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CSS-130 - Champion Industries

1. eene rennen nennen 36 TROUBLESHOOTING FLOW CHARTS e eeeeeseeeeeeeeeee ee nae 37 ELECTRICAL SCHEMATICS 45 REPLACEMENT PARTS 48 CONTENTS LIST OF FIGURES Figure 1 Component Locator 1 Figure 2 Minimum Clearance to Combustibles Top View eere 4 Figure 3 Minimum Clearance to Combustibles Front View esee 4 Figure 4 Clearance Dimensions Chart 4 Figure 5 Vent Pipe Slope and Horizontal Support 8 Figure 6 Vertical Through the Roof Vent Installation with Fire Stops 9 Figure 7 Vertical Vent Configuration 9 Figure 8 Type B 1 Vent Chimney Venting 11 Figure 9 B 1 Chimney Vent Connection without Elbows eene 12 Figure 10 Type B 1 Chimney Vent Connection with Elbows eene 12 Figure 11 Horizontal Through the Wall Venting esses 14 Figure 12 Horizontal Vent Exit Through Rear Wall eere 16 Figure 13 Horizontal Termination Clearance sees rennen 16 Figure 14 Horizontal Vent Termination Window and Grade Level 17 Figure 15 Horizontal Vent Exit Through Si
2. 1 4 111954 Orifice att i es tegeret e tefte mete redet 1 5 111931 Blower assembly me s iac dere e tene ec eene 1 6 111923 1 111955 Orifice gas erede eed eoe 1 111993 Peas sc tbi e tus 1 7 111919 Ignitor Includes gasket eene 1 8 111951 Air bleed off assembly eese 1 9 111928 Pressure switch stack differential sssssseeeeeee 1 10 111927 Thermostat high 1 11 112083 Fan control cabinet cooling see 1 12 111930 Gauge pressure temperature 1 13 111924 Thermostat operating control seen 1 14 112064 Valve manually operated 1 15 111853 Pump circulation w differential pressure switch ports 1 16 111952 Lower inlet elbow assembly eee 1 17 111929 Pressure switch circulation pump differential 1 18 112290 Eliminator Alb ss uice 1 19 112429 Valve water pressure reducing 1 20 100853 fo 1 22 104682 Th trmolneter uus fett 1 21 111746 Back flow preventer 1 23 111854 Pump circulation dede eed 1 24 111277 Transformer 24 VAG leto
3. Champion The Dishwashing Machine Specialists Technical Manual Gas Fired Boiler Model CSS 130 RE qq APPROVED CAUTION Read all instructions carefully before starting the installation Save this manual for future reference July 1997 Manual P N 111995 P O Box 4149 2674 N Service Road Winston Salem North Carolina 27115 4149 Jordan Station Ontario Canada LOR 1SO 336 661 1556 Fax 336 661 1660 905 562 4195 Fax 905 562 4618 Champion Industries Inc Complete the information below so it will be available for quick reference Model Number CSS 130 Serial Number Voltage and Phase 115 60 1 Champion Parts Distributor Phone Champion Service Agency Phone In the United States Call Champion Industries Service 1 800 858 4477 Champion Service Fax 1 336 661 1660 In Canada Call Champion Industries Service 1 800 263 5798 Champion Service Fax 1 905 562 4618 NOTE When calling to order parts be sure to have the model number serial number voltage and phase of your machine COPYRIGHT 1996 1997 by Champion Industries Inc CSS 130 GAS FIRED BOILER COMPONENT LOCATOR TO THE INSTALLER BEFORE YOU BEGIN It is important for you to read all Installation and Operating sections of this manual before you begin installation This will avoid mistakes and confusion when installing and operating the unit 1 Gas Burner 10 Blower Motor and Housing 2 Air Intake 11 Control Cabinet 3 O
4. N WARNING Gasoline or other flammable materials and liquids adhesives solvents etc and the vapors that they produce are extremely dangerous DO NOT handle use or store gasoline or other flammable liquids anywhere near or in the vicinity of the gas boiler N WARNING Inspect the vent system for proper installation BEFORE making gas supply connections Failure to install proper venting as described in the venting installation instructions of this manual See pages 6 17 can result in unsafe operation of the CSS 130 gas fired boiler To avoid the risk of fire explosion or asphyxiation from carbon monoxide never operate the CSS 130 gas fired boiler unless it is properly vented and an adequate air supply for proper operation is available Gas Fuel Requirements The CSS 130 is designed and certified for use with Natural Gas or LP Gas CAUTION Check the gas fuel specified on the CSS 130 rating plate before making any gas connection The rating plate is located on the lower left side of the unit If the rating plate and the gas supply do not agree refer to page 21 Field Conversion of Gas Orifice Gas Pressure Requirements 1 Inlet gas supply pressure must be at least 4 W C and no greater than 14 W C for Natural and LP gas installations 2 For LP Gas Only the CSS 130 operates best with a supply pressure of 9 10 W C If no other appliances are being supplied by the LP gas supply set the low pressure regulat
5. tei Hp uie tee EROR Ie e tette lg ui 6 Existing Boiler Removal deerit 6 Common brc 7 Vertical Venting ot e deae dct e de en Ret 8 Chimney Venting RI uae ac eens dee 10 Horizontal Through the Wall Venting enne enne 14 Pipe Cutting and Joining Procedures 15 Locating the Vent Opening in the Outside Wall eere 16 Installing the Horizontal Venting and Termination esee 17 GAS SUPPLY CONNECTIONS 18 Gas Fuel Requirements eben tanta 18 Gas Pressure Requirements nt eee ete ere e e edt det 18 Gas Piping Installation 19 Pressure Testing the Gas Piping Installation eene 20 Field Conversion of Gas Orifice 21 ELECTRICAL CONNECTIONS 1 2 2 Lege te ER Gee teo recette Pelr 22 PLUMBING CONNECTIONS 24 Water and Dr in Connections e i pede preterea 24 INITIAL START UP AND SERVICE 25 Instructions for Setting Air Pressure in Expansion Tank 26 Instructions for Manually Venting Air from Boiler Water System 27 Gas Valve Operating Instructions 28 Check Test and Start up iod al gae ce be e ad 29 Sequence of Operation Explained
6. 1 25 111925 Relay tim delay vw sent pe eet ae eee 1 26 100294 Strip terminal 5 2 d no er eerte HEURE 1 27 107369 Contactor fece mte te eed eds 1 28 109069 Thermostat control 1 29 112188 Lamp power indicator 1 30 111067 Relay control eei tete 1 31 111036 Socket relay 5 ec epp 1 32 111926 Module Ignition boiler control 1 33 111852 Went 1 34 111745 Tank expansion etate a eee ae 1 35 111953 Upper inlet elbow assembly eee 1 36 317943 Coil heat exchanger 44 66WS rack conveyor 1 37 317893 Coil heat exchager D H1 1 38 100123 Gauge COCK 1 112043 Valve pressure relief 3 4 30 PSI Not shown 1 100135 Gauge pressure Not shown eese 1 103309 Lug ground Not shown 1 112228 Nalve angle drain 1 2 eec oce tx 1 49
7. HEATER CONTROL The Integrated Heater Control Module controls the combustion process the gas valve the igniter the blower the unit pump and the system circulator It provides blower pre purge as well as burner flame sensing When replacing the heater control turn off disconnect switch and press in tabs on each end of plugs to remove from control All plugs are color coded and it is not possible to miswire the control STACK SWITCH The Stack Switch is a normally open single pole switch which is operated by the pressure difference across the air orifice It is set to close when a static pressure difference of 1 w c is generated by the combustion air blower Its function is to prove airflow and to inhibit burner operation in the event of flue or chimney stoppage The switch is wired directly to the heater control It is located behind the front panel and is attached to the left hand control cabinet support bracket STORAGE TANK The Storage Tank contains approximately 10 gallons of heater water It functions as an energy storage vessel to reduce heater cycling TIME DELAY RELAY TDR The Time Delay Relay controls the unit pump and keeps it operating for approximately one minute after the blower post purge stops Control voltage on the TDR is 24 volts from the limit circuit The contacts to supply pump power are 120 VAC They delay on open one minute after the 24 volt control voltage is interrupted Turn off disconnect switch befo
