Champion P5-24 Manual

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

COPYRIGHT © 2013 All rights reserved Printed in the USA
For future reference, record your Remote Waste Handling Systems information in the box below.
Model Number__________________________ Serial Number_______________________
Voltage________________Hertz_____________ Phase__________________
Service Agent __________________________________ Tel:______________________
Parts Distributor _________________________________ Tel:______________________
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.
National Service Department
In Canada: In the USA:
Toll-free: 800/ 263-5798 Toll-free: 800/ 858-4477
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]
email: [email protected] email: [email protected]
The USGBC Member Logo is a trademark owned by the U.S. Green Building Council and is used by permission. The logo signies only that
Moyer Diebel is a USGBC member; USGBC does not review, certify or endorse the products or services offered by its members.

http://www.championindustries.com/canada/register
REGISTER YOUR PRODUCT ONLINE
Make sure you are connected to the internet then enter the address below.
In the U.S.A
In Canada
http://www.championindustries.com/register

PRODUCT REGISTRATION
BY FAX
[phone] in the USA
1-[phone] in Canada
IMPORTANT IMPORTANT
Model Serial #
Date of Installation:
Company Name:
Telephone #: ( ) ---
Contact:
Address:
Address:
Telephone #:
Contact:
Installation Company:
(Street) Province Postal Code
FAILURE TO REGISTER YOUR PRODUCT MAY VOID YOUR WARRANTY
PRODUCT REGISTRATION CARD
COMPLETE THIS FORM AND FAX TO:

Revision History
Revision Revised Serial Number Revision
Date Pages Effectivity Description
Revision History
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 & added
P/N 319310 Auger Assembly
10.15.13 49 All Changed Item 9 to P/N 109568
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 [phone] in the USA or by calling
1 [phone] in Canada.
i

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, L0R 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 fteen (15) months after the date of shipment by
Champion, whichever occurs rst. [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 period, Champion, at its election,
will either repair or replace the defective machine or accept return of the machine for full credit; provided;
however, as to glasswashers, Champion's obligation with respect to labor associated with any repairs shall end
(a) 120 days after shipment, or (b) 90 days after installation, whichever occurs rst. 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:
a. Lighting of gas pilots or burners.
b. Cleaning of gas lines.
c. Replacement of fuses or resetting of overload breakers.
d. Adjustment of thermostats.
e. Adjustment of clutches.
f. Opening or closing of utility supply valves or switching of electrical supply current.
g. Cleaning of valves, strainers, screens, nozzles, or spray pipes.
h. Performance of regular maintenance and cleaning as outlined in operator’s guide.
i. 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 blocks, pulse vanes, and auger brush.
Examples of the defects not covered by warranty include, but are not limited to: (1) Damage to the exterior or
interior nish as a result of the above, (2) Use with utility service other than that designated on the rating plate,
(3) 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 INCIDENTAL 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.
ii

Revision History ...........................................................................................................i
Limited Warranty ...........................................................................................................ii
Model Descriptions ...........................................................................................................iv
Introduction..........................................................................................1
Theory of Operation....................................................3
Waste Handling Precautions ......................................6
Recirculating Pump Trough Connections ...................8
Installation............................................................................................9
Receiving....................................................................10
Utility Connections......................................................11
Initial Start-up ..................................................................................................13
Electrical Controls.......................................................15
Mechanical Adjustments.............................................17
Water Fill Adjustments................................................19
System Operation Checks..........................................20
Operation.............................................................................................. 23
Cleaning and Maintenance................................................................. 25
Cleaning......................................................................26
Maintenance...............................................................27
Troubleshooting..........................................................29
Service Replacement Parts ................................................................ 31
Remote Control Cabinet Component Selection Chart........................ 63
Electrical Schematic........................................................................................ 64
Table of Contents
Table of Contents
Waste Handling Systems: P5-24, P5-27, and P7-30
iii

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

Introduction
Introduction
1

Theory of Operation
Fresh make-up
water
Recirculated
slurry water
WASTE
IN
Grinding
disk
Cutters
Pulper
motor Drain
SLURRY OUT
Drain/overflow
Pulp compression
cone
Slurry PULP
OUT
Slurry auger
and screen
Optional slurry
recirculating
pump
2

