Service, Parts, Operation & Installation Manual 04/02/2012 (Rev.C)
Contents
1. a 58 Remote Control Cabinet Component Selection Chatt i 63 31 Water Extractor Assembly Inner View 32 Inner View Water Extractor Assembly Item Part Description Qty No No 1 100007 SCREW TRUSS HEAD 10 32 X 3 8 SST 3 2 100028 ELBOW STREET 1 1 2 X 90 GALV 1 3 100034 NIPPLE 1 1 2 NPT X 5 1 4 LG GALV 1 4 100036 TEE 1 1 2 NPT GALV 1 5 100043 NIPPLE 1 1 2 NPT X CLOSE GALV B 6 100140 HEX PLAIN NUT 3 8 16 SST 1 7 100141 T HEX GRIP NUT 1 4 20 X SST TOP LOCK 6 8 100153 BOLT HEX HD 3 8 16 X 1 SST 8 9 100054 HEX PLAIN NUT 5 16 18 SST 6 10 100159 ELBOX 1 1 2 X 90 GALV 1 11 100194 HEX GRIP NUT 10 32 SST 4 12 100736 BOLT HEX HD 1 4 20 X 3 4 SST 6 13 100740 BOLT HEX HD 5 16 18 X 1 SST 6 14 100754 SCREW FLAT HD 10 32 X 1 2 SST 2 15 102376 WASHER FLAT 5 16 X 3 4 X 06 SST 4 16 102506 PLUG 3 4 NPT SQ HD SST 1 17 105165 CLAMP HOSE M40 SST GEAR TYPE 2 18 104203 CLAMP HOSE M52 SST GEAR TYPE 4 19 105751 BALL VALVE 1 1 2 NPT BRONZE 1 20 106013 WASHER LOCK 5 16 SPLIT SST 4 21 106026 WASHER FLAT 1 4 X 5 8 X 06 SST 6 22 106035 COTTER PIN 3 32 X 1 UNEVEN 1 23 106407 WASHER LOCK 3 8 SPLIT SST 8 24 107033 WASHER FLAT 1 25 107136 BOLT HEX HD 10 32 X 3 8 SST 1 26 110564 REDUCER PULPER WATER EXTRACTOR 1 27 110594 HOSE 2 7 8 X 1 LG EPDM 2 28 110629 MOTOR 2HP P5 AUGER DRIVE MV 3PH 1 112442 MOTOR 3HP P7 AUGER DRIVE2. 58 Pulper Water Extractor Remote Control Cabinet Item Part Description Qty No No 1 100095 SCREW ROUND HD 10 32 X 3 8 SST 14 2 100302 PILOT LIGHT 120VAC RED 1 3 100735 BOLT HEX HD 1 4 20 X 5 8 SST 4 4 102292 NAMEPLATE ON OFF 1 5 103310 GROUND LUG 1 6 104873 LABEL GROUND 1 7 106026 WASHER FLAT 1 4 SST 4 8 106482 WASHER LOCK 1 4 SST 4 9 106975 LABEL 1CR 1 10 106976 LABEL 2CR 1 11 106977 LABEL 3CR 1 12 106978 LABEL 4CR 1 13 106980 LABEL 1M 1 14 106981 LABEL 2M 1 15 107096 LABEL 3M 1 16 107098 LABEL XFMR 1 17 107099 LABEL 1MOL 1 18 107100 LABEL 2MOL 1 19 107101 LABEL 3MOL 1 20 107351 SWITCH TOGGLE DPDT ON NONE OFF 1 21 CONTACTOR 3 POLE 120VAC COIL Water Extractor amp Recir 22 108311 CIRCUIT BREAKER 3 AMP 1 23 108370 LOCK WASHER ELECTRICAL 2 24 108498 LABEL MAX FUSE AMP 1 25 108615 LABEL MACH ELECTRICAL CONNECTION 1 26 STEP DOWN TRANSFORMER 250VA 1 27 CONTACTOR MOTOR 3 POLE 120VAC COIL Pulper Drive 1 28 110346 LABEL 5CR 1 29 110348 LABEL 24V XFRM 1 30 110541 SHAFT CIRCUIT BREAKER 1 31 CIRCUIT BREAKER 1 32 110612 NAMEPLATE CIRCUIT BREAKER 1 33 110613 NAMEPLATE FLUSHING VALVE 1 34 110628 NAMEPLATE POWER ON 1 35 111036 SOCKET RELAY 2 POLE 10A 5 36 111067 RELAY 2 POLE 10A 24VAC COIL 1 37 111068 RELAY 2 POLE 10A 120VAC COIL 4 38 111153 FUSE HOLDER ASSEMBLY 2 39 111162 NAMEPLATE DELAY STOP 1 40 111277 TRANS
3. N N A R 53 Deodorizer Pump Assembly Pulper Water Extractor 54 Pulper Water Extractor Deodorizer Pump Assembly Item Part Description Qty No No 1 317006 BOX DEODORIZER 1 2 104624 SCREW TRUSS HD 8 32 X 3 8 SST 4 3 106026 WASHER FLAT 1 4 SST 4 4 107967 HEX GRIP NUT 1 4 20 SST W NYLON 4 5 107970 SCREW FILLISTER HD 8 32 X 1 SST 2 6 111509 MOTOR GEAR REDUCER DEODORIZER PUMP 1 7 108173 SPACER SST 2 8 317007 COVER DEODORIZER BOX 1 9 111511 PUMP ASSY DEODORIZER 1 10 111510 SCREW SHOULDER ROUND HD 10 24 X 1 2 SST 2 11 111513 COLLAR DISPENSING PUMP HOSE 2 12 111512 TUBE ASSY DEODORIZER PUMP 1 13 108411 CLAMP HOSE SNP 2 2 14 110856 LOCKNUT 1 4 PLASTIC 1 15 110750 GASKET 1 4 PLASTIC 1 16 107065 ADAPTER 1 4 OD X 1 4 MPT PLASTIC 2 17 0502667 TUBING 1 4 id X 3 8 OD WHITE A R 18 108412 CLAMP HOSE SNP 6 1 19 107931 TUBE PICK UP 1 111514 DEODORIZER PUMP ASSY COMPLETE 1 INCLUDES ITEMS 6 9 10 11 12 55 Feed Trough Gaskets Pulper 56 Feed trough supplied by others Pulper Feed Trough Gaskets Item Part Description Qty No No 1 111873 GASKET PULPER 9 TROUGH 1 2 113324 GASKET PULPER 12 TROUGH 1 3 111478 BOLT HEX HD 10 32 X 1 2 SST 9 4 107033 WASHER FLAT 9 5 107966 GRIPNUT HEX HD 10 32 SST W NYLON INSERT 9 57 Pulper Water Extractor Remote Control Cabinet Comes with Item No 30 _
4. Installation Operation Manual with Service Replacement 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 Model P5 24 Issue Date 4 2 12 Manual P N 114509 rev C For machines beginning with S N J08072511 and above Winston Salem NC 27105 Ontario Canada LOR 1S0 336 661 1556 Fax 336 661 1660 905 562 4195 Fax 905 562 4618 GROUP Toll free 800 858 4477 Toll free 800 263 5798 0 511 FOUENT 3765 Champion Blvd 2674 N Service Road Jordan Station Printed in the USA For future reference record your Remote Waste Handling Systems information in the box below Model Number Serial Number Voltage Phase Service Agent Parts Distributor National Service Department In Canada In the USA Toll free 800 263 5798 Toll free 800 858 4477 Tel 905 562 4195 Tel 336 661 1556 Fax 905 562 4618 Fax 336 661 1660 email service moyerdiebellimited com email service championindustries com ATTENTION The Waste Handling System model no serial no voltage Hz and phase are needed to identify your machine and to answer questions The Serial No is located on the front of the remote mounted control cabinet Please have this information on hand if you call for service assistance The USGBC Member Logo is a trademark owned by the U S Green Building
5. Pulper Water Extractor Operation Operation 23 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 ode 10 11 12 13 14 15 16 Circuit Breaker Switch in the OFF position 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 Inspect the interior of the water extractor and make sure it is clean Check the optional deodorizer chemical container and replenish as necessary Open the water extractor discharge chute and make sure that the top of the water extractor and especially the space directly under the compression cone is clear of any obstructions Fully close the discharge chute and place a refuse container under the chute Make sure the safety switch on the water extractor and the pulper are in place and secure Make sure all access doors feed hoods curtains and covers are in place and secure Make sure all personnel are standing away from the waste handling system Turn the Main Circuit Breaker Switch on the remote control cabinet to the ON position The Power On light illuminates and the pulper fills with water Push the green Start push button on the Water Extractor A The pulper drive motor and the water extractor d
6. PUMP SUCTION 1 25 326054 FLANGE WELDMENT RECIRC PUMP 2 26 205435 HOSE PUMP SUCTION 1 27 100173 NIPPLE 1 1 2 NPT X 2 LG BRASS 1 28 104165 CLAMP HOSE M40 SST GEAR TYPE 2 51 Flushing Assembly Pulper Water Extractor 52 Wat 9 1 1 S2 Part No 317171 314131 100547 111518 102435 102388 109909 107380 108265 100209 102514 110551 101261 110676 109902 110549 100947 100675 112152 110549 100123 107065 0502667 100598 316653 Pulper Water Extractor Flushing Assembly Description SPRAY ARM WELDMENT SPRAY ARM ASSY Includes Item Nos 1 3 4 LOCKNUT 1 2 NPT BRASS NOZZLE SPRAY K 4 ELBOW 1 2 NPT X 90 BRASS BUSHING RED 1 2 NPT X 1 4 NPT BRASS FITTING COMP 1 2 OD X 1 4 MPT BRASS TUBING 1 2 TYPE L COPPER VALVE PRESSURE REG 1 2 NPT BRONZE NIPPLE 1 2 X CLOSE BRASS TEE 1 2 NPT BRASS BACKFLOW PREVENTER 1 2 NPT BRONZE ELBOW STREET 1 4 NPT X 90 BRASS VALVE SOLENOID 1 2 NPT W DIN PLUG REPAIR KIT 1 2 SOLENOID VALVE COIL SOLENOID VALVE 120VAC NIPPLE 1 4 NPT X CLOSE BRASS VALVE SOLENOID 1 4 NPT W DIN PLUG REPAIR KIT 1 4 SOLENOID VALVE COIL SOLENOID VALVE 120VAC PETCOCK 1 4 NPT FEMALE BRASS ADAPTER 1 4 OD X 1 4 MPT PLASTIC TUBING 1 4 ID X 3 8 OD WHITE CROSS 1 2 NPT BRASS TUBE WELDMENT PULPER FLUSHING Qty N N WOW A R Q IT
