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: 10.15.13 Manual P/N 114509 rev. D For machines beginning with S/N J08072511 and above 3765 Champion Blvd. Winston-Salem, NC 27105 336/661-1556 Fax: 336/661-1660 Toll-free: 800.858.4477 2674 N.
For future reference, record your Remote Waste Handling Systems information in the box below.
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.
PRODUCT REGISTRATION BY FAX COMPLETE THIS FORM AND FAX TO: (336) 661-1660 in the USA 1-(800) 204-0109 in Canada PRODUCT REGISTRATION CARD Serial # Model 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
Revision History Revision History A revision might be a part number change, a new instruction, or other information that was not available at print time. We reserve the right to make changes to these instructions without notice and without incurring any liability by making the changes. Equipment owners may request a revised manual, at no charge, by calling 1 (800) 858-4477 in the USA or by calling 1 (800) 263-5798 in Canada. Revision Date 10.10.08 2.15.10 10.11.
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.
Table of Contents _ Table of Contents Waste Handling Systems: P5-24, P5-27, and P7-30 Revision History ............................................................................................................i Limited Warranty ............................................................................................................ii Model Descriptions ............................................................................................................iv Introduction.....................
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.
Introduction Introduction 1
Theory of Operation Pulp compression cone Drain/overflow Slurry WASTE IN PULP OUT Fresh make-up water Recirculated slurry water Slurry auger and screen Grinding disk Cutters Optional slurry recirculating pump SLURRY OUT Pulper motor 2 Drain
Theory of Operation Theory of Operation Refer to the illustration on the preceding page as you read the theory of operation below. The close-coupled waste handling system is made up of 2 units: a pulper and a water extractor. 1. The close-coupled waste handling system is designed to reduce the volume of waste created in the food service operation thereby reducing the expense associated with conventional methods of waste removal and disposal.
Theory of Operation Theory of Operation Under-table Feed tray and Hood Configurations The illustrations below show the standard under-table designs employed to manually feed food and paper waste into the pulper. The feed tray/feed hood components are removable for cleaning and access to the pulper interior.
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.
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 objects are fed into the machine.
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.
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.
Installation Installation 9
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.
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.
Utility Connections • Installation Utility Connections (continued) 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.
Optional Remote Start/Stop Station Installation Model P5-24, P5-27, P7-30 Pulper Remote Start/Stop Station Option Installation Instructions Remote Start/Stop Station 67$ 57 672 3 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 (90ºC).
Initial Start-up - Pulper/Water Extractor WARNING! Death or serious injury may result if hands, clothing, or jewelry are caught in the machine. The Waste Handling System contains ROTATING PARTS moving at high speed. WARNING! Death or serious injury may result if safety devices are not working. NEVER operate the machine unless all safety devices are in good working condition and all safety covers are in place on the machine. Pulper • Initial Start-up 1. 2. 3. 4. 5.
Pulper/Water Extractor - Initial Start-up Pulper/Water Extractor Electrical Controls POWER MUST BE TURNED OFF UNTIL ALL MECHANICAL CHECKS ARE COMPLETE. The Remote Control Cabinet offers the following controls: START STOP A: ON/OFF manual reset breaker switch. Rotate handle fully CW to turn power ON. 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.
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.
Pulper - Initial Start-up Pulper Mechanical Adjustments 1. Refer to the illustrations below and check the clearance between the stationary cutter blocks and rotating cutter blades. 2. Slowly rotate the cutting disk to make sure that the rotating blades do not hit any of the blocks. 3. 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. 4.
Initial Start-up - Pulper/Water Extractor Water Extractor Mechanical Adjustments 1. The water extractor Compression Cone (A) should be adjusted to 3⅞" from the top of the water extractor housing and the top of Compression Cone. The main components of the water extractor interior are listed below: A A: Compression Cone Final stage in removing water from the pulp. The cone has a wiper blade that pushes the semi-dry pulp down the conveyor chute.
Pulper/Water Extractor - Initial Start-up Water Fill Adjustments 1. Make sure all access doors, panels and safety devices are in place, secure and operating. 2. Turn the Main Circuit Breaker Switch on the remote control cabinet to the ON position. Turn the Main Circuit Breaker Switch to the ON position. Push the START push button located on the water extractor. 3. Use an assistant to watch the pump and drive motors for proper rotation.
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 is open. Water extractor drive motor is running. Optional water extractor recirculating pump (if equipped) is running.
Pulper/Water Extractor- Initial Start-up System Operation Tests Test Delay Stop Option (if equipped) Note: The adjustable timer located inside the control cabinet is preset at the factory for 6-minutes. 1. While the system is running, push the Delay Stop Switch. The system should run for 6-minutes then shut off. 2. Restart the system. Push the Delay Stop Switch, then push the Stop push button on the Start/Stop station. The system should stop immediately.
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. Drain Closed 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.
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. 1. Turn on main power supply and water supply. 2. Make sure all drain valves are closed. 3. Inspect the interior of the pulper tank for metal or other debris. 4. Inspect the interior of the water extractor and make sure it is clean. 5.
