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Champion D-HBTM4 Technical Manual

Door-type extended hood dishwasher
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For machines beginning with
serial no. D1848 thru D3693.
February, 2003
P. O. Box 4149
Winston-Salem, North Carolina 27115-4149
336/661-1556
Fax: 336/661-1660
Technical Manual
www.championindustries.com
Door-Type
Extended Hood
Dishwasher
Model
D-HBTM4, D-HBTCM4
High Temperature
Extended Hood
with Built-in Booster
D-H1TM4, D-H1TCM4
High Temperature
Extended Hood
without Built-in Booster
Machine Serial No.
113138
P/N
Manual
2674 N. Service Road
Jordan Station, Ontario, Canada L0R 1S0
905/562-4195
Rev. C
Fax: 905/562-4618

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Summary of Contents for Champion D-HBTM4

  • Page 1 Technical Manual For machines beginning with serial no. D1848 thru D3693. Door-Type Extended Hood Dishwasher Model D-HBTM4, D-HBTCM4 High Temperature Extended Hood with Built-in Booster D-H1TM4, D-H1TCM4 High Temperature Extended Hood without Built-in Booster Machine Serial No. 113138 February, 2003 Manual Rev.
  • Page 2 Note: When calling to order parts, be sure to have the model number, serial number, voltage and phase of your machine, along with your customer account number. Machine Data Plate with Machine Model & Serial Number located on the front panel. COPYRIGHT ©2003 by Champion Industries, Inc.
  • Page 3 REVISONS Revision History Revision Revised Serial Number Comments Date Pages Effectivity 04/01/01 Issue of New Manual and Service Parts List 08/28/01 D2964 First S/N with electrical drain valve 113315 and timer 113314 08/28/01 — Added P/N 900830 Drain Valve Kit for machines D1848 thru D2963 01/03/02 D3291...

  • Page 4: Table Of Contents

    CONTENTS CONTENTS LIMITED WARRANTY ....................... iv INTRODUCTION ......................... 1 Model Number ........................2 Standard Equipment ......................2 Options ..........................2 Electrical Power Requirements ..................3 INSTALLATION ........................... 4 Unpack the Dishwasher ...................... 4 Electrical Connections ......................5 Plumbing Connections ......................7 Water Connections ......................
  • Page 5 CONTENTS LIST OF FIGURES (cont.) Figure 10 – Rinse Aid Injection Point (Top of Dishwasher) ............10 Figure 11 – Fuses ........................23 Figure 12 – Motor Overload ....................... 23 Figure 13 – Solid State Control Board ..................26 Figure 14 – Float Switch ......................27 Figure 15 –...

  • Page 6: Limited Warranty

    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, whichever occurs first.

  • Page 7: Introduction

    All information, illustrations and specifications contained in this manual are based upon the latest product information available at the time of publication. Champion constantly improves its products and reserves the right to make changes at any time or to change specifications or design without notice and without incurring any obligation.

  • Page 8: Model Number

    GENERAL Model Numbers D-HBT, D-HBTC, D-H1T, D-H1TC The D-HBT model is a high temperature (180°F/82°C rinse) sanitizing model with booster. The D-H1T, D-H1TC models are high tem- perature (180°F/82°C rinse) sanitizing models. Standard Equipment includes: D-HBT, D-HBTC, D-H1T, DH1TC • Automatic tank fill and start •...

  • Page 9: Electrical Power Requirements

    GENERAL Electrical Power Requirements: Electric Heat/Electric Booster Model Voltage Booster Rise Rated Minimum Supply Ckt. Maximum Overcurrent (D-HBT Only) Amps Conductor Ampacity Protective Device D-H1T 208/60/1 — 28 Amps 35 Amps 35 Amps D-H1T 220/60/1 — 28 Amps 35 Amps 35 Amps D-H1T 230/60/1...

  • Page 10: Installation

    1. Immediately after unpacking the machine, inspect for any shipping damage. If damage is found, save the packing material and contact the carrier immediately. POWER Champion 2. Remove the dishwasher from the skid. CYCLE Move the machine to its permanent location. WARNING!

  • Page 11: Electrical Connections

    INSTALLATION INSTALLATION (Cont.) Electrical Connections WARNING: Electrical and grounding connections must comply with all applicable Electrical Codes. WARNING: When working on the dishwasher, discon- nect the electric service and place a tag at the disconnect switch to indicate work is being done on that circuit.

  • Page 12: Figure 3 Hinged Control Panel

    INSTALLATION Electrical Connections (Cont.) Refer to Fig. 3 3. Remove (2) lower screws from the front panel of the machine to expose the electri- cal controls. Remove (2) screws on the control panel support. Swing the hinged control panel forward. Figure 3 Hinged Control Panel Refer to Fig.