7. 575 603 380 503 415 505 3 unit motor system 111671 111671 111671 111671 111671 2 unit motor system 111623 111633 111633 111633 111633 Step down Transformer Item 26 Voltage VAC 208 240v 60 3 480 6 3 575603 380503 415503 __ 109064 10064 11521 11464 111464 2 2 2 Circuit Breaker Item 31 Voltage VAC 208 240v 60 3 480 603 575 60 3 _ 380 50 3 415 503 __ 11059 110587 110587 110587 110587 63 Close coupled Pulper Water Press Electrical Schematic 1 2 CB 120 VOLTS ss L1 L2 L3 GND 3 Nor 1 p POWER HOLD IN RELAY LAMP DOOR INTERLOCK RELAY DEODORIZING UNIT RELAY WATER PRESS MOTOR OVERLOAD DEODORIZING UNIT ON OFF SWITCH IF USED DELAY STOP TIMER IF USED HOLD IN RELAY PULPER DRIVE MOTOR 3M RECIRCULATION MOTOR CONTACTOR 3MOL RECIRCULATION MOTOR OVERLOAD 1SOL PULPER FILL FLUSHING VALVE WATER PRESS DRIVE MOTOR RECIRCULATION PUMP MOTOR IF USED T ym NIH oropomzmerume _ PULPER SEAL FLUSHING VALVE PULPER FILL FLUSHING VALVE 2MOL 2M 3 WATER NASO ND WATER PRESS SLURRY FLUSHING CONTROL 4 IF USED mu OFF S1 2M 1 1 1 1 350L 2 WATER PRESS FLUSHING VALVE 3MOL 3M AX E ni LATION ANIA N 28 IF USED FU1 DIAGRAM STATE POWER OFF Q INTERLOCK DOORS
8. CLOSED c Q 59 DISCHARGE PULPER CHUTE CHUTE HOLD IN RELAY TANKS EMPTY SPEED CONTROL 3CR 40 YELLOW CUT BOARD WHITE 13 DEODORIZING PUMP 02 PULPER B 701012 Rev 64
9. Council and is used by permission The logo signifies only that Moyer Diebel is a USGBC member USGBC does not review certify or endorse the products or services offered by its members COPYRIGHT O 2012 All rights reserved Printed in the USA 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 Champion The Dishwashing Machine Specialists PRODUCT REGISTRATION BY FAX COMPLETE THIS FORMAND FAX TO 336 661 1660 in the USA 1 800 204 0109 in Canada PRODUCT REGISTRATION CARD Date of Installation Company Name Address Telephone _____ Street Province Postal Code Contact Installation Company Address Telephone Contact FAILURE TO REGISTER YOUR PRODUCT MAY VOID YOUR WARRANTY IMPORTANT IMPORTANT Hevision 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 Revision Revised Serial Number Revision Dat
10. MV 3PH 1 180286 MOTOR 2HP AUGER DRIVE 575 3PH 1 111742 MOTOR 3HP P5 AUGER DRIVE 575V 3PH 1 111412 MOTOR 2HP AUGER DRIVE 380V 3PH 1 29 110893 CAP SCREW 5 16 18 X 3 4 LG SOC HD 2 30 111001 GASKET WATER Extractor SHELL 1 31 111114 BOLT HEX HD 3 8 16 X 3 1 2 LG SST 1 32 111478 BOLT HEX HD 10 32 X 1 2 SST 1 33 111939 AUGER WITH CLIPS AND BEARING ONLY 1 34 111940 BRUSH AUGER CLIP ON ONLY 1 35 112295 NAMEPLATE P5 WATER EXTRACTOR DRAIN RH 1 36 202869 HOSE 1 7 8 ID X 10 1 2 LG 1 37 312395 DISCHARGE HOUSING P5 PULPER 1 38 312398 SCREEN WATER Extractor P5 6 1 39 312489 DRAIN TEE PULPER 1 40 312512 COMPRESSION CONE 2 41 312574 ANGLE REDUCER MTG RH 1 42 312611 OVERFLOW WATER EXTRACTOR 1 43 312782 WIPER BLADE PULPER 1 44 312783 CLAMP WIPER BLADE 1 45 312785 WATER EXTRACTOR WELDMENT RH 1 46 312788 ANGLE REDUCER MTG LH 1 47 313164 CHAIN LEVER 1 48 313878 CAP PLATE WATER EXTRACTOR SHELL 1 49 314378 DRAIN LIFT STRIP 1 50 314522 HANDLE DRAIN 1 51 317027 STOP DRAIN HANDLE 1 319310 PULPER AUGER AND BRUSH ASSY W CLIPS 1 INCLUDES ITEMS 33 AND 34 33 Pulper Assembly Inner View 34 Inner View Pulper Assembly Item Part Description Qty No No 1 100153 BOLT HEX HD 3 8 16 X 1 SST 3 2 100736 BOLT HEX HD 1 4 20 X 3 4 SST 4 3 100746 BOLT HEX HD 3 8 16 X 1 1 4 SST 1 4 100747 BOLT HEX HD 1 2 13 X 1 SST 6 5 102409 COUPLING 1 8
11. NPT 1 6 102563 BOLT HEX HD 3 8 16 X 3 4 SST 6 7 106314 BOLT HEX HD 3 8 16 X 1 2 SST 3 8 106407 WASHER LOCK 3 8 SPLIT SST 11 9 106482 WASHER LOCK 1 4 SPLIT SST 4 10 107589 WASHER LOCK 1 2 SPLIT SST 6 11 109814 ELBOW 1 4 OD X 1 8 NPT PLASTIC 1 12 110495 MOTOR 5HP PULPER DRIVE P5 1 111743 MOTOR 5HP PULPER DRIVE 575V 3PH P5 1 111411 MOTOR 5HP PULPER DRIVE 380V 3PH P5 1 110496 MOTOR 7 5HP PULPER DRIVE MV SPH P7 1 13 110611 SEAL ASSY PULPER SHAFT 1 14 110617 CAP SCREW 3 8 16 X 1 2 LG SOC HD 4 5 110618 SCREW 3 8 16 X 1 LG SOC HD 3 16 110620 LEG ASSY PULPER 3 17 110989 NIPPLE 1 8 NPT X 8 LG SST 1 18 112447 CAP SCREW 3 8 16 X 5 8 LG SOC HD 4 19 113901 CUTTING BLADE ROTATING PULPER 2 20 204474 PUMPING VANE PULPER 2 21 312391 CAP DISC PULPER 1 22 312393 SEAL RETAINER PULPER 1 23 312394 HUB DISC PULPER 1 24 312400 SIZING RING PULPER 1 25 312787 DISC CUTTING BLADE P5 1 26 113900 CUTTER BLOCK STATIONARY P5 3 ssa 113900 CUTTER BLOCK STATIONARY P7 4 27 113278 KEY 3 8 X 3 8 X 1 1 35 Water Extractor Pulper Assembly Front Outer View 36 Front Outer View Water Extractor Pulper Assembly Item Part Description Qty No No 1 100007 SCREW TRUSS HD 10 32 X 3 8 SST 4 2 100194 HEX GRIP NUT 10 32 SST 4 3 100734 BOLT HEX HD 1 4 20 X 1 2 SST 2 4 1
12. blades blocks and disk Inspect and clean the rubber flap and cross flow piping Except trough fed installations Inspect and clean the pulper feed trough connection Trough fed only 7 Reassemble the pulper and the water extractor Make sure all covers and safety switches are in place Remove the lock and the lock out tag on the main circuit breaker switch and turn the power on 8 Pour cup of a non foaming liquid detergent supplied by others into the pulper tank Push the Start push button and run for 10 minutes then shutdown and drain the system 9 Use a soft cloth and mild detergent to clean exterior surfaces Rinse by hand with fresh water DO NOT HOSE THE EXTERIOR OF THE MACHINE WITH WATER 26 Pulper Water Extractor Cleaning and Maintenance Cleaning DO NOT HOSE THE EXTERIOR OF THE MACHINE WITH WATER 27 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 Check the optional deodorizer injector if equipped chemical supply tubing and chemical pick up tube Refill the deodorizer chemical supply container supplied by others if necessary Inspect the water supply lines for leaks make sure t
13. how the start stop station is connected in the pulper control circuit WARNING Electrocution or serious injury may result when working on an energized circuit Disconnect power at the main breaker or service disconnect switch before working on the circuit Lock out and tag the breaker to indicate that work is being performed on the circuit NA The installation of the remote start stop station should be performed by za NS qualified personnel who will observe all local safety sanitary and electrical WS 1 2 Sealtite codes or in the absence of local electrical codes then personnel should follow the supplied by others National Electrical Code 0 Refer to the Champion Service Manual P N 114509 for complete operating instructions for the machine Remote Start Stop Station Wiring Diagram DELAY STOP TIMER IF USED 13 Initial Start up Pulper Water Extractor WARNING 4 gt Death or serious injury may result if hands clothing or jewelry 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 Pulper Initial Start up 1 The steps below describe the initial start up proc