8. CSS 130 burner system is a pre mixed forced combustion system Outside air is drawn through the air orifice located in the air induction system and mixed with the gas drawn in downstream of the air orifice The gas is metered through an orifice located in the gas orifice union All the air required for complete combustion comes into the unit in this manner Adjusting the input is limited to changing the gas orifice to achieve the proper input The air orifice cannot be altered and the gas valve pressure setting cannot be changed Before changing the gas orifice to correct input service representatives should make the following checks 1 The pressure on the inlet side of the gas valve is between 4 and 14 water column 2 The pressure on the outlet side manifold of the gas valve and T above air orifice is between 0 05 and 0 35 water column with the unit operating To increase the input install larger diameter gas orifice Each size will change the input approximately 5 C F H Once the correct input has been achieved the burner should be checked with an oxygen 0 or carbon dioxide 0 gas analyzer The unit should be in operation 5 minutes before adjusting input or taking CO or 0 readings This time will allow for preheating of the intake air Insert the probe of the 0 or CO tester at least 6 into the vent through the vent terminal If CO is being measured the readings should be between 8 0 and 8 5 for n
9. Figure 5 p Vent Pipe Slope E Vent Connector and Horizontal Support Support horizontal sections every 5 feet with metal straps The vent connector should be routed to the vent using the shortest route possible The entire length of a vent connector shall be readily accessible for inspection cleaning and replacement Vertical Venting The CSS 130 is certified for use with up to 50 equivalent feet of 3 diameter pipe for vertical vent installations A 90 elbow equals 5 equivalent feet of pipe Vent pipe and fittings must be securely supported horizontal sections require supports every 5 feet Fire stops can support up to ten feet of vertical run Galvanized or stainless steel vent pipe may be used for vertical runs Stainless steel vent pipe must be used for horizontal runs Saf T Vent manufactured by Heat Fab Inc is constructed from AL294C stainless steel and is approved for use in the United States and Canada INSTALLATION Vertical Venting Cont d Maintain six inches 6 air space to combustible around the pipe for single wall metal vent Maintain one inch 1 air space to combustible around pipe for Type B 1 vent Whenever possible the vent should be continued straight up through the roof If it is necessary to make an offset in the attic the horizontal run should slope upwards minimum of 1 4 inch per foot and be supported by metal straps Vent pipe passing through floors ceilings or framed walls must be
10. OFF Mare sure main water supply valve is OFF Check high vent knurled cap on boiler holding tank If closed turn knurled CCW one complete turn Open petcock on outlet side of dishwasher tank heater coil piping Remove silver air bleed plug in center of recirculating pump Pump is located on right front corner Remove silver air bleed plug D in center of burner recirculating pump Open air bleed petcock E on lower left front of burner assy Turn main water supply ON Water fills the gas boiler and dishwasher tank heater coil Air or a mixture of air and water then water only should be observed coming from petcock vents Plumbing and Electrical service connections must be completed BEFORE performing the following procedures INSTRUCTIONS FOR MANUALLY VENTING AIR FROM BOILER WATER SYSTEM CAUTION Failure to follow instructions will result in permanent damage to the recirculating pumps 9 10 11 12 13 Observe air bleed petcock E Make sure a steady stream of water comes from petcock then close the petcock When boiler holding tank is full turn dishwasher main power switch ON Dishwasher fills automatically Boiler may begin ignition cycle One or both boiler recirculating pumps run Observe vent ports Make sure a steady stream of water comes from all ports Close petcock and reinstall recirculating pump plugs in the following
11. Valve 2 The CSS 130 must be isolated from the gas supply piping system by closing its individual manual gas shut off valve during any pressure testing of the gas supply system at test pressures equal to or less than 1 2 psig Figure 19 Gas Connection Point Side View Figure 20 Gas Connection Point Top View 20 INSTALLATION Gas Supply Connections Field Conversion of Gas Orifice The CSS 130 requires a gas orifice specifically designed for either Natural or LP gas If the gas fuel supply at the installation site does not match the gas type marked on the machine data plate located on the front panel of the gas fired boiler you will have to change the gas orifice Figure 21 WARNING Gas Orifice Union Location When working on any electrical circuit disconnect the power at the main service disconnect switch or breaker and place a tag at the disconnect switch to indicate that work is being performed on the circuit N WARNING Close the CSS 130 manual gas shut off valve located on the left side of the unit before you remove the gas orifice union Refer to Figs 21 22 and 23 1 The gas orifice union is located behind the gas burner recirculation pump near the center of the CSS 130 CE 2 The gas orifice is screwed into the union i Q See Fig 22 Orifice Detail Orifice Detail Figure 22 3 To convert the gas orifice remove the orifice Gas Orifice Union union and u
12. normal manner close main shut off valve do NOT shut off switch and contact your heating contractor gas company or factory representative 5 You MUST check flame monitoring control ignition system safety shut off device a Close gas cock with burner operating b In 3 seconds FLAME indicator light will go out and blower will continue to run on post purge cycle Two additional attempts to light will follow including pre purge igniter on valve flame on and post purge Ignition will not occur gas off c Open gas cock Switch dishwasher power switch OFF and then ON again Burner should start after about 45 secs It is recommended that the unit be checked with a standard CO or 0 tester Insert tester probe at least 6 into exhaust pipe through outside vent terminal Readings should be 8 to 8 5 nat gas 9 to 9 8 LP gas 0 7 to 6 6 Check burner input other equipment off a Measure the time in seconds it takes to use one cubic foot of gas b Divide the number of seconds into 3 600 c Multiply the result by the heating value of the gas to obtain BTU HR input Example If it takes 36 seconds to use one cubic foot of gas and the heating value of the gas is 1 000 BTU CU FT approximate natural gas value INPUT 3 600 36 x 1 000 100 000 BTU HR Input Ranges 127 400 BTU HR to 132 600 BTU HR Because of the altitude and other minor variations it is possible the input will not
13. of 50 cubic feet per 1 000 BTU HR input of the total of all appliances in the area Adjoining rooms may be counted as one area only if there are no doors between the rooms Air Contaminants Compounds bearing contaminants such as chloride fluoride iodide and bromide when present in certain concentrations in the air supplied for combustion to the boiler can result in an accelerated and severe corrosion condition in the heat exchanger and or the venting systems Avoid storing or using chemicals containing these compounds in the vicinity of the boiler if at all possible CAUTION Combustion air must not be contaminated by corrosive chemical fumes which can damage the heat exchanger in the boiler INSTALLATION INSTALLATION WARNING Read all of the instructions included with your machine before attempting any installation Faulty vent installation can cause improper operation of the gas fired boiler Vent Installation General The CSS 130 gas fired boiler is approved as a Category I Boiler when the following vent installations are used 1 Common vent installation 2 Vertical through the roof vent installation 3 Masonry chimney vent installation using Type B 1 Double wall vent The CSS 130 is approved as a Category III Boiler when a horizontal through the wall vent installation is used This installation is a positive pressure venting system and requires that all connections be sealed with an approved high tempera
