Champion Eseries HRU Installation/Operation Manual With Service Replacement Parts

High temperature heat recovery unit

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Installation/Operation Guide with Service Replacement Parts

3765 Champion Blvd.,

Winston-Salem, NC 27105

336/661-1556 Fax: 336/661-1660

www.championindustries.com

2674 N. Service Road,

Jordan Station Ontario, Canada L0R 1S0

905/562-4195 Fax: 905/562-4618

For machines built from 8.21.09 and above

series High Temperature

Heat Recovery Unit

Model:

HRU

Issue Date: 2.18.11

Manual P/N

Printed in the USA

114819 rev.A

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Page 1 Installation/Operation Guide with Service Replacement Parts For machines built from 8.21.09 and above series High Temperature Heat Recovery Unit Model: 3765 Champion Blvd., Issue Date: 2.18.11 Winston-Salem, NC 27105 336/661-1556 Fax: 336/661-1660 Manual P/N 114819 rev.A www.championindustries.com 2674 N. Service Road,...
Page 2 The USGBC and the CaGBC Member Logos are trademarks owned by the U.S. Green Building Council and The Canadian Green Building Council, respectively, and are used by permission. The logos signify only that Champion Industries is a USGBC member and a CaGBC member; USGBC and CaGBC do not review, certify nor endorse the products or services offered by its members.
Page 3: Revision History
Revision History Revision History The revision history contains part number changes and instructions not available at the time of printing. We reserve the right to make any changes without notice and without incurring any liability by making these changes. Equipment owners may request a revised manual at no charge, by calling: 1 (800) 858-4477 in the U.S.A.
Page 4: 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 5: Table Of Contents
Table of Contents Table of Contents Model HRU: Heat Recovery Unit Revision History........................i Limited Warranty ........................ii Model Description ......................... iv Installation ......................1 Receiving ................ 1 Mounting ................. 3 Plumbing Connections ........... 5 Setting the PRV's ............6 Operation Lights and Exhaust Blowers ......
Page 6: Model Description
Model Description Model: HRU Heat Recovery Unit The HRU heats cold water supplied to the dishwasher's built-in heat exchanger which raises the incoming temperature to approximately 110°F/43°C. The preheated water is plumbed to the final rinse water booster which ensures a minimum final rinse water temperature of 180°F/82°C to sanitize the clean wares.
Page 7: Installation
Installation Installation Receiving NOTE: The installation of your Heat Recovery Unit (HRU) must be performed by qualified service personnel. Problems due to improper installation are not covered by the Warranty. The HRU may have be installed at the factory. Proceed to the operation section of this manual if your HRU is already attached to the machine.
Page 8 Installation Installation Receiving CAUTION: Metal edges in the HRU may be sharp. Use appropriate caution when working on and in the vicinity of metal components NOTE: The installation of the HRU must comply with local safety and health codes. The HRU weighs approximately 175 lbs./79.4 Kg and mounts on the top of the unload end of the dishwasher.
Page 9: Mounting
Installation Installation Mounting NOTE: The HRU may have been mounted at the factory so the procedures described below may not be required. Install the HRU after the dishwasher is completely assembled. Lift the unit with a forklift or a minimum of four persons capable of positioning and lowering the HRU into its final position.