14. that work is being performed on the circuit INSERT LOCK HERE 16 Pulper Initial Start up Pulper Mechanical Adjustments Refer to the illustrations below and check the clearance between the stationary cutter blocks and rotating cutter blades Slowly rotate the cutting disk to make sure that the rotating blades do not hit any of the blocks Using a feeler gauge adjust each stationary block between a minimum clearance of 010 015 and a maximum clearance of 020 060 A close clearance produces a finer waste cut In the event that the cutting blades have burrs on the cutting side of the blade then remove them with a metal file File outward toward the cutting block and dress the blade with fine grit metal oxide sandpaper if necessary Securely tighten all fasteners and recheck the clearances to ensure that the clearances are maintained Stationary cutting block Rotating cutting blade Rotating cutting disk Et N 06 ex SS E uc 010 015 Minimum clearance 020 060 Maximum clearance Rotating cutting blade vali Stationary cutter block 17 Initial Start up Pulper Water Extractor Water Extractor Mechanical Adjustments 1 The water extractor Compression Cone A should be adjusted to 3 from the top of the water extractor housing and the top of Compression Cone The main components of the water extractor interior are listed below A Compression Cone Final stage in remo
15. the system on 1 A powerful magnet is in the pulper grinding chamber The magnet will attract utensils and other metal objects if they contain enough iron in their composition 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 2 below are two suggested methods of making the trunk connection to the trough which is supplied by others Recirculating Pump Trough Connection Kit P N 407365 No Part Description Qty 1 102448 Elbow 1 x 90 Brass 2 100585 Locknut 1 NPT Brass 3 111557 Nipple RTOE 1 x 2 12 Brass 1 4 111079 Tee Red 1 1 2 x 1 1 2 x 1 Brass 1 5 111080 Plug 1 1 2 Brass 1 6 204731 Stub End Recirc Pump 7 107340 Clamp Hose SST w CS Screw 2 8 111117 Hose 1 5 8 1 0 1 9 104889 Compound Grey Sealing 1 ft Trough supplied by others Slurry Water Recirculating Trunk Option B lt s 1 Pipe supplied by others Suggested Trough Baffle I ATTENTION 26 A splash baffle supplied by others must be fabricated and installed in the discharge end of the trough to create the p
16. 00754 SCREW FLAT HD 10 32 X 1 2 SST 24 5 102442 ELBOW 3 4 NPT X 90 BRASS 1 6 102669 NIPPLE 3 4 NPT X 8 1 2 LG BRASS 1 7 106026 WASHER FLAT 4 8 106482 WASHER LOCK 1 4 SPLIT SST 2 9 112823 NAMEPLATE STOP 1 10 112822 NAMEPLATE START 1 11 107966 HEX GRIP NUT 10 32 SST W NYLON 3 12 107967 HEX GRIP NUT 1 4 20 SST W NYLON 4 13 108966 HANDLE DOOR 2 14 110596 GASKET PULPER TANK RING 24 1 113311 GASKET PULPER TANK RING 27 1 Sa 113336 GASKET PULPER TANK RING 30 1 15 110654 COUPLING RED 3 4 NPT X 1 4 NPT BRASS 1 16 110656 HOSE BARB 1 4 MPT X 1 4 OD X 90 1 17 110872 GUARD FLOW RETURN PULPER 1 18 111614 PUSHBUTTON ASSY GREEN 1 19 111615 PUSHBUTTON ASSY RED 1 20 111616 CONTACT BLOCK NC START STOP 1 21 111617 CONTACT BLOCK NO START STOP 1 22 113140 BOOT PUSHBUTTON 2 23 307831 COVER START STOP SST 1 24 307833 ENCLOSURE BOX SST 1 25 312397 ACCESS DOOR WATER EXTRACTOR 1 26 312480 RING PULPER TANK 24 1 325940 RING PULPER TANK 27 1 326077 RING PULPER TANK 30 1 27 313415 MTG STRIP FLOW BACK GUARD 1 28 108150 TUBING 1 4 ID CLEAR 37 Water Extractor Pulper Assembly Hear Outer View 38 Rear Outer View Water Extractor Pulper Assembly Item Part Description Qty No No 1 100003 HEX PLAIN NUT 1 4 20 SST 4 2 100007 SCREW TRUSS HD 10 32 X 3 8 SST 8 3 100073 SCREW TRUSS HD 1 4 20 X 1 2 SST 2 4 100123 PETCOCK 1 4 NPT FE
17. 0V 50 3PH MOTOR 3 4HP 415V 50 3PH REWOUND MOTOR 2HP 380V 50 3PH Qty 49 Recirculating Pump Option Water Extractor Pulper Rear View E 2 50 eV 24 7 3 Ni Rear View Water Extractor Pulper Recirculating Pump Option Item Part Description Qty No No 1 100739 BOLT HEX HD 5 16 18 X 3 4 SST 12 2 102376 WASHER FLAT 5 16 SST 40 3 100154 HEX PLAIN NUT 5 16 18 SST 16 4 106013 WASHER LOCK 5 16 18 SST 24 5 104203 CLAMP HOSE M52 SST GEAR TYPE 4 6 326045 1 BASE PLATE FRONT MTD RECIRC PUMP 1 7 107340 CLAMP HOSE M28 SST GEAR TYPE 4 8 102448 ELBOW 1 NPT X 90 BRASS 1 9 100585 LOCKNUT 1 NPT BRASS 1 10 111157 NIPPLE RTOE 1 NPT 2 1 2 LG BRASS 1 11 111079 TEE RED 1 1 2 X 1 1 2 X 1 NPT BRASS 1 12 111080 PLUG 1 1 2 NPT SQ HD BRASS 2 13 204731 STUB END PULPER 2 14 202291 HOSE 1 5 8 ID X 4 LG 2 15 104751 BALL VALVE 1 1 2 NPT BRONZE 2 16 100740 BOLT HEX HD 5 16 18 X 1 SST 12 17 315147 FLANGE TEE WELDMENT RECIRC PUMP 1 18 106990 GASKET PUMP DISCHARGE 1 19 113331 ROD THREADED 5 16 18 X 19 1 2 SST 1 20 326050 BRACKET DRAIN HANDLE SUPT 1 21 326065 EXTENSION BALL VALVE HANDLE 1 22 111134 5 STEM EXTENDED BALL VALVE HANDLE 1 23 111134 2 STOP BRACKET EXTENDED BALL VALVE HANDLE 1 24 104638 GASKET
18. 32 SST W NYLON 6 7 108954 HEX GRIP NUT 6 32 SST W NYLON 4 8 109666 HANDLE 1 9 109934 MAGNETIC SWITCH DOOR 2 10 110593 LATCH ASSY PULPER FEED TRAY 4 11 110762 CURTAIN UNDER TABLE FEED HOOD PULPER 1 12 111026 MAGNET 2 13 111478 SCREW HEX HD 10 32 X 1 2 SST 3 14 113489 COTTER PIN CIRCLE 2 15 309753 BRACKET UC DRIVE SWITCH 2 16 313230 FEED HOOD UNDER TABLE 24 PULPER 1 17 314187 COVER MAGNET 1 18 319877 LID FEED TRAY 1 19 321147 ROD CURTAIN 1 20 327100 FEED TRAY 26 X 31 HINGED LID 1 43 Two Piece Feed Tray with Flushing Nozzles 44 30 Pulper Assembly Part No 100194 100709 101000 101026 102434 102438 102507 102528 107261 102767 102775 103435 107016 107340 107525 108954 109158 110110 110593 113489 113719 113937 206332 206737 331168 331172 30 Pulper Assembly Two Piece Feed Tray with Flushing Nozzles Description HEX GRIP NUT 10 32 SST LOCKNUT 1 2 NPT BRASS NIPPLE 1 NPT X CLOSE TEE RED 1 X 1 X 1 2 NPT BRASS ELBOW 1 2 NPT X 45 ELBOW STREET 1 2 NPT X 90 BRASS PLUG 1 NPT SQ HD BRASS TEE 1 NPT BRASS NIPPLE 1 NPT X 3 LG BRASS NIPPLE 1 NPT X 5 LG BRASS NIPPLE 1 NPT X 8 LG BRASS NIPPLE RTOE X 1 2 NPT X 1 3 4 LG BRASS HEX GRIP NUT 4 40 SST W NYLON CLAMP HOSE M28 SST GEAR TYPE SCREW ROUND HD 10 32 X 1 2 SST HEX GRIP NUT 6 32 SST W NYLON NAMEPLATE CHAMPION SCREW ROUND HD 4 40 X 1 2 SST LATCH ASSY PULPER FEED TR
19. 3226 gt lt Remote Control Cabinet Component Selection Chart Motor Overloads e Motor Contactors e Bus Systems Step down Transformers e Circuit Breakers Motor Starter Overload Items 45 46 47 Voltage VAC 208 240v60 3 480v 60 8 575603 380503 415503 Motor HP 0 0 aan mese 111629 111620 11602 113161 5HP 13810 360 113161 113161 WATER PRESS IS aHP j 111629 111627 111627 1167 111627 BHp noas 1168 11628 8 RECIRC PUMP W __ j j 34HP 111628 111625 111625 111626 111626 IH __ 1168 1162 1 Motor Overload Range and Setting PartNo Range Amps Setting 111625 10 16 15 1116200 16 24 20 id 111627 25 40 Adjust 111628 40 63 11169 11180 130 180 113161 90 140 11310 240 320 6 0 10 0 Motor Contactor tem 27 Voltage VAC 208 240V 60 3 480 60 3 575 60 3 415 50 3 380503 yT 10982 10982 109582 109582 109582 109582 109582 109582 MEN 108122 108122 108122 108122 108122 BHP 108122 108122 108122 1012 108122 RECIRC PUMP TT 3 4 HP 10822 108122 1012 _ 108122 108122 108122 108122 108122 1012 108122 Bus System 49 Voltage VAC 208 240v 60 3 480v 60 3
20. 39 Under table Feed Trays Pulper Assembly 40 Pulper Assembly Under table Feed Trays Item Part Description Qty No No 1 107654 SCREW TRUSS HD 6 32 X 1 SST 2 2 100194 HEX GRIP NUT 10 32 SST 24 3 100734 BOLT HEX HD 1 4 20 X 1 2 SST 2 4 104985 HEX PLAIN NUT 10 32 SST 2 5 106482 WASHER LOCK 1 4 SPLIT SST 2 6 106486 WASHER LOCK 10 SPLIT SST 2 7 107033 WASHER FLAT SST 2 8 107135 WASHER FLAT SST 1 9 107966 HEX GRIP NUT 10 32 SST W NYLON 2 10 108954 HEX GRIP NUT 6 32 SST W NYLON 8 11 108966 HANDLE DOOR 1 12 109934 MAGNETIC SWITCH DOOR 1 13 109935 MAGNET DOOR SWITCH 3 14 110593 LATCH ASSY PULPER FEED TRAY 12 15 110763 CURTAIN FEED TRAY W HOOD 1 16 110890 CURTAIN FEED TRAY 2 17 110891 ROD CURTAIN FEED TRAY 24 PULPER 2 18 111026 MAGNET 1 19 113489 COTTER PIN CIRCLE 6 20 309753 BRACKET UC DRIVE SWITCH 1 21 312475 FEED TRAY 1 22 313228 ROD CURTAIN FEED TRAY W HOOD 24 PULPER 1 23 313229 FEED TRAY W HOOD 24 PULPER 1 24 314187 COVER MAGNET 1 25 316145 FEED TRAY P5 24 1 26 316147 MANHOLE COVER P5 27 1 27 320985 ALIGNMENT PIN MANHOLE COVER 1 41 Feed Tray with Hinged Lid Pulper Assembly 42 Pulper Assembly Feed Tray with Hinged Lid Item Part Description Qty No No 1 107654 SCREW TRUSS HD 6 32 X 1 SST 4 2 100194 HEX GRIP NUT 10 32 SST 8 3 104985 HEX PLAIN NUT 10 32 SST 4 4 106486 WASHER LOCK 10 SPLIT SST 7 5 107033 WASHER FLAT SST 4 6 107966 HEX GRIP NUT 10