14. pressure in the expansion tank is sometime before the water and electric service are connected to the boiler For boiler assembly BEFORE it is filled with water 1 26 Make sure Dishwasher s main power switch is OFF Mare sure main water supply valve is OFF Check the expansion tank pressure with an air guage Depress valve stem to allow air to escape Check pressure and repeat the above until the tank pressure reading is 20 PSI If too much air is released use a tire chuck and add air until the pressure gauge reads 20 PSI Acceptable pressure range is 19 20 PSI INSTRUCTIONS FOR SETTING AIR PRESSURE IN EXPANSION TANK NOTE Expansion tank air pressure should be set to 20 PSI for proper operation 1 For boiler assembly AFTER it is filled with water Make sure Dishwasher s main power switch is OFF Mare sure main water supply valve is OFF Slightly open drain valve located at the bottom of the storage tank to bleed off some water until the dishwasher Final Rinse Gauge reads 0 PSI Close the storage tank drain valve Check the expansion tank pressure with an air guage Check pressure and repeat the above until the tank pressure reading is 20 PSI If too much air is released use a tire chuck and add air until the pressure gauge reads 20 PSI Acceptable pressur range is 19 20 PSI Open water supply valve NOTE ATTENTION INSTALLER Make sure Dishwasher s main power switch is
15. than 1 2 of sensing bulb should be visible after installation Fill the heater and be sure to bleed the coil at the coil bleed petcock Turn on disconnect switch and check heater operation OPERATING CONTROL The Operating Control maintains boiler discharge temperature between 180 199 F It has a fixed set point of 210 F at the output of the burner and a differential of 30 F If replacement is necessary shut off the 120 volt power and disconnect the wires to the sensor Valve off and drain water from the unit and remove sensor Install new sensor refill heater and bleed coil at coil bleed petcock Check boiler operation after installation of new Operating Control Its contacts open at 210 F and they reclose at 180 F IGNITER The igniter is a glow bar type silicon carbide unit It is energized whenever there is a call for heat and the red IGNITER light on the heater control is lit After the igniter is switched off and the heater continues to run the igniter functions as a flame sensor for the heater control If the igniter fails and must be replaced always install a new igniter gasket with the replacement igniter CAUTION Ignitor gets hot PRESSURE SWITCH The Differential Pressure Switch is a normally open single pole switch which is designed to detect pump operation water flow and operate as a low water cut off device To replace turn off electrical power amp boiler feed water Valve off and drain water from t
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17. Canadian local codes as appli cable or in the absence of local codes to the Canadian installation code CAN CGA B149 Vent pipe and fittings must be securely supported Horizontal runs must be supported at five foot intervals and at each point where an elbow is used To prevent condensate collection at any one point in the horizontal vent run slope the vent pipe down 1 4 min per foot of horizontal run See Fig 11 below Support every 5 feet Slope down 1 4 min per foot e CSS 130 Figure 11 Horizontal Through the wall Venting Slope down 1 4 min per foot INSTALLATION Horizontal Through the Wall Venting Cont d Pipe Cutting and Joining Procedure 1 Using a sharp 24 teeth per inch hacksaw hand cut pipe to length as square as possible AN Caution Do not use a power saw as it may cause damage to the pipe 2 Clean pipe mating surfaces of all dirt grease and moisture TM 3 Use Dow Corning Silastic 736 RTV high temperature adhesive sealant UltraVent sealant from Hart and Cooley Inc or other approved adhesive sealant N Caution Do not use solvent cements or other adhesives to join vent piping 4 Insert one section of pipe into another Use a felt marker or soft lead pencil to mark the pipe at the full insertion depth 5 Separate the pipe sections and apply a generous bead of adhesive material around the end of the pipe within the marked area 6 Using a twi
18. Force Turn manual gas valve located on left side of unit to OFF position INITIAL START UP AND SERVICE CHECK TEST amp START UP FILLING SYSTEM 1 Open all supply and return valves 2 Fill heating system to minimum operating pressure 20 psig 3 Open bleed pet cock and bleed air from heater coil until a good dream of water comes out 4 Purge all lines by opening vents or with flushing valves 5 Close gas valve 6 Turn on 120 volt power and listen for unit circulator to start Unit will cycle off on lockout 7 Open all vents again to discharge any additional air and close off after air is eliminated 8 System is now ready for operation INITIAL FIRING 1 Be sure that system has been filled properly see above and does not leak 2 Open gas cock s Open manual gas shut off valve by turning to on position 3 Turn on main dishwasher power switch and set thermostat to call for heat In approximately 2 seconds blower will come on NOTE Burner may not ignite on first attempt because of air in gas lines In this case blower will stop after 5 minutes Should this happen turn off main switch Wait 5 minutes and turn on main switch again 4 If burner fails to ignite after three attempts refer to Trouble shooting Section 2 Service Manual or call service for troubleshooting WARNING Should any pronounced odor of gas be detected or if the gas burner does not appear to be functioning in a
19. If the stack switch contacts are closed for any reason when the blower isn t operating a sequence will not occur and after 45 seconds the control will lockout and the PURGE light will flash If the stack switch contacts are open and do not close during purge period after 5 minutes the control will lockout and the PURGE light will flash If the boiler does not operate the green power light is on and no indicator lights are flashing check for an open pressure switch low limit switch operating control or safety limit switch on either series For additional troubleshooting information refer to the troubleshooting flow charts on the pages that follow PowerLED 1 Aquastat Auxiliary Limits Circulator One minute Air Proving Switch Fl pd on TDR Combustion Air Blower Purge LED Igniter Proof of Flame Igniter LED Gas Control Valve Flame LED 1 2 3 Power LED blinks once when 24V power is applied and when thermostat calls for heat On as long as control is powered and operating properly If either switch opens during the run cycle burner will stop followed by postpurge Circulator will run as long as thermostat is calling for heat Burner ignition sequence will restart if switch closes GENERAL TROUBLESHOOTING Reset boiler control by interrupting power at side of unit for 15 seconds Yes No Green Light Flashes Green Light Comes On 1 Is service switch on 2 ls circuit on 3 Are fuses or c