  • Page 13: Plumbing Connections

    INSTALLATION INSTALLATION (Cont.) Plumbing Connections NOTE: Plumbing connections must comply with all applicable sanitary and plumbing codes. Water Connections 1. All D-HB/H1T series dishwashers require a 8-7/8" [225 mm] single, hot water supply. The hot water connection to all D-HB/H1T series dishwashers is 3/4"...

  • Page 14: Drain Connections

    INSTALLATION Water Connections (Cont.) 2. A manual shut-off valve for steam and water (supplied by others) should be installed in the supply line to allow for servicing of the machine. The shut-off valve should be the same size or larger than the supply line. 3.

  • Page 15: Chemical Connections

    INSTALLATION INSTALLATION (Cont.) Chemical Connections NOTE: Consult a qualified chemical supplier for your chemical needs. The detergent that you will need to use should be for automatic dishwashing machines. Refer to Fig. 7 1. A chemical signal terminal block is supplied for chemical dispensing equipment.

  • Page 16: Figure 9 - Detergent Probe Injection Points, 1/2

    INSTALLATION Chemical Connections (Cont.) Refer to Fig. 9 5. A 1/2" detergent probe injection point is provided at the rear and left side of the dishwasher. 6. Detergent may be added manually if your dishwasher is not equipped with dispensing equipment. Consult your chemical supplier for recommended amounts.

  • Page 17: Initial Start-Up

    INITIAL START-UP INITIAL START-UP Complete the Installation After plumbing and electrical connections are made, follow the steps below to complete the installation of your dishwasher. 1. Remove the white protective covering from the exterior of the machine. 2. Remove any foreign material from inside the machine. 3.
  • Page 18 INITIAL START-UP INITIAL START-UP (Cont.) POWER WASH CYCLE CYCLE 1 MIN THE POWER SWITCH IS 2 MIN ON DURING INITIAL FILL. 4 MIN 6 MIN Make sure the doors are fully closed. Push the On/Off power WASH RINSE PRESSURE switch to the UP position. THE DISHWASHER FILLS AUTOMATICALLY.
  • Page 19 INITIAL START-UP INITIAL START-UP (Cont.) Fully close the dishwasher doors. The dishwasher will begin the automatic cycle. Opening the doors anytime during the cycle will stop the dishwasher. Closing the doors will resume the automatic cycle where it left off. The cycle times are listed below: 1 Minute Wash Cycle Setting 2 Minute Wash Cycle Setting...
  • Page 20 INITIAL START-UP INITIAL START-UP (Cont.) Check Final Rinse Water Temperature Check the final rinse water temperature during the final rinse cycle. The final rinse water temperature gauge is located in the final rinse piping at the top of the dishwasher. The final rinse water tempera- ture should be a minimum of 180°F/82°C for (D-HBT, D-H1T).
  • Page 21 INITIAL START-UP INITIAL START-UP (Cont.) POWER WASH CYCLE The Wash Cycle Selector CYCLE Switch 1 MIN 2 MIN 4 MIN The wash cycle selector switch provides 6 MIN the option of choosing four different dishwasher cycle times. WASH RINSE PRESSURE To select a cycle time —...
  • Page 22 INITIAL START-UP INITIAL START-UP (Cont.) Complete the initial start-up Check all the plumbing for leaks. Also, check the drain plumbing for leaks and be sure that the drain will handle the drain water flow (15 gal/min-56.8 liters/min) from the dishwasher. After the drain and the plumbing connections are checked, turn off the dishwasher power switch.

  • Page 23: Operation Summary

    OPERATION OPERATION SUMMARY Action Result 1. Push the On/Off power switch “UP” to 1. The power indicator light illuminates. The the ON position. Dishwasher fills wash tank heater (D-HBT/H1T) and the automatically. booster tank heater (D-HBT) begin to heat. 2. Wait approximately 10 minutes for the 2.

  • Page 24: Cleaning

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

  • Page 25: Deliming Process

    CLEANING 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 fluorine.

  • Page 26: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING Perform the seven checks listed below in the event that your dishwasher does not operate as expected. 1. All switches are ON 2. Wash and rinse nozzles are clean 3. Wash and rinse pipe assemblies are installed correctly 4.
  • Page 27 TROUBLESHOOTING TROUBLESHOOTING (Cont.) CONDITION CAUSE SOLUTION Insufficient pumped Clogged pump intake screen ....Clean spray pressure Clogged spray pipe ....... Clean Scrap screen full ........Must be kept clean and in place Pump motor rotation incorrect ....Reverse connection between L1 and L2 in Control Cabinet Defective pump seal ......