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.
Pulper/Water Extractor - Cleaning and Maintenance Cleaning DO NOT HOSE THE EXTERIOR OF THE MACHINE WITH WATER 2 3 1 6 4 2 5 1 Drain 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. 2. Check the optional deodorizer injector (if equipped) chemical supply tubing and chemical pick-up tube. 3. Refill the deodorizer chemical supply container (supplied by others) if necessary. 4.
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 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. Cause(s) Solution(s) Main Power Supply OFF Turn on or reset breaker. Remote Control Cabinet 3A push button breaker tripped.
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Service Replacement Parts Service Replacement Parts Illustrations Water Extractor Assembly - Inner View................................................................................................... 32 Pulper Assembly - Inner View.................................................................................................................. 34 Water Extractor / Pulper Assembly - Front Outer View...........................................................................
Water Extractor Assembly - Inner View 41 28 13 26 23 23 8 46 37 35 11 47 51 22 15 20 9 24 50 14 11 25 9 31 45 1 38 11 49 13 44 43 40 6 32 21 42 12 33 7 34 48 30 36 16 27 39 2 19 5 4 5 3 10 32 27 29 8
Inner View - Water Extractor Assembly Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 --------29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 Part No.
Pulper Assembly - Inner View 6 8 15 26 24 18 19 3 8 25 21 1 20 23 8 14 2 11 9 13 5 17 22 7 27 12 10 4 16 34
Inner View - Pulper Assembly Item No. Part No. Description Qty. 1 2 3 4 5 6 7 8 9 10 11 100153 100736 100746 100747 102409 102563 106314 106407 106482 107589 109814 BOLT, HEX HD., 3/8-16 X 1" SST BOLT, HEX HD., 1/4-20 X 3/4" SST BOLT, HEX HD., 3/8-16 X 1-1/4" SST BOLT, HEX HD., 1/2-13 X 1" SST COUPLING, 1/8" NPT BOLT, HEX HD., 3/8-16 X 3/4" SST BOLT, HEX HD.
Water Extractor/Pulper Assembly - Front Outer View 4 26 14 27 11 17 24 7 12 20 2 1 9 19 21 23 10 3 8 25 16 15 6 5 36 28 13 18 22
Front Outer View - Water Extractor/Pulper Assembly Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ----15 16 17 18 19 20 21 22 23 24 25 26 ----27 28 Part No. 100007 100194 100734 100754 102442 102669 106026 106482 112823 112822 107966 107967 108966 110596 113311 113336 110654 110656 110872 111614 111615 111616 111617 113140 307831 307833 312397 312480 325940 326077 313415 108150 Description SCREW, TRUSS HD. 10-32 X 3/8" SST HEX GRIP NUT, 10-32 SST BOLT, HEX HD., 1/4-20 X 1/2" SST SCREW, FLAT HD.
Water Extractor/Pulper Assembly - Rear Outer View 2 34 30 19 22 21 5 7 17 23 35 27 18 19 11 20 18 31 11 6 29 6 12 14 10 28 29 4 16 26 32 15 1 36 3 8 21 2 34 38 24 6 13 21 33 9
Rear Outer View - Water Extractor/Pulper Assembly Item No. Part No.
Under-table Feed Trays - Pulper Assembly 19 22 15 23 2 13 9 23 8 24 14 10 25 21 11 26 27 2 13 5 3 17 14 10 19 16 12 6 4 1 7 20 10 40
Pulper Assembly - Under-table Feed Trays Item No. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 107654 100194 100734 104985 106482 106486 107033 107135 107966 108954 108966 109934 109935 110593 110763 110890 110891 111026 113489 309753 312475 313228 313229 314187 316145 316147 320985 Description SCREW, TRUSS HD., 6-32 X 1" SST HEX GRIP NUT, 10-32 SST BOLT, HEX HD.
Feed Tray with Hinged Lid - Pulper Assembly 17 8 6 18 12 4 13 6 20 2 10 16 19 14 6 12 1 9 15 11 15 1 4 3 42 9 5 5 7 7 4 3
Pulper Assembly - Feed Tray with Hinged Lid Item No. Part No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 107654 100194 104985 106486 107033 107966 108954 109666 109934 110593 110762 111026 111478 113489 309753 313230 314187 319877 321147 327100 Description SCREW, TRUSS HD., 6-32 X 1" SST HEX GRIP NUT, 10-32 SST HEX PLAIN NUT, 10-32 SST WASHER, LOCK #10 SPLIT SST WASHER, FLAT SST HEX GRIP NUT 10-32 SST W/NYLON HEX GRIP NUT, 6-32 SST W/NYLON HANDLE MAGNETIC, SWITCH DOOR LATCH ASSY.
Two Piece Feed Tray with Flushing Nozzles - 30" Pulper Assembly 22 16 15 19 15 18 19 17 26 13 1 1 16 23 15 21 19 20 24 26 14 10 8 9 2 3 6 11 4 44 7 12 5
30" Pulper Assembly - Two Piece Feed Tray with Flushing Nozzles Item No. Part No.