20. TU HR Table 11 2a Fan Assist Type B 1 Double Wall Venting Vent and Connector Diameter Derated for Sizing Flexible Metal Flueliners Total Lateral For CSS 130 Gas Fired Boiler Rated 130 000 BTU HR EN Fan Assist Total Total 4 Diameter 5 Diameter 6 Diameter Height Pi Pipe INSTALLATION 14 INSTALLATION CONT D Vent Installation Cont d Horizontal Through the Wall Venting The CSS 130 is approved as a Category Boiler when a horizontal through the wall vent installation is used This installation is a positive pressure venting system and requires that all connections be sealed with an approved high temperature sealant such as Dow Corning Silastic 736 RTV high temperature adhesive sealant or UltraVent sealant from Hart and Cooley Inc The CSS 130 is certified for use with up to 50 equivalent feet of 3 diameter stainless steel pipe for horizontal vent installations A 90 elbow equals 5 equivalent feet of pipe gt NOTE STAINLESS STEEL VENT PIPE MUST BE USED FOR HORIZONTAL RUNS Saf T Vent manufactured by Heat Fab Inc is constructed from AL294C stainless steel and is approved for use in the United States and Canada Vent installation must be in compliance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 Latest Edition local codes or ordinances these instructions and good trade practices For Canada the installation of this unit must conform to all
21. able 11 3 If dimension H equals 30 feet and the total L equals 10 feet then the required vent diameter would be 8 inches 8 as denoted by the dot in the 8 Diameter Pipe column of the Table Table 11 3 Type B 1 Chimney Venting 8 Diameter Pipe Minimum Internal Area of Chimney Square Inches A Maximum Internal Area of Chimne Square Indies 269 352 A Capacity of Masonry Chimney Flue with Type B 1 Double Wall Flue Connector Serving a Single Category Appliance Figure 9 Type B 1 Chimney Vent Connection without Elbows Lateral slopes up 1 4 min per foot LL lt L gt Slope up 1 4 min per foot Y 130 Adapter Figure 10 Type 1 Chimney Vent Connection with Elbows Laterals slope up 1 4 min per foot 12 INSTALLATION Chimney Venting Refer to Figs 9 10 on the preceding page to determine the dimensions for your installation Use the appropriate Table for your installation to determine the correct diameter of vent and vent connector H Height of the chimney or Type B vent L Total lateral length of the vent connector D Required diameter of vent connector Minimum maximum size limits of internal area of the chimney Table 11 2 Type B 1 Double Wall Venting with Single Wall Metal Connectors Serving a Single Category Appliance For CSS 130 Gas Fired Boiler Rated 130 000 B
22. an extend into or pass through any circulating air duct or plenum All vent pipe passing through floors walls and ceilings must be installed with the listed clearance to combustible materials and be fire stopped according to local codes Common Venting Vent connectors serving Category I appliances shall not be connected to any portion of the mechanical draft systems operating under positive pressure such as Category or Category IV venting systems When two or more vent connectors enter a common gas vent chimney flue or a single wall metal pipe the smaller of the connectors shall enter at the highest level consistent with the available headroom or clearance to combustible material Vent connectors shall be firmly attached to draft hood outlets or flue collars by sheet metal screws or other approved means except vent connectors of listed Type B 1 vent material which shall be assembled in accordance with the vent manufacturer s instructions Fasten joints between sections of single wall connector piping with sheet metal screws or other approved means INSTALLATION INSTALLATION CONT D Vent Installation Common Venting Cont d Horizontal portions of the venting system must be supported at least every 5 feet with metal straps to prevent sagging All horizontal sections of the vent connection must slope upwards 1 4 inch per foot from the boiler to the vent termination See Figure 5 below N Upward slope 1 4 minimum per foot
23. atural gas and 9 0 and 9 8 for propane If 0 is being measured the readings should be between 7 and 6 Measuring When operating on natural gas readings below 8 0 generally indicate a lean mixture not enough gas Readings above 9 25 generally indicate a rich mixture too much gas Inputs should be increased or decreased to correct lean or rich mixtures NOTE If the mixture is very rich not enough air for complete combustion it is possible to get low readings on a CO analyzer This situation does not occur often but it can be detected if reading continues to go lower as the input is increased If this condition is suspected a CO test should be taken at the vent outlet Inputs must be reduced to correct high CO reading and to bring CO readings to proper levels The following numbers apply to natural gas only The range of operation for LP is 9 0 to 9 8 CO Measuring 0 Readings above 7 indicate a lean mixture not enough gas Readings below 6 indicate a rich mixture Input should be increased or decreased to correct lean or rich mixtures CLEANING COMBUSTION CHAMBER COIL 1 Turn off electric and gas supplies and remove the jacket 2 Remove the vent assembly and top cover 3 Remove the top half of the combustion chamber by removing the 3 screws and nuts that clamp the top half to the bottom half Remove the clamp on the air orifice hose and the two clear plastic lines connected to the T on the air in
24. de Wall eee 17 Figure 16 Pipe Sizing Table deer e Re ted ete eet ended 19 Figure 17 Gas Supply Piping Drip Leg 19 Figure 18 CSS 130 Manual Gas Shut off Valve 20 Figure 19 CSS 130 Gas Connection Point Side View sese 20 Figure 20 CSS 130 Gas Connection Point Top View esset 20 Figure 21 Gas Orifice Union Location eese eterne ep rennen nnne 21 Figure 22 Gas Orifice Union uou de eere D ree seeks dt Dre e Medea ende 21 Figure 23 LP Gas Orifice Kit P N 111993 21 Figure 24 Electrical Connections Right side of CSS 130 eene 22 Figure 25 Electrical Schematic 23 Figure 26 CSS 130 Control Panel Power Connections Inside right front side 23 Figure 27 Plumbing Connections Right side of CSS 130 sese 24 Figure 28 Electrical Diagrams oie teer eet esee eee ete 46 Pisure 29 Parts Diagrams eee ett e e ea ee Ete ie rtu sies 48 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 North Service Road Jordan Station Ontario Canada LOR 150 warrants machines and parts as set out below Warranty of Machines Champion
25. dryers and any appliance NOT connected to the common vent system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed DO NOT operate a summer exhaust fan Close fireplace dampers 5 Follow the lighting instructions of the appliance being tested and place the appliance in operation Adjust the thermostat so the appliance operates continuously 6 After five minutes of main burner operation test for air spillage at the draft hood relief opening Use the flame of a match or candle or the smoke from a cigarette cigar or pipe 7 Repeat steps for each appliance connected to the common vent system After it has been determined that each appliance remaining connected to the common vent system properly vents when tested as outlined above return all doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use If necessary the common vent should be re sized to approach the minimum size as determined by using the appropriate tables in Appendix G in the National Fuel Gas Code ANSI Z223 1 Latest Edition For Canada the installation of this unit must conform to all Canadian local codes as applicable or in the absence of local codes to the Canadian installation code CAN CGA B 149 The boiler should not be connected to a chimney flue serving a separate appliance that is designed to burn solid fuel No portion of the venting system c