21. AL OR CONSEQUENTIAL DAMAGES THE REMEDIES SET OUT ABOVE ARE THE EXCLUSIVE REMEDIES FOR ANY DEFECTS FOUND TO EXIST IN CHAMPION DISHWASHING MACHINES AND CHAMPION PARTS AND ALL OTHER REMEDIES ARE EXCLUDED INCLUDING ANY LIABILITY FOR INCIDENTALS OR CONSEQUENTIAL DAMAGES Champion does not authorize any other person including persons who deal in Champion dishwashing machines to change this warranty or create any other obligation in connection with Champion Dishwashing Machines Table of Contents Table of Contents Waste Handling Systems P5 24 P5 27 and P7 30 kashapa O E i Emme Warranty tcc ii iv 000 99 Model uuu 1 Theory of o es 3 Waste Handling Precautions 6 Recirculating Pump Trough Connections 8 _ dina 9 BROCE VO p 10 Utility Connections uyu us aaa 11 Initial Start Up aci 13 te 15 Electrical Controls lr Mechanical Adjustments 17 Water Fill Adjustments 19 System Operation CHECKS 20 23 0618 1310 0 Cleaning and Maintenance 25 Clea
22. ALUMINUM CONDUCTORS IN ACCORDANCE WITH LOCAL ELECTRIC CODE RATED MINIMUM 90 C 194 F MINIMUM SUPPLY CONDUCTOR AMPACITY Janes MAXIMUM SUPPLY OVERCURRENT PROTECTION DEVICE LLL Jams OVERCURRENT PROTECTION DEVICE DELAY FUSE OR INVERSE TIME BREAKER Phase HERZ Make sure the installation site power supply matches the data recorded on the connection plate 3 Install the Remote Control Cabinet adjacent to or in sight of the waste handling system The control cabinet location should make the operation of the system practical for the operator and service technician 4 The 3 phase motor rotation was checked at the factory The pulper disk must rotate CCW and the water extractor auger screw must rotate CCW If it is necessary to reverse the motor rotation reverse L1 and L2 main incoming power supply wires in the remote control cabinet DO NOT REVERSE L1 and L2 at the motors 12 Optional Remote Start Stop Station Installation Model 5 24 P5 27 P7 30 Pulper Remote Start Stop Station Option Installation Instructions An optional remote start stop station may have shipped inside the pulper tank for remote installation by others The remote station consists of two push buttons in a metal enclosure Mounting hardware flexible1 2 sealtite wiring and connectors are supplied by others Wire size must be 14 AWG THHN 90 C Refer to the wiring diagram below which shows
23. AY COTTER PIN CIRCLE REED SWITCH ALEPH MAGNET REED SWITCH ROD CURTAIN FEED TRAY 30 PULPER CURTAIN MODIFIED 30 PULPER FEED TRAY BOTTOM FEED TRAY TOP Qty WWW W O N 45 Recirculating Pump Option Water Extractor Pulper Front View See next page for ump assembly O o SNe 1 GL Comes with Item No 11 46 Part No 100154 100173 100585 100739 100740 102376 102448 104165 104203 104638 104751 106013 106990 107340 111709 111080 111134 2 111134 5 111157 113329 202291 204731 204535 315147 326045 326050 326052 326054 103378 111614 111615 111616 111617 113140 307831 307833 106026 107967 100007 112823 112822 Front View Water Extractor Pulper Recirculating Pump Option Description HEX PLAIN NUT 5 16 18 SST NIPPLE 1 1 2 X 2 LG BRASS LOCKNUT 1 NPT BRASS BOLT HEX HD 5 16 18 X 3 4 SST BOLT HEX HD 5 16 18 X 1 SST WASHER FLAT ELBOW 1 NPT X 90 BRASS CLAMP HOSE M40 SST GEAR TYPE CLAMP HOSE M52 SST GEAR TYPE GASKET PUMP SUCTION BALL VALVE 1 1 2 NPT BRONZE WASHER LOCK 5 16 SPLIT SST GASKET PUMP DISCHARGE CLAMP HOSE M28 SST GEAR TYPE TEE RED 1 1 2 X 1 NPT BRASS PLUG 1 1 2 NPT SQ HD BRASS STOP BRACKET EXTENDED BALL VALVE HANDLE STEM EXTENDED BALL VALVE HANDLE NIPPLE RTOE 1 NPT X 2 1 2 LG BRASS ROD
24. FORMER 120VAC 24VAC 1 41 111508 CIRCUIT BD DEODORIZER SPEED CONTROL 1 42 111523 NAMPLATE DEODORIZER ON OFF 1 43 111615 PUSHBUTTON ASSY RED 1 44 111617 CONTACT BLOCK NO START STOP 1 CONTINUED ON NEXT PAGE ATTENTION Refer to the Remote Control Cabinet Component Selection Chart at the end of the manual 59 Remote Control Cabinet Pulper Water Extractor continued No No 45 46 47 48 111636 49 50 111822 51 112351 52 112352 53 113769 54 114194 55 114195 56 312583 57 313114 58 107860 59 107431 60 317008 ATTENTION Refer to the Remote Control Cabinet Component Selection Chart at the end of the manual 60 Description MOTOR STARTER OVERLOAD Optional Recirculating Pump MOTOR STARTER OVERLOAD Water Extractor Drive MOTOR STARTER OVERLOAD Pulper Drive BUS CONNECTOR 3 POLE BUS SYSTEM 3 POLE FUSE ATDR 5 AMP TIMER OMRON SOCKET OMRON TIMER RAIL DIN SWITCH SELECTOR CONTACT BLOCK N O 2 POLE use with 114194 PANEL INNER CONTROL CABINET WELDMENT CLIPS DOOR HOLD DOWN GASKET DOOR 3 8 X 3 4 X 12 BRACKET DEODORIZER SPEED CONTROL BD Qty A R gt gt DI lt D Electrical Schematic Electrical Schematic Remote Control Cabinet Component Selection Chart 61 Blank Page This Page Intentionally Left Blank 62 Remote Control Cabinet Component Selection Chart gt Z 9 953 NE 5 2
25. MALE BRASS 1 5 100194 HEX GRIP NUT 10 32 SST 3 6 100209 NIPPLE 1 2 X CLOSE BRASS 3 7 100213 SCREW TRUSS HD 10 32 X 1 4 SST 4 8 100734 BOLT HEX HD 1 4 20 X 1 2 SST 4 9 100947 NIPPLE 1 4 X CLOSE BRASS 1 10 102388 BUSHING RED 1 2 NPT X 1 4 NPT BRASS 1 11 102435 ELBOW 1 2 NPT X 90 BRASS 1 12 102514 TEE 1 2 NPT BRASS 1 13 106026 WASHER FLAT 1 4 SST 2 14 106314 BOLT HEX HD 3 8 16 X 1 2 SST 2 15 106482 WASHER SPLIT 1 4 SST 8 16 107065 ADAPTER 1 4 OD X 1 4 MPT PLASTIC 1 17 107967 HEX GRIP NUT 1 4 20 SST W NYLON 6 18 108954 HEX GRIP NUT 6 32 SST W NYLON 4 19 108966 HANDLE DOOR 1 20 109934 SWITCH MAGNET DOOR SWITCH 1 21 109935 MAGNET DOOR SWITCH 1 22 110525 PRESSURE SWITCH PULPER 1 N S 111264 SWITCH MICRO PRESSURE SWITCH 1 23 110545 SNUBBER PRESSURE SWITCH 1 24 110551 BACKFLOW PREVENTER 1 2 NPT BRONZE 1 25 110620 LEG ASSY 5 26 110640 MAGNET SILVER SAVER 1 27 110655 HOSE BARB 1 4 MPT X 1 4 OD 1 28 110675 VALVE SOLENOID 1 4 120VAC 1 112152 REPAIR 1 4 SOLENOID VALVE 1 110549 COIL SOLENOID VALVE 120VAC 1 29 110676 VALVE SOLENOID 1 2 120VAC 1 109902 REPAIR 1 2 SOLENOID VALVE 1 110549 COIL SOLENOID VALVE 120VAC 1 30 312686 LID DISCHARGE CHUTE 1 31 312695 DISCHARGE CHUTE 1 32 313319 BRACKET MAGNET MTG PULPER 1 33 313402 COVER WIREWAY 6 X 8 1 34 313403 WIREWAY 8 1 35 108150 TUBING 1 4 ID X 3 8 OD CLEAR 36 0502667 TUBING 1 4 ID X 3 8 OD WHITE
26. Off switch Push toggle switch ON to run the Injector The injector speed control is located inside the remote control cabinet Amount of deodorizer injected depends on the customer s requirements E Optional Delay Stop switch with adjustable 6 minute timer Push the Delay Stop switch Depending on the timer setting the system will STOP after the preset time DELAY F Optional Flushing Valve On Off selector switch Turn the selector switch ON and the water extractor and or pulper flushing system will operate G System START STOP station located on the water extractor Push the Start push button and the waste handling system will run Push the Stop push button and the system will shut off Remote Control Cabinet shown with deodorizer delay stop and flushing valve options and the system Start Stop Station located at the top of the water extractor 15 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 3 Engage the handle lock and insert a locking device to prevent the Breaker Switch from turning Attach a tag on the Breaker Switch to indicate