1. The close-coupled waste handling system is designed to reduce the volume of waste created in the food
service operation thereby reducing the expense associated with conventional methods of waste removal
and disposal. The waste handling system accomplishes this by combining food, paper and water,
removing the water and then compressing the waste for disposal.
2. The waste 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.
3. 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.
4. 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.
5. A compression cone, located at the top of the water extractor is the nal 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.
6. The pulper is lled 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-ow piping or via an optional recirculating pump and waste trough system.
The cross-ow piping is blocked when the optional recirculating pump is used. A drain/overow
skims excess water from the water extractor during normal operation and is used to drain the system
during the clean-up operation.
7. There are 2 methods for feeding waste into the pulper. In the rst 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.
8. 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.
9. The waste handling system must be cleaned
daily after the day's operation. Optional ushing
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 ushed 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.
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.
Waste is compressed into a semi-dry, papery pulp.
2
3

Theory of Operation
Theory of Operation
Under-table Feed tray and Hood Congurations
Direct feed w/cover
Feed tray w/hood
Feed hood w/hinged lid
The illustrations below show the standard under-table designs employed to manually feed
food and paper waste into the pulper. The feed tray/feed hood components are removable
for cleaning and access to the pulper interior.
4

#1 #2
#3 #4
#5 #6
Theory of Operation
Theory of Operation
Feed-trough Congurations
Six standard feed-trough congurations 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 ows down the trough, carries the waste into the pulper. The slurry water is
supplied by a recirculating pump mounted on the water extractor.
4
5

Waste Handling Precautions
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. DO NOT 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. Condiment packages (e.g., ketchup, mustard, etc.)
8. Plastic bottles/bottle caps
CAUTION:
Damage to the waste handling system will result
if metal objects 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.
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.
Waste Handling Precautions
6

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 the system.
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.
6
7

Recirculating Pump Trough Connection Kit: P/N 407365
½" Critical Gap
Trough (supplied by others)
Suggested Trough Baffle
(supplied by others)
Trunk Option A
Trunk Option B
Slurry Water
Recirculating
Pump
1½" Pipe
(supplied by others)
1
2
3
4
5
677
8
1 102448 Elbow, 1" x 90° Brass 1
2 100585 Locknut, 1" NPT Brass 1
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 1
7 107340 Clamp, Hose SST w/CS Screw 2
8 111117 Hose, 1-5/8" I.D. 1
9 104889 Compound, Grey Sealing 1 ft.
Item No. Part No. Qty.Description
Recirculating Pump Trough Connection Kit: P/N 407365
Recirculating Pump Trough Connection Kit P/N 407365
1
2
3
Form # 900822
P-5 Recirculating Pump Trough Connection Kit: P/N 407365
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.
!! ATTENTION !!
A splash baffle (supplied by others) must be
fabricated and installed in the discharge end of
the trough to create the proper 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
between the baffle and the trough bottom.
The trough must be removable for cleaning.
Form # 900822
8

9
Installation
Installation

10
Receiving • Installation
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. Inspect the installation site before moving the machine, then place the machine and the
remote control cabinet at their permanent locations.
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.
6. Follow the instructions (supplied by others)
to permanently attach the machine to the floor.
7. A rubber gasket and mounting hardware is
supplied with the pulper if the installation
includes a feed trough system. The feed
trough system is supplied by others.
Receiving
IMPORTANT:
Plan the route used to transport the main components/pallets. Halls and doorways may be to small to travel through to
the nal site.
Rubber gasket for a trough connection is
supplied with the pulper.
2" [51mm]
Legs are tted with adjustable feet.

10
11
Installation • 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.
Utility Connections
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 authorized installers who will follow all
electrical, plumbing, sanitary, safety procedures and regulations.
Plumbing and Electrical Connection Diagram (P&E)
The plumbing and electrical specications and connection locations are detailed in a P&E
diagram. This diagram is supplied for the installation prior to shipment. Contact a supervisor
if you do not have the P&E at the time of installation.

12
Utility Connections • Installation
The Plumbing and Electrical Diagram-P&E (continued)
1. Refer to the P&E and match the utilities at the installation site to the P&E.
2. Contact a supervisor if the installation site does not match P&E.
3. The general utility requirements may include, but are not limited:
Cold water supply
Electrical supply
Drain
Cold Water Supply
1. 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
2. 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.
Utility Connections (continued)
MACHINE ELECTRICAL CONNECTION
FOR SUPPLY CONNECTION, USE COPPER OR COPPER-CLAD ALUMINUM CONDUCTORS
MINIMUM SUPPLY CONDUCTOR AMPACITY
MAXIMUM SUPPLY OVERCURRENT PROTECTION DEVICE
OVERCURRENT PROTECTION DEVICE
VOLTAGE
TIME DELAY FUSE OR INVERSE TIME CKT BREAKER
IN ACCORDANCE WITH LOCAL ELECTRIC CODE, RATED MINIMUM 90°C(194°F)
PHASE HERTZ
AMPS
AMPS
AMPS