26. duction elbow 4 Remove the top insulator cap by spreading the retainer 5 Remove the igniter 6 Clean the finned tubing with a wire brush and vacuum all loose material from the combustion chamber 7 Replace all parts in the reverse order in which they were removed 8 Restart the unit as indicated by the lighting instruction label UNIT PUMP The unit pump operates whenever there is a call for heat or hot water It is a wetted rotor type pump and should always be filled with water when it is operating so that it will cool properly If a pump change is required for any reason close gas valve and drain water from the unit Turn off the main disconnect switch and unplug the pump wires remove the pump motor The pump housing need not be removed The replacement pump motor should be installed in the reverse order from which the old pump motor was removed After filling the System be sure to bleed the coil at coil bleed petcock NOTE If the pump motor is not defective the pump cartridge alone may be changed GAS VALVE The gas valve is a solenoid operated negative pressure regulated valve The outlet pressure is regulated at 0 2 w c It is designed to operate with supply pressures of 4 14 w c Within that range of supply pressures the regulated discharge pressure may vary from 0 05 to 0 35 inches w c The regulator is not adjustable and the effect of this variation in discharge pressure is not significant Beca
27. er N CAUTION Care should be taken when lifting the machine to prevent damage 1 Immediately after unpacking the machine inspect for any shipping damage If damage is found save the packing material and contact the carrier immediately 2 Remove the gas fired boiler from the skid Move the boiler to its permanent location Installation Codes The installation of this unit must conform to local codes or in the absence of local code to the National Fuel Gas Code ANSI Z223 1 Latest Edition Where required by the authority having jurisdiction the installation also must conform to the Standards for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 For Canada the installation of this unit must conform to all Canadian local codes as applicable or in the absence of local codes to the Canadian installation code CAN CGA B149 and CSA C22 1 Canadian Electrical Code Part 1 Locating the Gas Fired Boiler Locate the gas fired boiler as near to the exhaust venting system as practical Air openings on the front back and sides of the boiler housing should not be obstructed since they supply air to the combustion chamber The location of the boiler should be chosen with regard to venting dimensions convenient access to piping ventilation of operating components and accessibility for service and cleaning The boiler shall be installed such that the gas ignition system components are protected from water drippin
28. fall within this range and the gas orifice must be replaced See chart in an orifice kit LIGHTING AND SHUTDOWN INSTRUCTIONS A LIGHTING Ensure that heater is filled with water air is bled from boiler coil and water pressure is at a minimum of 12 psi Open manual gas valve Open gas cock on gas valve Turn ON dishwasher power ak wo After 45 seconds ignition will occur if there is a call for heat SHUTDOWN Turn OFF disconnect switch to boiler and dishwasher Close manual gas valve op Close gas cock on gas valve MAINTENANCE OWNER CARE AND MAINTENANCE 1 Inspect venting system Annually remove screws on vent terminal and remove terminal Inspect interior with flash light Reassemble and reseal exhaust vent air system 2 General Housekeeping Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Keep boiler cabinet louvers clear for proper cooling of internal components Do not obstruct boiler room ventilation screens or grills SERVICE MAINTENANCE Cleaning heat exchanger to be done by qualified service person CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing 29 INITIAL START UP AND SERVICE This Page Intentionally Left Blank INITIAL START UP AND SERVICE ADJUSTING BURNER INPUT The
29. fire stopped at floors and ceilings The fire stop must close in the area between the outside of the vent and the opening in the structure Fire stops and supports can be purchased from Plexco Inc or Hart and Cooley Inc When the vent passes through the roof a flashing and storm collar must be used Seal the storm collar to the pipe using a high temperature sealant Terminations must be used in all installations above the roof to ensure the proper performance of the boiler and to prevent the entrance of debris Type B 1 gas vents shall terminate above the roof surface with a U L listed cap or roof assembly 7 Vent Termination Storm collar and flashing Maintain minimum air space Figure 6 Vertical Through the Roof Chase Fire stop Vent Installation with Fire Stops 5 CSS 130 55 130 Top View Figure 7 Slope up 1 4 min per foot CSS 130 Vertical Vent Configuration CSS 130 Front View Dishwasher INSTALLATION 10 Vent Installation Cont d Chimney Venting The CSS 130 is certified as a Category I Boiler and approved for venting in a masonry chimney with Type B 1 Double walled vent connector The following requirements must be met to use this type of vent installation 1 The chimney must be internal lined or internal B vent type 2 An external or unlined chimney may serve as a chase for the use of high
30. g kettling lower frequency noise which varies with temperature moan a Combustion noise occurs at any boiler discharge temperature and is heard the loudest at the flue outlet espe cially on units with side wall venting There are two basic causes for the noise rich mixture and cross contamination To check for a rich mixture it will be necessary to measure the percent 0 or CO in the flue products 0 readings lower than 4 1 2 or CO readings higher than 9 1 4 natural gas and 10 8 LP will often cause combustion noise To eliminate the noise it will be necessary to install a smaller gas orifice so that the 0 will rise above 4 1 2 or the CO will drop to 9 1 4 natural or 10 8 LP Sometimes the readings are influenced by cross contamination and a check for cross contamination should be done before changing orifices if it is suspected A strong smell from the flue products is generally an indication Check for cross contamination using the procedure listed in the index If there is no cross contamination reorificing should be done b Boiling kettling may occur at heater discharge temperatures from 170 F to 210 F The temperature at which it starts will vary from one installation to another The primary cause of the problem is poor heat transfer on the inside of the heater coil This may be caused by scaling from the heater water if no antifreeze is present Many times it is difficult to determine if the noise
31. g spraying rain etc during appliance operation and servicing procedures such as pump replacement burner cleaning and the like When the unit is located in an unconfined space of a building air infiltration may be adequate to provide air for combustion and ventilation Where normal infiltration does not provide the necessary air outside air must be introduced In buildings of unusually tight construction or when locating the unit in a confined space additional air must be provided For confined spaces two 2 permanent openings shall be provided One 1 opening within 12 of the ceiling and one 1 within 12 of the floor of the enclosing space Each opening shall be at least 1 square inch per 1 000 BTU HR heater input of the total for all appliances in the area but not less than 100 square inches These openings shall freely connect with areas having adequate infiltration from outside The boiler should be placed beside the Champion dishwasher model that it serves so that all plumbing and electrical connections between the boiler and the dishwasher can be made per Champion s specifications If installed in a finished area provisions should be made for drainage of any accidental spillage or leakage of water The boiler pressure relief valve and back flow preventor should be piped to a drain to protect from the occasional discharge of water INTRODUCTION INTRODUCTION CONT D Locating the Gas Fired Boiler Cont d Clearance to Co