  • Page 28: 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 schemat- ics 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 29: Figure 11 - Fuses

    BASIC SERVICE ELECTRICAL SERVICE (Cont.) Fuses — Refer to Fig. 11. There are two fuse blocks. A 3-pole block (A) is located in the main control cabinet. The (A) fuses protect the wash tank heater circuit. Booster heater circuits (D-HBT only) are not fused. A 2-pole fuse block is located on the machine base to protect the control circuit.
  • Page 30 BASIC SERVICE SOLID STATE D-HBT AND D-H1T OPERATING INSTRUCTIONS Automatic Operation 1. Check that screens are clean and in place. 2. Turn on main power to the machine. 3. Flip machine control panel power switch to ON. 4. Close doors. •...
  • Page 31 BASIC SERVICE TROUBLESHOOTING TIMER CIRCUIT BOARD (cont.) Power Terminals • Verify that the board is receiving power of 120 VAC at the terminals: – T2, marked “H” (AC Hot). – T1, marked “N” (AC Neutral). If either of these terminals is not receiving 120 VAC, then there is a problem elsewhere with the unit not receiving power.

  • Page 32: Figure 13 Solid State Control Board

    BASIC SERVICE 1.4 Testing Board Outputs After you have verified that the circuit board is receiving power (as explained above), then test the board outputs. There are 4 board outputs: • Wash Cycle. • Rinse Cycle. • Heaters. • In-Cycle Lamp. Perform the following steps to test a board output: 1.

  • Page 33: Figure 14 Float Switch

    BASIC SERVICE Models D-HBT and D-H1T use a float switch and circuit board to control tank fill and tank heat. For Model D-HBT 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 34: Figure 16 Heater Element Wiring

    BASIC SERVICE ELECTRICAL SERVICE (Cont.) 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.

  • Page 35: Figure 17 Pump Motor Wiring Diagrams

    BASIC SERVICE ELECTRICAL SERVICE (Cont.) Motor Connections — 1. Models D-HBT and D-H1T 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 36: Figure 18 Pump Seal Replacement

    BASIC SERVICE 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 37: Replacement Parts

    REPLACEMENT PARTS REPLACEMENT PARTS...

  • Page 38: Figure 19 - Panels

    REPLACEMENT PARTS Figure 19 - D-HBT/D-H1T Panels...
  • Page 39 REPLACEMENT PARTS D-HBT/D-H1T PANELS Fig. 19 Part Item No. Part Description Qty. 321929 RH Panel No Cut Out ................. 324588 Panel, Instrument ................113051 Label, Panel Overlay DH-T/TC ............322074 Panel, Front Lower ................321941 LH Panel W/Cut Out ................108418 Plug Plastic ..................

  • Page 40: Figure 20 - Doors, Guides, & Stops (D-Hbt, D-H1T)

    REPLACEMENT PARTS Figure 20 - DHB-T/DH1-T Doors, Guides, & Stops...
  • Page 41 REPLACEMENT PARTS DHB-T/DH1-T DOORS, GUIDES, AND STOPS Fig 20 Part Item No. Part Description Qty. 100141 Nut, Grip 1/4-20 SST ................. 317345 Bracket, Door Catch ................317344 Hook, Door Catch ................108053 Plug, Corner Post ................107970 Screw, 8/32 x 1" Filister Head............112704 Door Guide, Side Door Left ...............

  • Page 42: Figure 21 - Doors, Guides & Stops (Corner Model Only) (D-Hbtc/Dh1Tc)

    REPLACEMENT PARTS Figure 21 - D-HBTC/D-H1TC Doors, Guides, & Stops (Corner Model Only)
  • Page 43 REPLACEMENT PARTS D-HBTC/D-H1TC DOORS, GUIDES, AND STOPS Fig 21 Part Item No. Part Description Qty. 108053 Plug, Corner Post ................107970 Screw 8-32 x 1 Filister Head .............. 112704 Guide, Door Left ................112705 Guide, Door Right ................325633 Door, Side Upper ................322788 Door, Lower Side ................

  • Page 44: Figure 22 - Door Handle, Spring Assembly And Safety Switch

    REPLACEMENT PARTS Figure 22 - D-HBT/D-H1T Door Handle, Spring Assembly, and Safety Switch...
  • Page 45 REPLACEMENT PARTS DHB-T/DH1-T DOOR HANDLE, SPRING ASSEMBLY, AND SAFETY SWITCH Fig 22 Part Item No. Part Description Qty. 112723 Bolt 5/16-18 x 15 ................108066 Spring, Extension ................107397 Block, Spring Hook ................112687 Door Handle (Standard Machine) ............112860 Door Handle (Corner Machine) ............