Page 10 Blank Page This Page Intentionally Left Blank...
Page 11: Plumbing Connections
Installation Installation Plumbing Connections Refer to the photograph below and follow the instructions to connect the water lines to the HRU. Connect compression fittings from the cold water supply line located at the base of the dishwasher booster heater to the HRU. Connect compression fittings from the HRU return line at the rear of the HRU to the booster inlet located at the base of the machine.
Page 12 Installation Installation Setting the Booster Pressure Reducing Valves (PRV's) Refer to the illustrations on the next two pages for the location of the water valves and the Green indicator lights. Ensure that all utility connections are complete. Remove the lower front panel of the unload section. Remove the coil assembly (A) from the multi-rinse valve.
Page 13 Installation Installation Setting the Booster Pressure Regulating Valves (PRV's) Reinstall the main control cabinet cover. Reinstall the coil assembly on the multi-rinse valve (A). Open all drain valves and drain the dishwasher. Turn the hot water supply ON. Makes sure the main power supply is ON. Multi-rinse Valve To Final Rinse Hot PRV...
Page 14 Installation Operation Indicator Lights Green Indicator Lights Green indicator lights inside the HRU control cabinet indicate the operation state of the valves during the REHEAT FINAL FILL set-up procedures. Refer to the set-up procedures on the previous two pages to set the pressure reducing valves. In addition, the green lights will indicate the operation of the booster valves during normal operation.
Page 15: Operation
Operation Operation NOTE: The operation of the HRU is automatically controlled by the dishwasher control circuit. The HRU has a control that is accessed only by a trained service technician. Refer to the illustration below to prepare the HRU for operation. Open the top cover of the HRU and remove any foreign objects.
Page 16: Cleaning
Cleaning Cleaning CAUTION: Do not place objects on top of the condenser coil nor with the cleaning devices. Avoid the use of cleansers or other detergents to prevent damage to the top of the coil Refer to the illustration below. Monthly Cleaning Schedule: Open the top cover over of the HRU.
Page 17: Service Replacement Parts
Service Replacement Parts Service Replacement Parts Illustrations Page Heat Recovery Unit ......................Control Cabinet - Prior to S/N J11022850 ................Control Cabinet Terminal Block - Prior to S/N J11022850 ........... Control Cabinet - Beginning with S/N J11022850 and above ..........Control Cabinet Terminal Block - Beginning with S/N J11022850 and above .....
Page 18: Heat Recovery Unit
Heat Recovery Unit 62 66...
Page 19 Heat Recovery Unit 100097 SCREW, TRUSS HD., 10-32 X 1/2" SST 0512027 COUPLER, BARB 3/4" MPT X 3/4" HOSE 100156 LOCKNUT, 3/4" NPT BRASS 333557 ACCESS PLATE WELDMENT, HRU PLENUM G3 100209 NIPPLE, 1/2" NPT X CLOSE BRASS 100735 BOLT, HEX HD., 1/4-20 X 5/8" SST 100736 BOLT, HEX HD., 1/4-20 X 3/4"...
Page 20: Control Cabinet - Prior To S/N J11022850
Control Cabinet - Prior to S/N J11022850 See next page Prior to S/N J11022850 (Left to Right Direction Shown)
Page 21 Prior to S/N J11022850 - Control Cabinet 333305 CONTROL CABINET WELDMENT, HRU W/XFRM 106364 LIGHT, INDICATOR 107966 HEX GRIP NUT, 10-32 W/NYLON INSERT SST 333536 BRACKET, LIGHTS HRU CONTROL CABINET 114661 TIMER, FIXED 15 SECOND 120VAC 113769 DIN RAIL 35MM X 15MM 100095 SCREW, ROUND HD., 10-32 X 3/8"...
Page 22: Control Cabinet Terminal Block - Prior To S/N J11022850
Control Cabinet Terminal Block - Prior to S/N J11022850...