27. Push the deodorizer toggle switch to OFF The deodorizer injector will stop 1 The Deodorizer Power Switch is located on the The Deodorizer Injector Speed Control Circuit board front of the remote control cabinet is located in the top left corner of the remote control cabinet 21 Initial Start up Pulper Water Extractor System Operation Tests Waste Processing and System Balancing Attention Waste processing adjustments are best performed under normal loading conditions Note A water level fill adjustments and or the condition of the water extractor pulp usually requires some time before the system responds to a change Make small incremental changes to balance the waste handling system and closely observe operation response Read the Waste Handling Precautions on page 6 before processing waste in the system 1 10 11 22 Close the pulper drain valve and the water extractor drain overflow handle Place a refuse container under the water extractor discharge chute FOR OPTIONAL FEED TROUGH CONFIGURATIONS ONLY Perform Step No 1 above and open the recirculating pump feed trough valve half way Adjust this setting to achieve the slurry water flow best suited to the waste being processed Make sure the main water and power supplies are on Turn the remote control cabinet breaker switch on Wait for the pulper to fill then push the Start push button on the water extractor Check the water leve
28. THREADED 5 16 18 X 4 LG SST HOSE 1 5 8 ID X 4 LG STUB END PULPER HOSE PUMP SUCTION FLANGE TEE WELDMENT RECIRC PUMP BASE PLATE FRT MTD RECIRC PUMP BRACKET DRAIN HANDLE SUPT EXTENSION BALL VALVE HANDLE FLANGE WELDMENT P5 RECIRC PUMP TIE WRAP PUSHBUTTON ASSY GREEN PUSHBUTTON ASSY RED CONTACT BLOCK NC START STOP CONTACT BLOCK NO START STOP BOOT PUSHBUTTON COVER START STOP SST ENCLOSURE BOX SST WASHER FLAT HEX GRIP NUT 1 4 20 SST W NYLON SCREW TRUSS HD 10 32 X 3 8 SST NAMEPLATE STOP NAMEPLATE START Qty 47 Recirculating Pump Assembly Water Extractor Pulper 48 Part No C3819 D4820 12799 1 14269 1 100002 100153 100735 102504 104638 107364 106407 106482 106619 109678 109679 110276 106990 113326 204725 180287 112678 111413 180409 114843 Water Extractor Pulper Recirculating Pump Assembly Description PUMP SUCTION MACHINED PUMP DISCHARGE HOUSING IMPELLER HOUSING PUMP SEAL BOLT HEX HD 1 4 20 X 1 3 8 SST BOLT HEX HD 3 8 16 X 1 SST BOLT HEX HD 1 4 20 X 5 8 SST PIPE PLUG 1 2 NPT BRASS GASKET PUMP SUCTION WASHER FIBER 1 4 iD X 7 8 OD WASHER LOCK 3 8 SPLIT SST WASHER LOCK 1 4 SPLIT SST KEY 3 16 X 3 16 LG SST GASKET FIBER GASKET FIBER PUMP SEAL 1 GASKET PUMP DISCHARGE MOTOR 1HP 208 240 480V 60 3PH MOTOR 3 4HP 208 240 480V 60 3PH MOTOR 3 4HP 575V 60 3PH MOTOR 3 4HP 200V 50 60 3PH MOTOR 3 4HP 38
29. and pressure switch tubing Check water level setting Inspect cross flow piping recirculating pumps if equipped drain valves and drain piping o Inspect the water extractor compression cone and wiper blade for wear and proper adjustment 9 Inspect the water extractor slurry screen and auger brush for wear 10 Inspect the pulper and or water extractor flushing nozzles and piping 11 Inspect the remote control cabinet electrical components and tighten all connections APPROVED LUBRICANTS Kluber Klubersynth UH1 6 460 Synthetic Gearbox oil capacity 35 9 ounces 1 06 liters ExxonMobil Mobil SHC 634 Non synthetic Do not mix lubricants 28 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 No fill water to pulper Pulper fills constantly Banging noise coming from pulper Pulp discharge is too wet System shuts down unexpectedly Main Power Supply OFF Remote Control Cabinet 3A push button breaker tripped Remote control cabinet Main Circuit Breaker Switch OFF Safety Switch not closed or defective Start Stop Station switch not operated or defective Main water supply valve is closed Remote control cabinet Main Circuit Breaker Switch OFF Pulper water level pressure swi
30. arge chute cover and lean it against the extractor gearbox then remove the water extractor side access door For Feed hood Pulper Remove splash curtain s and release the black rubber retaining handles holding the hood to the pulper tank Lift the feed hood off the pulper tank Clean and flush the feed hood separately if possible For Trough feed Pulper Remove the round pulper tank cover Clean and flush the cover separately Remove any large waste then use a wash down hose to flush the trough clean 3 Use a wash down hose and plenty of fresh water to thoroughly flush the top of the water extractor Make sure the area around and below the water extractor compression cone is clean PULP LEFT IN THE AREA OF THE CONE CAN SERIOUSLY DAMAGE THE WATER EXTRACTOR 4 Use the wash down hose and thoroughly flush all pulp from the water extractor screen Be sure that you flush behind the screen assembly and around the drain overflow tube Remove by hand large particles remaining in the bottom of the water extractor tank 5 Inspect the interior of the pulper tank for metal utensils A strong magnet is located on the bottom of the pulper tank to attract metal but it will not attract silverware or high quality stainless steel Remove by hand any plastics un shredded paper or other deposits 6 Use a wash down hose and thoroughly flush the interior of the pulper tank Inspect and clean the screen in the bottom of the pulper Inspect and clean the cutting
31. authorized installers who will follow all electrical plumbing sanitary safety procedures and regulations Plumbing and Electrical Connection Diagram P amp E The plumbing and electrical specifications and connection locations are detailed in a P amp E diagram This diagram is supplied for the installation prior to shipment Contact a supervisor if you do not have the P amp E at the time of installation 11 Utility Connections Installation Utility Connections continued The Plumbing and Electrical Diagram P amp E continued 1 Refer to the P amp E and match the utilities at the installation site to the P amp E Contact a supervisor if the installation site does not match P amp E 3 The general utility requirements may include but are not limited Cold water supply Electrical supply Drain Cold Water Supply Connect a 1 2 NPT cold water supply line to the pulper 2 If the incoming water pressure is greater than 25 PSI 172 kPa then install a pressure regulating valve PRV in the cold water supply 3 Install a 3 4 NPT shut off valve in the 1 2 NPT water supply line as close to the machine as possible Drain 1 Connect a 1 1 2 NPT gravity drain line to the pulper 2 Drain discharge must comply with local sanitary codes and regulations Electrical 1 Refer to the Machine Electrical Connection Data Plate located inside the Remote Control Cabinet MACHINE ELECTRICAL CONNECTION FOR SUPPLY CONNECTION USE COPPER OR COPPER CLAD