32. he heater unplug wires from the switch and remove switch Install new switch in reverse order Refill heater and bleed air from the coil bleed petcock Turn on electrical power and recycle system TRANSFORMER The control transformer accepts 120 VAC power and provides 40 VA of 24 VAC power for the heater control only 32 BLOWER The Combustion Air Blower is a high head centrifugal blower It is designed to provide about 2 w c of suction at 30 CFM This performance is necessary to operate the gas valve reliably to overcome induction system friction losses and to eliminate any sensitivity to wind striking the vent terminal It is powered by a 120 volt motor which draws about 1 3 amps at rated load It is powered by the integrated heater control whenever there is a call for heat and 30 seconds thereafter If a blower change is required turn off the 120 volt power and unplug the power wires from the blower motor Remove the three nuts from the blower discharge flange and the four nuts from the blower inlet flange The blower may now be deflected enough to permit its removal Install the new blower using new gaskets in the reverse order from which the old blower was removed The four inlet flange nuts however should only be finger tight initially and then tighten with a wrench after all other operations have been completed The combustion should be checked for correct air fuel ratio whenever the blower is replaced see Burner Adjustment
33. he 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 EXTENT 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 INTRODUCTION INTRODUCTION Welcome to Champion and thank you for allowing us to take care of your dishwashing needs This manua
34. ing off boiler switch for 15 seconds and then try again After two seconds does green power light come on Yes No Refer to general trouble shooting section 120 volts at pump plug Pump operates After five minutes are any red lights flashing Yes 24 volts at control CN6 plug PIN 7 Purge Limit circuit open No Replace No call boiler for heat control Check Valve Flame Check Limit Circuit Troubleshooting Troubleshooting 120 volts at pump motor Replace Check pump wires to cartridge pump 43 1 4 pue 29 57 65 Jenuew uo S paziBiaua sex HOUS 9 55010 Jaye 5205 91 21 oes 6g 3 uonoes Huljooys ees efundisod sajsuen yun V 1 UO SI 3 ponad 205 66 5 U9UM 526 uo pue 526 uo peziDJeue sey OVA 10 2949 1961 ueuM 1e 1961 10269 BIA pue dn sye y eniq OVA 021 40 Y09949 uo 196
35. ipment Do not locate termination near an alcove over a window well or closer than 5 feet to the corner of joining parts of the building structure 6 Do not locate under any kind of deck or patio If possible the wall through which the vent will pass should not be exposed to prevailing winds Select a point of wall penetration where the minimum 1 4 minimum per foot downward slope can be maintained Rear Wall away from Boiler 1 4 min per foot Front View Top View Slope down 1 1 e Horizontal Vent Termination C Figure 13 Horizontal Termination Clearance CSS 130 Window and Grade Level 16 Figure 12 Horizontal Vent Exit Through Rear Wall INSTALLATION Horizontal Through the Wall Venting Installing the Horizontal Venting and Termination 1 Cut a hole in a wall of the building at least 7 in diameter 2 The hole must be located to maintain a downward slope of 1 4 minimum per foot of horizontal run from the boiler 3 Install an approved thimble one sleeve each to the inside and outside walls of the building 4 Install the horizontal run from the boiler to the wall 5 Install the last section of vent pipe so that it extends through both wall plates and terminates 1 1 4 beyond the outside wall thimble See Fig X be
36. ircuit Yes No breaker OK Yes No Test limit Did boiler run through Check for voltage circuit a complete cycle as 120 VAC between ee n described in sequence black and white a er Open of events on page_ wires at back of 120 5 brin AIEN OK VAC connector control pave 0 Volts Have qualified electricain repair fault in wiring to the boiler Check stack No No Pump operates 120 V to pump Yes switch OK Defective Check for voltage 24 VAC between yellow wires at back of VAC 24 x FMR connector Replace boiler on boiler control control Refer to flow chart for specific 24 Volts problem After 5 minutes are any red lights flashing Replace boiler control Yes No Replace transformer 1 Limit circuit open and run boiler Purge Light 2 No call for heat through a few cycles 0 Volts Check Valve Flame hot water Troubleshooting switch contact on relays or thermostats can cause a flashing green light 37 TESTING LIMIT CIRCUIT Complete General Troubleshooting First 1 Switch boiler on 2 Check for 24V at PIN 6 NOTE Plug orientation may differ from diagram 24V Present No Unplug CN6 from boiler control and test as indicated All limits OK Boiler should cycle properly for heat or hot water Check for continuity across pressure switch contacts boiler pressure above 12 PSI Continuity No Conti
37. is combustion or boiling related The best clue is when in the cycle the noise appears and if its frequency changes with heater discharge temperature Combustion noises always have the same frequency however their volume may change from the time that the burner first fires to the time that it shuts off Boiling noises have a frequency that varies with boiler discharge temperature and sometimes they will disappear completely at higher temperatures just before the heater goes off on limit Vibration of the heater pressure gauge needle may also occur with boiling noises 33 INITIAL START UP AND SERVICE INSUFFICIENT HOT WATER Possible Cause a Low limit failure b Coil contamination a Failure of the low limit to operate within its normal calibration points will have the same effect as incorrect system circulator wiring b Coil scaling may occur in some areas of the country where there are high concentrations of minerals in the water These minerals may cause fouling of the domestic hot water coil over an extended period of time lime build up or they may in rare instances cause a problem in less than a year of operation The minerals which react quickly mostly magnesium in well systems cause a slime on the inside of the coil which prevents adequate heat transfer These minerals must be filtered out by a special incoming water filter or inhibited to protect the coil and also to provide acceptable water quality The minerals con
38. l covers the Champion Single Source Gas Fired Boiler Model CSS 130 The CSS 130 operates in conjunction with the Champion door type dishwasher model D HB and the rack conveyor dishwasher model 44 WS and 66 WS The CSS 130 is a low pressure gas fired boiler capable of supplying hot water to the dishwasher wash tank heating coil for wash tank heat and 180 F final rinse water for sanitizing Your gas fired boiler was completely assembled inspected and thoroughly tested at our factory before it was shipped to your installation site This manual contains Installation Instructions Operation Instructions Maintenance Instructions Service Instructions Replacement Parts Lists Electrical Schematics All information illustrations and specifications contained in this manual are based upon the latest product information available at the time of publication Champion constantly improves its products and reserves the right to make changes at any time or to change specifications or design without notice and without incurring any obligation For your protection factory authorized parts should always be used for repairs Replacement parts may be ordered directly from your Champion authorized parts distributor or authorized service agency When ordering parts please supply the model number serial number voltage and phase of your machine the part number part descriptions and quantity INTRODUCTION Unpacking the Gas Fired Boil