Page 23 Prior to S/N J11022850 - Control Cabinet Terminal Block 114520 TERMINAL, SINGLE MZB 1.5-NS35 114512 TERMINAL, SINGLE, ST 2.5 (GRAY) 114517 TERMINAL, DOUBLE STTB 2.5 114519 END BLOCK, E/NS 35N 114522 BUS BAR 4-POLE (CUT TO FIT) 114518 END COVER, DOUBLE TERMINAL, D-STTB 2.5 114515 TERMINAL, SINGLE GROUND, ST 2.5 PE (GREEN) 114516...
Page 24: Control Cabinet - Beginning With S/N J11022850 And Above
Control Cabinet - Beginning with S/N J11022850 and above FILL REHEAT RINSE See next page for terminal block detail. Prior to S/N J11022850 (Right to Left Direction Shown) (For left to right direction, flip inner panel to place transformer to the left)
Page 25 Beginning with S/N J11022850 and above - Control Cabinet 100003 HEX PLAIN NUT, 1/4-20 SST 100095 SCREW, ROUND HD., 10-32 X 3/8" SST 100735 BOLT, HEX HD., 1/4-20 X 5/8" SST 106396 SCREW, TRUSS HD., 10-32 X 3/8" SST 106402 BLOCK, FUSE 2 POLE 106482 WASHER, LOCK, 1/4"...
Page 26: Control Cabinet Terminal Block - Beginning With S/N J11022850 And Above
Control Cabinet Terminal Block - Beginning with S/N J11022850 and above...
Page 27 Beginning with S/N J11022850 and above - Control Cabinet Terminal Block 114520 TERMINAL, SINGLE MZB 1.5-NS35 114512 TERMINAL, SINGLE, ST 2.5 (GRAY) 114517 TERMINAL, DOUBLE STTB 2.5 114519 END BLOCK, E/NS 35N 114522 BUS BAR 10-POLE (CUT POLES TO FIT) 114518 END COVER, DOUBLE TERMINAL, D-STTB 2.5 114515...
Page 28: Hru Electric Booster Assembly
HRU Electric Booster Assembly To Final Rinse Hot PRV To HRU To Tank Hot Water In Fill Cold PRV From HRU Cold Water In Control High Limit Thermostat Thermostat...
Page 29 HRU Electric Booster Assembly 100003 HEX PLAIN NUT 1/4-20 SST 100097 SCREW, TRUSS HD. 10-32 X 1/2” SST 100100 SCREW, ROUND HD., 8-32 X 1/4” SST 100113 CAP, 3/4” NPT SST 100154 HEX PLAIN NUT, 5/16-18 SST 100734 BOLT, HEX HD., 1/4-20 X 1/2” SST 100736 BOLT, HEX HD., 1/4-20 X 3/4”...
Page 30: Hru Electric Booster Piping
HRU Electric Booster Piping To Final Rinse Hot PRV To HRU To Tank Hot Water In Fill Cold PRV From HRU Cold Water In...
Page 31 HRU Electric Booster Piping 100184 NIPPLE, 3/4” NPT X CLOSE, BRASS 100209 NIPPLE, 1/2” NPT X CLOSE, BRASS 102438 ELBOW, STREET, 1/2” NPT X 90°, BRASS 102514 TEE, 1/2” NPT BRASS 102549 UNION, 1/2” NPT, BRASS 102392 BUSHING, REDUCING 3/4” NPT X 1/2” NPT, BRASS 109879 FITTING, COMP.
Page 32: Hru Steam Booster Assembly
HRU Steam Booster Assembly...
Page 33 HRU Steam Booster Assembly 100140 HEX PLAIN NUT, 3/8-16 SST 100153 BOLT, HEX HD. 3/8-16 X 1" SST 100154 HEX PLAIN NUT, 5/16-18 SST 100739 BOLT, HEX HD., 5/16-18 X 3/4" SST 102376 WASHER, FLAT 5/16" SST 104618 WASHER, FLAT 3/8" SST 106013 WASHER, LOCK 5/16"...
Page 34: Hru Steam Booster Piping
HRU Steam Booster Piping...
Page 35 HRU Steam Booster Piping 100123 PETCOCK, 1/4” FEMALE BRASS 100134 ELBOW, STREET, 1” NPT X 90° MI 100979 BUSHING, RED 1-1/2” NPT X 1” NPT BI 102288 ELBOW, 1/2” NPT X 90° MI 102402 BUSHING, RED. 3/4” NPT X 1/2” NPT BI 103465 BUSHING, RED.
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Page 37: One Line Piping Diagram
Electrical Schematics and Operation Logic Diagram One Line Piping Diagram Operation Logic Diagram Electrical Schematic...
Page 38 Blank Page This Page Intentionally Left Blank...
Page 39 One Line Piping Diagram FROM MAIN CABINET MULTI- RINSE HEADER MULTI-RINSE VALVE USED ON EEUC ONLY FINAL COIL TEMP RINSE FAN 1 FAN 2 COLD WATER VALVE HEADER COLD WATER BSTR COIL INITIAL FILL VALVE REHEAT RINSE VALVE HOT WATER ONE LINE DIAGRAM FOR HEAT RECOVERY UNIT (HRU) MODELS - EUCC4, EUCC8, EUCC6, EEUCC8, EEUCC6, EEUCC4...
Page 40 Operation Logic Diagram HRU Logic Diagram v.8410...
Page 41: Electrical Schematic
Electrical Schematic...
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