32. cks pulse vanes and auger brush ze 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 8 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 warrants all new machine parts produced or authorized by Champion 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 will replace the defective part without charge DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY CHAMPION S WARRANTY IS ONLY TO THE EX TENT REFLECTED ABOVE CHAMPION MAKES NO OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURPOSE CHAMPION SHALL NOT BE LIABLE FOR INCIDENT
33. e Pages Effectivity Description 10 10 08 All J08072511 Released First Edition 2 15 10 8 J08072511 Added trough conversion kit instructions 10 11 10 34 35 J08072511 Added Key P N 113728 to P L 49 All Added 2HP 380V 50 3PH to P L 4 2 12 33 All Changed P N 111939 description amp added P N 319310 Auger Assembly Limited Warranty LIMITED WARRANTY Champion Industries Inc herein referred to as Champion P O Box 4149 Winston Salem North Carolina 27115 and P O Box 301 2674 N Service Road Jordan Station Canada LOR 1S0 warrants machines and parts as set out below Warranty of Machines Champion warrants all new machines of its manufacture bearing the name Champion and installed within the United States and Canada to be free from defects in material and workman ship 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 See below for special provisions relating to glasswashers The warranty registration card must be returned to Champion within ten 10 days after installation If warranty card is not returned to Champion within such period the warranty will expire after one year from the date of shipment Champion 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 pe
34. e STOP push button and check the rotation of the pumps pulper drive and water extractor drive motors Correct the phasing of the motors as required 4 Push the green Start push button on the Start Stop station located on the Water Extractor All motors will run and the pulper will fill with water to the level previously set at the factory 5 The pulper water level is controlled by the water level pressure switch located on the side of the pulper tank The water level pressure switch is housed in a blue enclosure See photos below 6 To adjust the water level pressure switch A Remove 2 screws on the switch cover B Remove the cover C Turn the level adjusting screw CW to reduce the water level CCW to increase 7 The proper water level in the pulper tank should be below the level of the water extractor return piping If the pulper is fed by a trough system then the pulper water level should be below the trough inlet to the pulper The water should not flow back into the trough when the water level is set at the correct level 19 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 Pulper drive motor seal flushing valve i
35. e system during the clean up operation There are 2 methods for feeding waste into the pulper In the first method the operator manually feeds the waste directly into the pulper In the second method waste is conveyed into the pulper via a water fed trough system The standard electrical controls consist of a common remote mounted control box 1 Start Stop push button station on the pulper and 1 push button station on the water extractor The pulper water level is controlled by a pressure switch mounted on the side of the pulper Safety switches mounted on the pulper and the water extractor protect the operator from rotating components An optional deodorizer injector can be mounted on the water extractor The waste handling system must be cleaned daily after the day s operation Optional flushing systems in the pulper and the water extractor aid in removing solids that may be present Foreign matter must be removed manually and the machine interiors must be flushed with fresh water The machine exteriors must be cleaned as well as the surrounding work areas to prevent odors and reduce the accumulation of debris Waste is compressed into a semi dry papery pulp 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 cl
36. eaning and access to the pulper interior Direct feed w cover 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 Slurry water which flows down the trough carries the waste into the pulper The slurry water is supplied by a recirculating pump mounted on the water extractor 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 CAUTION Damage to the waste handling system will result if metal obj
37. ects are fed into the machine This includes but is not limited to box staples metal foil steel wool metal fasteners wire coins and metal utensils WHEN IN DOUBT KEEP IT OUT 1 The waste handling system is designed to process a wide range of waste products that are water soluble including food waste paper e g paper napkins cardboard 2 The system will process waxed paper in limited amounts but only if the waxed paper is loaded in conjunction with waste products described above 3 DONOT FEED THE FOLLOWING MATERIALS INTO THE PULPER 4 Metal e g box staples metal foil steel wool metal fasteners wire coins and metal utensils 5 Styrofoam 6 Plastic spoons forks knives cups plates or bowls 7 packages e g ketchup mustard etc 8 Plastic bottles bottle caps 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 The magnet will not attract high quality stainless steel nor sterling silver The waste handling system can process a wide range of waste products but plastic products should not be fed into
38. edure for the close coupled pulper and water extractor The Remote Control Cabinet controls both units Make sure the waste handling system matches the specifications detailed in the P amp E Make sure the pulper and the water extractor are securely mounted to the finished floor Review the Theory of Operation beginning on page 2 Make sure the main power supply is disconnected Lock out the circuit and place a tag on the switch and or breaker to indicate that work is being performed on the circuit N WARNING 6 EIN 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 14 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 A ON OFF manual reset breaker switch Rotate handle fully CW to turn power ON Rotate handle fully CCW to reset tripped breaker and to lock out breaker to service B 3 amp manual reset circuit breaker Push reset button in if 120VAC control circuit breaker trips C Red POWER ON indicator light Indicator illuminates when ON OFF breaker switch A is in the ON position D Optional Deodorizer Injector On
39. he floor drains are clear Inspect the pulper and water extractor to ensure that all safety switches are in good working condition Make sure that access panels and covers are in good working condition Inspect the splash curtains for wear and replace if necessary o N Inspect the Remote Control Cabinet and the Start Stop Station Make sure that switch covers switches indicator lights latches and fasteners are installed and in good working condition 9 Inspect warning and caution labels on the components Make sure these labels are legible and if not then order replacement labels and replace immediately Weekly Maintenance Checks 1 Perform all of the Daily Checks listed above 2 Inspect the rotating cutter blades stationary cutter blocks and rotating cutter disk for damage 3 Contact a Factory Authorized Service Agent if any damage is found Semi Annual Maintenance Checks Must be performed by a Factory Authorized Service Agent Only 1 Drain flush and refill the water extractor drive motor gearbox with approved lubricant see below every 6 months or 2500 hours of operation which ever occurs first Clean the gearbox vent plug Proper oil level is to the bottom edge of the oil fill hole Inspect the rotating cutter blades stationary cutter blocks for wear Check tolerances Inspect the rotating disk and sizing ring for wear Inspect the pulper drive motor seal and flushing system Inspect the pressure switch