  • Page 46: Figure 23A - Straight Track Assembly

    REPLACEMENT PARTS Figure 23A – D-HBT/D-H1T Straight Track Assembly Figure 23B – D-HBT/D-H1T Corner Track Assembly...
  • Page 47 REPLACEMENT PARTS D-HBT/D-H1T STRAIGHT TRACK ASSEMBLY Fig. 23A Part Item No. Part Description Qty. 0309472 Track, Rear ..................100073 Bolt (1/4 -20 x 1/2 Truss Head) ............106482 Washer, Lock ..................100003 Nut (1/4-20 Hex Hd) ................D-HBT/D-H1T CORNER TRACK ASSEMBLY Fig.

  • Page 48: Figure 24 - Wash/Rinse Spray Piping

    REPLACEMENT PARTS Figure 24 - D-HBT/D-H1T Wash/Rinse Spray Piping...
  • Page 49 REPLACEMENT PARTS D-HBT/D-H1T WASH/RINSE SPRAY PIPING Fig 24 Part Item No. Part Description Qty. 325632 Rinse Manifold Weldment..............113027 Connector, Rinse Arm ................ 113028 Top Rinse Arm Connector ..............0507445 Spindle, Wash Arm ................109864 Support, Wash Arm ................113252 Standpipe, Wash .................

  • Page 50: Figure 25 - Wash/Rinse Spray Arms

    REPLACEMENT PARTS Figure 25 - D-HBT/D-H1T Wash/Rinse Spray Arms...
  • Page 51 REPLACEMENT PARTS D-HBT/D-H1T WASH/RINSE SPRAY ARMS Fig. 25 Part Item No. Part Description Qty. 0507443 Spindle, Rinse Arm ................0508376 Nozzle, Rinse Arm ................112164 Bearing, Rinse Arm ................0707453 Rinse Arm Assy. (Includes 2 & 3) ............0507444 Nut, Rinse Arm ................... 109835 Screw (#8 x 1/2 Pan Hd) ..............

  • Page 52: Figure 26 - Drain Assembly And Scrap Screens

    REPLACEMENT PARTS Figure 26 - D-HBT/D-H1T Drain Assembly and Scrap Screens...
  • Page 53 REPLACEMENT PARTS D-HBT/D-H1T DRAIN ASSEMBLY AND SCRAP SCREENS Fig 26 Part Item No. Part Description Qty. 305164 Screen 10" ..................324582 Filler Plate ..................100736 Bolt 1/4-20 x 3/4 Hex Head ............... 106026 Washer, Flat ..................107967 Grip, Nut 1/4-20 w/Nylon Insert ............304816 Strainer ....................

  • Page 54: Figure 27 - Wash Tank Heat And Thermostats

    REPLACEMENT PARTS Figure 27 - D-HBT/D-H1T Wash Tank Heat and Thermostats...
  • Page 55 REPLACEMENT PARTS D-HBT/D-H1T WASH TANK HEAT AND THERMOSTATS Fig. 27 Part Item No. Part Description Qty. 113622 Thermometer 4 Ft. Gas Filled (Replaces 108391) ......109069 Thermostat W/Cap 110-220°F ............201041 Washer ....................201029 Nut, Lock 1/2" ..................322076 Dual Thermostat Bracket ..............110561 Thermostat, Fixed High Limit ............

  • Page 56: Figure 28 - Electric Booster And Thermostats

    REPLACEMENT PARTS Figure 28 - D-HBT Only Electric Booster and Thermostats...
  • Page 57 REPLACEMENT PARTS D-HBT ONLY ELECTRIC BOOSTER AND THERMOSTATS Fig. 28 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 ............108954 Nut, Grip 6-32 W/Insert ..............110562 Thermostat, High Limit ..............

  • Page 58: Figure 29 - Lower Fill Piping Assembly (D-Hbt Only)

    REPLACEMENT PARTS TO UPPER PIPING CUSTOMER WATER INLET Figure 29 - D-HBT Only Lower Fill Piping Assembly...
  • Page 59 REPLACEMENT PARTS D-HBT ONLY LOWER FILL PIPING ASSEMBLY Fig. 29 Part Item No. Part Description Qty. 112387 Line Strainer/PRV Combo..............102444 Street Ell 3/4" NPT Brass ..............102651 Nipple 3/4" x 2" Brass ................ 111437 Valve 3/4" NPT Hot Water ..............100184 Nipple 3/4"...

