CIRCLE...
  • Page 54 Recirculating Pump Option - Water Extractor/Pulper • Front View See next page for pump assembly. 6 12 Comes with Item No. 11...
  • Page 55 Front View • Water Extractor/Pulper - Recirculating Pump Option Item Part Description Qty. 100154 HEX PLAIN NUT, 5/16-18 SST 100173 NIPPLE, 1-1/2" X 2" LG. BRASS 100585 LOCKNUT, 1" NPT BRASS 100739 BOLT, HEX HD., 5/16-18 X 3/4" SST 100740 BOLT, HEX HD., 5/16-18 X 1"...
  • Page 56 Recirculating Pump Assembly - Water Extractor/Pulper...
  • Page 57 Water Extractor/Pulper - Recirculating Pump Assembly Item Part Description Qty. C3819 PUMP SUCTION, MACHINED D4820 PUMP DISCHARGE HOUSING 12799-1 IMPELLER 14269-1 HOUSING, PUMP SEAL 100002 BOLT, HEX HD. 1/4-20 X 1-3/8" SST 100153 BOLT, HEX HD. 3/8-16 X 1" SST 100735 BOLT, HEX HD.
  • Page 58 Recirculating Pump Option - Water Extractor/Pulper • Rear View See previous page for pump assembly. 14 13 Comes with Item No. 15...
  • Page 59 Rear View • Water Extractor/Pulper - Recirculating Pump Option Item Part Description Qty. 100739 BOLT, HEX HD., 5/16-18 X 3/4" SST 102376 WASHER, FLAT 5/16 SST 100154 HEX PLAIN NUT, 5/16-18 SST 106013 WASHER, LOCK 5/16-18 SST 104203 CLAMP, HOSE M52 SST GEAR-TYPE 326045-1 BASE PLATE, FRONT MTD, RECIRC PUMP 107340...
  • Page 60 Flushing Assembly - Pulper/Water Extractor Water Supply...
  • Page 61 Pulper/Water Extractor - Flushing Assembly Item Part Description Qty. 317171 SPRAY ARM WELDMENT 314131 SPRAY ARM ASSY., (Includes Item Nos. 1,3, 4) 100547 LOCKNUT, 1/2" NPT BRASS 111518 NOZZLE, SPRAY, K-4 102435 ELBOW, 1/2" NPT X 90º BRASS 102388 BUSHING, RED., 1/2" NPT X 1/4" NPT BRASS 109909 FITTING, COMP 1/2"...
  • Page 62 Deodorizer Pump Assembly - Pulper/Water Extractor...
  • Page 63 Pulper/Water Extractor - Deodorizer Pump Assembly Item Part Description Qty. 317006 BOX, DEODORIZER 104624 SCREW, TRUSS HD. 8-32 X 3/8" SST 106026 WASHER, FLAT, 1/4 SST 107967 HEX GRIP NUT, 1/4-20 SST W/NYLON 107970 SCREW, FILLISTER HD. 8-32 X 1" SST 111509 MOTOR/GEAR REDUCER, DEODORIZER PUMP 108173...

  • Page 64: Feed Trough Gaskets - Pulper

    Feed Trough Gaskets - Pulper Feed trough supplied by others...
  • Page 65 Pulper - Feed Trough Gaskets Item Part Description Qty. 111873 GASKET, PULPER, 9" TROUGH 113324 GASKET, PULPER 12" TROUGH 111478 BOLT, HEX HD. 10-32 X 1/2" SST 107033 WASHER, FLAT 107966 GRIPNUT, HEX HD., 10-32 SST W/NYLON INSERT...
  • Page 66 Remote Control Cabinet - Pulper/Water Extractor Comes with Item No. 30 15 14 53 16...
  • Page 67 Pulper/Water Extractor - Remote Control Cabinet Item Part Description Qty. 100095 SCREW, ROUND HD., 10-32 X 3/8" SST 100302 PILOT LIGHT, 120VAC, RED 100735 BOLT, HEX HD., 1/4-20 X 5/8" SST 102292 NAMEPLATE, ON-OFF 103310 GROUND, LUG 104873 LABEL, GROUND 106026 WASHER, FLAT 1/4 SST 106482...
  • Page 68 Remote Control Cabinet - Pulper/Water Extractor (continued) Item Part Description Qty. --- * --- MOTOR STARTER OVERLOAD (Optional Recirculating Pump) --- * --- MOTOR STARTER OVERLOAD (Water Extractor Drive) --- * --- MOTOR STARTER OVERLOAD (Pulper Drive) 111636 BUS CONNECTOR, 3 POLE --- * --- BUS SYSTEM, 3 POLE 111822...

  • Page 69: Remote Control Cabinet Component Selection Chart

    Electrical Schematic Electrical Schematic Remote Control Cabinet Component Selection Chart...
  • Page 70 Blank Page This Page Intentionally Left Blank...

  • Page 71: Remote Control Cabinet Component Selection Chart

    Remote Control Cabinet Component Selection Chart...
  • Page 72 Close-coupled Pulper/Water Press Electrical Schematic 120 VOLTS HOLD-IN RELAY POWER LAMP MAIN DISCONNECT DELAY STOP (IF USED) SWITCH/CB DOOR INTERLOCK RELAY DEODORIZING UNIT RELAY DELAY STOP RELAY DEODORIZING UNIT DELAY STOP HOLD IN RELAY DELAY STOP ON/OFF SWITCH (IF USED) TIMER (IF USED) BOOSTER HEAT HOLD-IN RELAY PULPER DRIVE MOTOR CONTACTOR...

This manual is also suitable for:

P7-30P5-27

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