40. his Page Left Intentionally Left Blank 30 Service Replacement Parts Service Replacement Parts Illustrations Water Extractor Assembly Inner VieW sss 32 Pulper Assembly IMGT VIEW ete 34 Water Extractor Pulper Assembly Front Outer VieW ii 36 Water Extractor Pulper Assembly Rear Outer View 38 Under table Feed Trays Pulper Assembly 40 Feed Tray with Hinged Lid Pulper Assembly aan 42 Two piece Feed Tray with Flushing Nozzles 30 Pulper Assembly 44 Recirculating Pump Option Front View Water Extractor Pulper Assembly 46 Recirculating Pump Assembly Water Extractor Pulper Assembly 48 Recirculating Pump Option Rear View Water Extractor Pulper Assembly 50 Flushing Assembly Water Extractor Pulper ASSEMDIY ii 52 Deodorizer Pump Assembly Water Extractor Pulper Assembly 54 Feed Trough Gaskets lt EE E es 56 Remote Control Cabinet Assembly
41. ipment consult factory Anti vibration feet Recirculating pump Flushing systems for pulper and water press Deodorizer injector Remote start stop station unmounted Automatic shut down timer Spray reel 30 ft unmounted Feed tray and hood assembly Trough feed configurations Introduction Introduction Theory of Operation Pulp compression cone Fresh make up water WASTE IN Drain overflow Recirculated slurry water Drain 00090009000 95950 00995 o 09500 o 02900 09 0 O O PULP OUT Slurry auger 0 0 and screen Optional slurry recirculating pump 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 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 The waste handling system accomplishes this by combining food paper and water removing the water and then compressing the waste for disposal The was
42. l in the pulper tank The water must be rotating in a counter clockwise direction and have a whirlpool appearance The pulper water level is too high if the whirlpool effect is not observed There should be a pulsating sound to the water as it rotates in the pulper tank Begin feeding a mixture of food waste paper and cardboard into the pulper Cardboard boxes must be reduced The pulper will shudder when heavy items such as cardboard are fed into the tank This is normal Pulper water should begin to turn a milky color In the water extractor a wet pulp should begin to appear around the screen A semi dry pulp will appear at the top of the water extractor and be forced into the discharge chute by the wiper blade There are 3 main factors that affect the dryness of the pulp 1 The ratio of food waste water and paper in the pulper 2 How finely the waste is shredded in the pulper tank 3 The cone setting at the top of the water extractor The inter relationship of these 3 variables makes it impossible to provide a definite procedure for adjusting the waste handling system Observation careful adjustment and consultation with the end user is the only way to reach a favorable result when balancing the system Drain Closed Closed Water extractor drain overflow handle in the closed position Water extractor drain overflow handle in the open position Feed trough supply valve and system drain valve
43. ning iaia 26 Maintenance nennen ane 27 aide 29 Tro bleshoollng Service Replacement Parts 31 Remote Control Cabinet Component Selection Chart 63 Electrical 64 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 Ib hr input capacity P5 27 and P5 30 27 or 30 diameter waste grinding chamber with 5 HP grinder motor respectively 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 Ib hr input capacity P7 30 30 diameter waste grinding chamber with 7 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 3 HP motor 1000 Ib hr input capacity Optional Equ
44. ocated inside the pulper and or the water extractor flushing piping 2 Flushing systems are used to pulp deposits but are not intended to replace the daily cleaning procedures explained in the Cleaning section of this manual 20 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 While the system is running push the Delay Stop Switch The system should run for 6 minutes then shut off Restart the system Push the Delay Stop Switch then push the Stop push button on the Start Stop station The system should stop immediately Deodorizer Injector Option if equipped Note The deodorizer injector pump speed control is located inside the remote control cabinet Consult a chemical supplier for the correct deodorizing chemical 1 Deodorizer speed adjustments depend upon the customer s needs and the chemical recommended by the chemical supplier therefore the factory cannot provide speed adjustment guidelines Place the chemical pick up tube in the chemical container The container must not be higher than the injection point on the water extractor Push the Deodorizer Toggle Switch to ON The deodorizer injector will run Turn the adjustment screw on the deodorizer speed control circuit board CW to increase the injector motor speed or CCW to reduce the injector motor speed
45. riod 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 a 120 days after shipment or b 90 days after installation whichever occurs first In the event that Champion 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 authorized service technician Defective parts become the property of Champion Use of replacement parts not authorized by Champion will relieve Champion of all further liability in connection with its warranty In no event will Champion s warranty obligation exceed Champion s charge for the machine The following are not covered by Champion s warranty Lighting of gas pilots or burners Cleaning of gas lines Replacement of fuses or resetting of overload breakers Adjustment of thermostats Adjustment of clutches Opening or closing of utility supply valves or switching of electrical supply current Cleaning of valves strainers screens nozzles or spray pipes Performance of regular maintenance and cleaning as outlined in operator s guide Damages resulting from water conditions accidents alterations improper use abuse tampering improper installation or failure to follow maintenance and operation procedures j Wear on Pulper cutter blo
46. rive motor will run B The optional recirculating pump motor if equipped will run If equipped push the optional deodorizer switch ON The switch is located on the remote control cabinet Feed a combination of food waste paper waste and cardboard into the pulper Cardboard boxes must be reduced in size before loading Push the red Stop push button on the water extractor to Stop the system In case of an emergency the system also can be turned off by rotating the Main Circuit Breaker Switch on the remote control cabinet counter clockwise CCW to the OFF position Main Circuit Breaker Switch in the ON position Start Stop Station OFF Start Stop Station ON Pulper Water Extractor Cleaning and Maintenance Cleaning and Maintenance 25 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 THE WASTE HANDLING SYSTEM MUST BE CLEANED EVERY DAY OF OPERATION Refer to the illustration on the next page and follow the steps below to clean the waste handling system 1 Open the water extractor drain by turning the drain handle to the OPEN position then open the main system drain located at the bottom of the pulper water extractor drain line 2 Open the water extractor disch