39. ling do not disturb the air orifice in the coupling Cover the air induction elbow with your hand or plug it with a rag and restart the heater If no short cycling occurs there is a leak in the 3 flue pipe which must be corrected Do not leave the heater operating in this manner Re assemble the air duct after removing plug rag and connect the balance line and stack switch tubes Disassemble flue and fix leak LOCKOUTS Integrated Heater Control Lockout Possible Causes a Cross Contamination Moisture in Combustion Chamber Gas Valve Malfunction Poor Combustion Boiler Control Malfunction Control Contact Failure 1 Stack Switch 2 Operating Control g Failure of Air Source h Igniter Failure a If cross contamination is suspected see Cross Contamination and check for it One percent CO in the air duct can cause nuisance lockouts b Moisture in the combustion chamber will also cause lock outs by weakening the flame signal to the heater control It should be suspected if the heater temperature does not rise above 160 F during long periods of operation This condition can be caused by an improperly wired system circulator On sidewall vented units moisture can get into the combustion chamber from a flue pipe that is pitched incorrectly back toward the heater without a condensate trap Quick Vented systems should always pitch down from the heater defective gas valve one that does
40. low 6 Install a 3 inch 3 coupling to the end of the last section and seal with high temperature adhesive sealant 7 Seal all joints between the mounting plates and thimble with high temperature adhesive sealant Install a 90 elbow to a 6 3 4 piece of 3 inch vent pipe Install a debris screen in the 90 elbow 10 Install the assembly to the 3 inch coupling described in step 6 sealing all joints and making sure that the discharge end of the elbow is pointing straight down 11 After installation the distance between the outside wall thimble and the closest edge of the termination elbow must not be less than six inches See Fig 14 Wall thimble Vent extends 1 1 4 90 elbow points down Figure 14 Debris screen Horizontal Vent Termination Seal with adhesive 12 min above 5 3 4 highest snow fall Slope down away from Boiler 1 4 min per foot Figure 15 Horizontal Vent Exit Through Side Wall 17 INSTALLATION INSTALLATION CONT D Gas Supply Connections gt NOTE Gas connections must be in compliance with Part 3 Gas Piping Installation of the National Fuel Gas Code ANSI Z223 1 Latest Edition local codes or ordinances these instructions and good trade practices For Canada the installation of this unit must conform to all Canadian local codes as applicable or in the absence of local codes to the Canadian installation code CAN CGA B149
41. mbustibles The CSS 130 is certified by the American Gas Association AGA and the Canadian Gas Association CGA for installation on combustible flooring The CSS 130 is rated for alcove installation gt NOTE DO NOT INSTALL THE GAS FIRED BOILER ON CARPETING Refer to Fig 2 4 below for the minimum allowable clearances to combustible and noncombustible materials Figure 2 Minimum Clearance to Combustibles CSS 130 Top View Horizontal Vent Arrangement Shown Dishwasher Figure 3 Minimum Clearance to Combustibles CSS 130 Front View Dishwasher Horizontal Vent Arrangement Shown CLEARANCE TO COMBUSTIBLES Dimensions in Inches Location ltem Boiler to Top Back amp Side Walls Double wall Type B 1 Vent 1 inch Figure 4 Single Wall SST of 6 inches Clearance Dimensions Chart See Fig 2 3 above EN Through Combustible Wall INTRODUCTION Clearance to Combustibles Cont d The clearances listed in the Clearance Chart See Fig 4 are minimum clearances Clearances for service accessibility to the gas fired boiler must take preference over the fire protection clearances The installer should allow a minimum of 12 for servicing at the sides and back of the boiler if possible Z N WARNING Provide a screen or other type of protective barrier around exposed vent pipe to reduce burn hazards where inadvertent contact with hot vent surfaces by personnel can occur Air for Combus
42. n t always open properly can cause a nuisance lockout however occurrences like this are rare d Amore common cause of nuisance lockouts is poor combustion If there is an odor in the flue gases this should be suspected Check or 0 to determine if combustion is within limits Poor combustion causes a weak flame signal to the burner control and lockouts may result If combustion is within limits and none of the causes mentioned above seems to be the cause of the lockout it is possible that the heater control may be defective 25 36 SEQUENCE OF OPERATION On a call for heat from the tank thermostat on the CSS 130 the pump operates and the boiler control is energized through the operating control pressure switch and the safety limit It checks to ensure that the stack switch contacts are open and then energizes the blower The blower starts and the air pressure increases until the stack switch contacts close and the red PURGE light lights The pump and blower continue to run and for 15 seconds the red PURGE light stays on Following that the red PURGE light goes out the red igniter light lights and the igniter heats for 20 seconds At the end of the 20 seconds the red VALVE FLAME light is lit and the gas valve is energized For 2 seconds the valve and igniter are energized and burner will ignite Following this the igniter is de energized and the red IGNITER light goes out The pump and blowe
43. nect Incoming Power 120V 60Hz 1PH at Power Contactor Figure 26 CSS 130 Control Panel Power Connections Inside right front side 23 INSTALLATION INSTALLATION CONT D Plumbing Connections WARNING Plumbing connections must comply with local sanitary and plumbing codes Water and Drain Connections Refer to Fig 27 1 The CSS 130 requires a single 3 4 NPT hot water connection Minimum incoming water supply temperature should be 140 F 60 C Minimum and maximum incoming water supply pressure should 23 PSI 159 kPa 2 The CSS 130 is equipped with a 3 4 pressure reducing valve PRV on the incoming water supply line 3 The CSS 130 is equipped with a pressure relief valve 30 PSI 207 Kpa 130 Ibs hr minimum capacity on the CSS 130 water outlet N CAUTION The boiler pressure relief valve and back flow preventer should be piped separately to a floor drain to remove any water discharge from the gas fired boiler 4 The CSS 130 is equipped with the piping required to interconnect it to the dishwasher Figure 27 Plumbing Connections Right side of CSS 130 valve Pressure Relief Valve Pipe to Drain From wash tank heater coil EN s To dishwasher fill solenoid valve Towashtank 7 heater coil x Water Supply Connection 3 4 NPT Back Flow Preventer Pipe to Drain 24 INITIAL START UP AND SERVICE ATTENTION INSTALLER Note The best time to check the air
44. nscrew the gas orifice 4 Install the correct orifice for your gas supply 5 An LP gas conversion kit P N 111993 is available from Champion This kit contains a label marked Propane Gas Be sure to apply this sticker to the data plate on the front panel of the CSS 130 adjacent to the data plate 4 Reassemble the gas union All threaded joints in the gas piping should be coated with piping Figure 23 compound LP Gas Orifice Kit P N 111993 5 Turn the gas supply on Test for gas leaks Check the CSS 130 for proper operation 21 INSTALLATION INSTALLATION CONT D Electrical Connections Refer to Figs 24 26 1 The CSS 130 requires a single 120 v 60 Hz 15 amp electrical power source 2 Electrical fittings with conduit run through the interior of the boiler is provided to connect the incoming power supply Conduit to interconnect the CSS 130 to the dishwasher is provided 3 All electrical connections are made in the CSS 130 control cabinet which is located on the right side front of the unit See Fig 25 Wiring connections should be made as shown in the electrical schematic See Fig 26 4 Control wiring for an optional dishwasher ventilation fan contactor or starter may be run through the same conduit into the terminal strip located in the boiler control cabinet Optional fans must be approved by local authority 5 A fused disconnect switch or circuit breaker supplied by others is required to protect the