  • Page 60: Figure 30 - Upper Fill Piping Assembly (D-Hbt/D-H1T)

    REPLACEMENT PARTS WATER IN FROM LOWER PIPING Figure 30 - D-HBT/D-H1T Upper Fill Piping Assembly...
  • Page 61 REPLACEMENT PARTS D-HBT/D-H1T UPPER FILL PIPING ASSEMBLY Fig 30 Part Item No. Part Description Qty. 100156 Locknut, 3/4" NPT Brass ..............100571 Union 3/4" NPT Brass ................ 102392 Bushing, Reducing 3/4" NPT x 1/2" Brass ........100599 Cross., 3/4 NPT Brass ................ 108181 Bushing, Reducing 3/4 x 1/4 NPT Plastic ..........

  • Page 62: Figure 31 - Lower Fill Piping Assembly (D-H1T Only)

    REPLACEMENT PARTS TO UPPER PIPING CUSTOMER WATER IN Figure 31 - D-H1T Only Lower Fill Piping Assembly...
  • Page 63 REPLACEMENT PARTS D-HBT/D-H1T LOWER FILL PIPING ASSEMBLY Fig 31 Part Item No. Part Description Qty. 102444 Street Ell 3/4" NPT Brass ..............0309340 Plumbing Support Bracket ..............110768 Line Strainer 3/4" Brass ..............111437 Valve 3/4" NPT Hot Water ..............109903 Repair Kit, 3/4"...

  • Page 64: Figure 32 - Pump Assembly

    REPLACEMENT PARTS Figure 32 - D-HBT/D-H1T Pump Assembly...
  • Page 65 REPLACEMENT PARTS D-HBT/D-H1T PUMP ASSEMBLY Fig 32 Part Item No. Part Description Qty. 324580 Strainer ....................107966 Nut, Grip 10-32 w/Nylon Insert ............104203 Clamp, Hose ..................104165 Clamp, Hose ..................107340 Clamp, Hose ..................112383 Hose Pump, Discharge ............... 0508515 Hose, Suction ..................

  • Page 66: Figure 33 - Control Panel And Gauges

    REPLACEMENT PARTS POWER WASH CYCLE CYCLE 1 MIN 2 MIN 4 MIN 6 MIN WASH RINSE PRESSURE 9 10 CHAMPION INDUSTRIES, INC. WINSTON-SALEM, NC MODEL W P/N 108391 120V TIMER Figure 33 - D-HBT/D-H1T Control Panel and Gauges...
  • Page 67 REPLACEMENT PARTS D-HBT/D-H1T CONTROL PANEL AND GAUGES Fig 33 Part Item No. Part Description Qty. 0501361 Switch, On-Off ................... 112390 Lite, Red (Power) ................112391 Lite, Amber (In-Cycle) ............... 113054 Switch, Time Select (4 Position) ............113055 Contact Block (NO) ................113056 Contact Block (NO) ................

  • Page 68: Figure 34 - Control Cabinet

    REPLACEMENT PARTS Figure 34 - D-HBT/D-H1T Control Cabinet...
  • Page 69 REPLACEMENT PARTS D-HBT/D-H1T CONTROL CABINET Fig 34 Part Item No. Part Description Qty. 900911 Kit* DM Board & Instructions ............106925 Block, Fuse (30A, 3 Pole) ..............100913 Fuse, 10A (DHB-T) 208-240/380-415/3 ..........100906 Fuse, 5A (DHB-T) 480V/3 ..............100913 Fuse, 10A (DH1-T) 208-240/380-415/3 ..........

  • Page 70: Figure 35 - Dishracks And Prv

    REPLACEMENT PARTS Figure 35 - Dishracks and PRV...
  • Page 71 REPLACEMENT PARTS DISHRACKS AND PRV Fig. 35 Part Item No. Part Description Qty. 101273 Rack (Flat Bottom) ................101285 Rack (Peg) ..................112387 Line Strainer/PRV Combo..............

  • Page 72: Appendix A – Drain Valve/Timer Circuit

    REPLACEMENT PARTS APPENDIXES APPENDIX A DRAIN VALVE/TIMER CIRCUIT Models D and D-H1T use 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 position, the 3CR relay coil is then energized, closing the 3CR contacts.

  • Page 73: Electrical Schematic

    REPLACEMENT PARTS ELECTRICAL SCHEMATICS...

This manual is also suitable for:

D-h1tm4D-hbtcm4D-h1tcm4

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