47. roper water flow See No 3 at left for a suggested design for the baffle The splash baffle must extend across the entire length of the trough and maintain a 1 2 gap Liv between the baffle and the trough bottom v2 Critical Gap trough must be removable for cleaning Form 900822 Installation Installation 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 NOTE The waste handling system may require parts and materials that are not supplied by the factory The scrapping station water trough is an example of an item typically supplied by others NOTE Observe all safety regulations and procedures when moving and placing the machine CAUTION To prevent damage to the machine do not lift the machine by any of its piping or electrical conduit 1 The waste handling system is shipped on a single pallet The system consists of a pulper water extractor and remote control cabinet 2 If specified optional fasteners trough gaskets and anti vibration feet are stored inside the pulper tank 3 Inspectthe installation site before moving the machine then place the machine and the remote control cabinet at their permanent location
48. s 4 Complete the Warranty Registration Card located at the front of this manual and mail it immediately to validate the machine warranty 5 Level the pulper and water extractor front to back and side to side The legs are fitted with adjustable feet to level the machine Legs are fitted with adjustable feet 6 Follow the instructions supplied by others to permanently attach the machine to the floor T A rubber gasket and mounting hardware is supplied with the pulper if the installation includes a feed trough system The feed Rubber gasket for a trough connection is trough system is supplied by others supplied with the pulper 10 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 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 ATTENTION Utility connections must be performed by
49. s open Water extractor drive motor is running Optional water extractor recirculating pump if equipped is running Optional water extractor and or pulper flushing valve if equipped is open Test Safety Switches Note The waste handling system must stop running when the pulper cover or the water extractor discharge chute are opened 1 Lift the pulper tank cover The pulper and water extractor must stop running 2 Lift the water extractor discharge chute The pulper and water extractor must stop running Test Main Circuit Breaker Switch Caution Turn the main incoming power OFF before performing this test 1 With the main power supply to the waste handling system turned off turn the Remote Control Cabinet Main Breaker Switch to the ON position Loosen do not remove the control cabinet cover retaining clips 3 Try to open the control cabinet It should not open Repair or replace the switch if you are able to open the control cabinet 4 Tighten the retaining clips turn the switch to OFF and turn main power supply on Test Start Stop Push button Station 1 Push the Start push button The pulper water extractor drive motors and optional pumps run 2 Push the Stop push button The drive motors and optional pumps stop Test the Flushing Valve Option if eguipped 1 Turn the Flushing Valve Selector Switch located on the bottom right corner of the remote control cabinet to the ON position Water will spray from nozzles l
50. tch mis adjusted or defective Water solenoid valve defective Drain valve or water extractor drain overflow open Pulper water level pressure switch mis adjusted or defective Pressure switch tubing or air snubber is clogged or broken Water solenoid valve defective Water extractor screen clogged and or auger brush defective Metal object in tank Cutting blades hitting cutting blocks Waste input lacks paper Extractor drain overflow restricted Compression Cone mis adjusted Remote Control Cabinet Main Circuit Breaker Switch has tripped Handle is in the TRIP position Main Power Supply to system OFF Turn on or reset breaker Push to reset 3A breaker Rotate Handle to ON Position Check replace pulper and or water extractor safety switch Push Start push button to run Open valve Rotate Handle to ON Position Adjust or replace switch Repair or replace solenoid valve Close drain valve rotate drain overflow handle to closed position Adjust or replace switch Clean or replace snubber tubing Repair or replace solenoid valve Clean extractor screen and or contact service agent Remove object Shut down system and contact service agent Feed cardboard into pulper to thicken slurry Check drain overflow in water extractor Contact service agent to adjust Turn handle CCW to RESET then CW to OFF and contact service agent Check Main Power Supply Breaker 29 Blank Page T
51. te handling system consists of a grinding tank pulper and a water press water extractor The 2 components are physically connected close coupled and share a common electrical control system The pulper contains a spinning grinding disk and cutting blocks which shred food waste and paper to a water laden mixture called slurry The pulper forces the slurry into the water extractor The water extractor contains an auger and screen The auger rotates inside the circular screen moving the slurry upward to the top of the water extractor Water is gradually removed from the slurry by the action of the auger and screen A compression cone located at the top of the water extractor is the final stage in the water extraction process The cone compresses the waste into a semi dry papery pulp and then pushes it out of the water extractor and into waste containers for disposal The pulper is filled with fresh water initially After that the water level in the pulper and the water extractor is maintained by the combination of recirculated slurry water and fresh make up water Slurry moves from the pulper into the extractor water is removed from the slurry and then returned to the pulper via cross flow piping or via an optional recirculating pump and waste trough system The cross flow piping is blocked when the optional recirculating pump is used A drain overflow skims excess water from the water extractor during normal operation and is used to drain th
52. ving water from the pulp The cone has a wiper blade that pushes the semi dry pulp down the conveyor chute B Auger Conveyor Screw Carries the de watered pulp from the bottom of the water extractor up to the compression cone C Drain overflow Lever Raises the drain overflow tube to drain the water extractor during cleaning D Drain overflow Tube Maintains water level in the water extractor to prevent overflowing and to drain the machine E Auger Conveyor Brush Attached to the auger conveyor screw The brush sweeps across the water extractor screen in order to keep the screen clean and allow slurry water to Wiper blade flow from the pulp F Extractor Screen Allows water to flow off the auger conveyor screw and back to the bottom of the water extractor The auger brush sweeps the screen to keep it from becoming clogged with pulp 18 98mm li 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 1 3 i Turn the Main Circuit Breaker Switch Push the START push button located on to the ON position the water extractor 3 Usean assistant to watch the pump and drive motors for proper rotation Push the START push button and then immediately push th
Download Pdf Manuals
Related Search