Recirculating Pump Option - Water Extractor/Pulper • Front View 36 37 38 32 39 40 31 33 35 6 12 4 5 10 12 23 11 1 12 6 3 19 16 28 9 10 See next page for pump assembly. 13 26 6 7 6 4 21 6 14 22 12 4 26 17 18 27 20 16 4 21 14 15 22 46 34 1 9 8 30 28 6 1 29 41 Comes with Item No.
Front View • Water Extractor/Pulper - Recirculating Pump Option Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Part No.
7 18 11 6 16 12 4 3 13 5 8 10 2 12 15 9 14 17 8 1 12 7 Recirculating Pump Assembly - Water Extractor/Pulper 48
Water Extractor/Pulper - Recirculating Pump Assembly Item No. Part No. Description Qty. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 C3819 D4820 12799-1 14269-1 100002 100153 100735 102504 104638 107364 106407 106482 106619 109678 109679 110276 106990 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.
Recirculating Pump Option - Water Extractor/Pulper • Rear View 1 2 3 16 4 2 4 3 4 2 5 2 6 2 1 2 1 28 15 24 25 23 50 2 22 4 24 25 2 18 1 21 20 19 12 17 2 Comes with Item No. 15 9 8 7 27 26 3 See previous page for pump assembly.
Rear View • Water Extractor/Pulper - Recirculating Pump Option Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 Part No. 100739 102376 100154 106013 104203 326045-1 107340 102448 100585 111157 111079 111080 204731 202291 104751 100740 315147 106990 113331 326050 326065 111134-5 111134-2 104638 326054 205435 100173 104165 Description BOLT, HEX HD.
Flushing Assembly - Pulper/Water Extractor 1 2 3 7 5 4 6 8 9 7 10 14 6 13 10 12 10 21 14 10 11 or 20 6 10 18 19 52 Water Supply 10 3 5 16 17
Pulper/Water Extractor - Flushing Assembly Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ----15 16 ----17 18 19 20 21 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 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 90º BRASS BUSHING, RED.
Deodorizer Pump Assembly - Pulper/Water Extractor 1 5 2 3 6 9 7 10 4 8 11 12 13 14 15 17 16 18 19 54
Pulper/Water Extractor - Deodorizer Pump Assembly Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Part No. 317006 104624 106026 107967 107970 111509 108173 317007 111511 111510 111513 111512 108411 110856 110750 107065 0502667 108412 107931 111514 -- Description Qty. BOX, DEODORIZER SCREW, TRUSS HD. 8-32 X 3/8" SST WASHER, FLAT, 1/4 SST HEX GRIP NUT, 1/4-20 SST W/NYLON SCREW, FILLISTER HD.
Feed Trough Gaskets - Pulper 1 Feed trough supplied by others 5 4 56 2 4 3
Pulper - Feed Trough Gaskets Item No. 1 2 3 4 5 Part No. 111873 113324 111478 107033 107966 Description GASKET, PULPER, 9" TROUGH GASKET, PULPER 12" TROUGH BOLT, HEX HD. 10-32 X 1/2" SST WASHER, FLAT GRIPNUT, HEX HD., 10-32 SST W/NYLON INSERT Qty.
Remote Control Cabinet - Pulper/Water Extractor Comes with Item No.
Pulper/Water Extractor - Remote Control Cabinet Item No. Part No.
Remote Control Cabinet - Pulper/Water Extractor (continued) Item No. Part No.
Electrical Schematic Electrical Schematic Remote Control Cabinet Component Selection Chart 61
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Remote Control Cabinet Component Selection Chart Remote Control Cabinet Component Selection Chart Motor Overloads ● Motor Contactors ● Bus Systems Step-down Transformers ● Circuit Breakers 111628 111628 111629 113161 111632 113810 208-240V/60/3 111625 111626 111627 111628 111629 113161 480V/60/3 111625 111626 111627 111628 111629 113161 575/60/3 111626 111627 111630 380/50/3 111626 111627 111628 113161 113161 415/50/3 Motor Starter Overload (Items 45, 46, 47) Voltage (VAC) Motor (HP) P
Close-coupled Pulper/Water Press Electrical Schematic 1 CB 3 2 120 VOLTS L1 L2 L3 GND 3A 5CR 3 4CR 33 34 OFF DELAY STOP TIMER (IF USED) 4CR 3 32 2CR 4 3 7 2 TR 5 STOP 30 HOLD-IN RELAY 2CR DOOR INTERLOCK RELAY 3CR DEODORIZING UNIT RELAY 4CR DELAY STOP RELAY 5CR DELAY STOP HOLD IN RELAY 2 7CR BOOSTER HEAT HOLD-IN RELAY 5CR 2 1M PULPER DRIVE MOTOR CONTACTOR 2 1MOL PULPER DRIVE MOTOR OVERLOAD 1CR 2M WATER PRESS MOTOR CONTACTOR 2MOL WATER PRESS MOTOR OVERLOAD 3M