45. nuity Replace Pump operates Check for continuity across pressure p op safety limit contacts switch No Check pump Check for continuity across operating control limits Replace safety limit No Continuity No Continuity Continuity Continuity Limit circuit appears OK Recycle boiler a few times after plugging in control plug NOTE After completing limit circuit testing recycle boiler a few times If boiler does not recycle connect a jumper temporarily between the red wires If boiler starts remove jumper and temporarily jump each safety control until the defective control is located NEVER leave a safety control jumped 38 Red Purge Light Flashing Complete General Troubleshooting First Reset boiler control by switching power off for 15 seconds and then on again With a call for heat hot water afte rtwo 2 seconds does green power light come on Yes No After five 5 minutes red After 45 seconds red Purge light flashes Purge light flashes Yes No Shut off power disconnect wires to stack switch turn on power after two 2 seconds blower starts Stack switch contacts not il closing Check for flue aoe cole tay times to try to create blockage snow leaves etc a malfunction against vent terminal Blockage Yes No exists No Reconnect stack e EDGE a Blockage switch wires Check blower Check stack switch t
46. o inspect do BOE use any phone in your the appliance and to replace any part building of the control system and any gas call your gas supplier control which has been under water from a neighbor s phone Follow the gas supplier s instructions OPERATING INSTRUCTIONS STOP Read the safety information 5 Turn manual gas valve located on left above on this label side of unit to ON position Make sure system has been properly Push in gas control knob slightly and filled with water and bled of air turn clockwise Nto OFF Do not force Turn off all electric power to the Wait five 5 minutes to clear out any appliance gas Then smell for gas including near This appliance is equipped with an the floor If you smell gas STOP ignition device which automatically Follow B in the saftey information lights the burner Do not try to light above on this label If you do not the burner by hand smell gas go to the next step Turn the gas control knob counter clockwise to ON Close the access door on the left side cover panel Turn on all electric power to the appliance If the appliance will not operate follow the instructions to Turn Off Gas Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE Turn off all electric power to the 3 Push in gas control knob slightly and appliance if service is to be performed turn clockwise OFF Do Not
47. or to 9 10 W C 3 A maxitrol RV48 regulator or equivalent is recommended for regulating the inlet gas pressure 18 INSTALLATION Gas Supply Connections Cont d vee Piping Installation 1 Supply piping must be sized correctly to minimize pressure drop between the meter or regulator and the CSS 130 Refer to Fig 16 below for pipe capacity ratings and size the pipe for your installation to meet or exceed the 130 000 BTU HR rating of the CSS 130 2 Run gas supply line in accordance with all applicable codes Length of Capacity of Pipe in MBTU HR 3 If the CSS 130 is installed above Pipe 6 Specific Gravity of Gas Straight Length 4 2 3 4 4 1 4 the gas supply run piping up toa point above the vent center line 10 ft 132 278 520 1 050 and back down to the unit 20 ft 92 190 350 730 This prevents water from entering the gas supply line should a water 30 ft 73 152 285 590 leak develop in the boiler section of 40 ft 63 130 245 500 the unit 50 ft 115 215 440 4 All threaded joints in the gas piping 75 ft 93 175 360 should be coated with piping 100 ft 79 150 305 compound The compound must be resistant to the action of liquefied 150 ft 64 120 250 petroleum gases LP gas even if Add equivalent your unit uses natural gas ft listed at right 9 ft 7 ft 2 2 ft foreach gt gt gt 5 Pipe unions used in the gas line Tee or Bend must be the ground joint type Fig
48. order Install the plug D on burner recirculating pump Install the plug C on return recirculating pump Close dishmachine s petcock B located on outlet side of wash tank heater coil Check the amp draw on the boiler recircu lating pumps The correct reading should be between 1 2A to 1 7A If reading is less than 1 2A repeat Steps 3 12 and recheck recirculating pump amps FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance does not have a pilot ee you cannot readh your gas It is equipped with an ignition device supplier call the fire department which automatically lights the burner DO NOT try to light the burner by hand C Use only your hand to push or turn BEFORE OPERATING smell all around the gas control knob Never use tools the appliance area for gas Be sure If the knob will not push in or turn by to smell next to the floor because hand do not try to repair it call some gas is heavier than air and will qualified service technician Force or settle oh the floor attempted repair may result in a fire WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance or explosion Do not use this appliance if any part has been under water Immediately call Do not touch any electric switch qualified service technician t
49. power supply circuit gt NOTE WARNING All electrical and grounding connec When working on any electrical tions must be made in accordance with circuit disconnect the power at the requirements of the authority the main service disconnect having jurisdiction or in the absence of switch or breaker and place a such requirements with the National tag at the disconnect switch to Electrical Code ANSI NFPA 70 indicate that work is being Installation should also conform with performed on the circuit CSA 22 1 Canadian Electrical Code Part I Incoming Power gt Figure 24 Electrical Connections Right side of CSS 130 22 INSTALLATION Electrical Connections Cont d 6 The schematic detail Fig 25 shows the incoming power connected at CONTROL CABINET the power contactor The contactor is located inside the CSS 130 control cabinet 120V INPUT POWER 7 The incoming power must be connected GROUND gt 10 CONNECTION POINT to the power contactor as shown Any TO DISH MACHINE 10 CONTROL CABINET 2 RACK MACHINE other connection point will prevent the CONTROL CABINET BREAKER CSS 130 from operating properly LOAD SIDE SUP SEM s SUN CONTROL CABINET 8 The complete wiring schematic for the CSS 130 can be found on page 44 CONTROL CABINET EXHAUST FAN SIGNAL TO TURN ON EXHAUST Figure 25 FAN WHEN BOOSTER 1 Electrical Schematic VENTED INTO DISH Detail MACHINE VENT HOOD A701339 D Con
50. pplicable If the on cycles are at least 1 1 2 minutes long then the short cycling will not be a problem CROSS CONTAMINATION AND COMBUSTION RELATED SHORT CYCLING UNITS INSTALLED WITH QUICK VENT Heater short cycling nuisance lockouts and objectionable flue gas orders may be caused by leakage of flue products into the combustion air stream This results from poorly sealed joints in the inner 3 pipe The symptom of this problem is continual restarts without a lockout occurring The VALVE FLAME light will be on for only a short time but more than 6 seconds before the post purge starts This condition is generally seen on new installations however it is possible that a poorly as sembled flue pipe could come apart and cause the same effect Cross contamination can best be detected with a CO analyzer Bacharach kit for example Remove the Stack switch tube from the tee fitting above the air orifice and connect the sampling tube of the analyzer to the tee Run heater and check CO If there is any measurable CO cross contamination exists somewhere in the flue system If the heater will not operate long enough to get a CO sample it is possible to check for cross contamination in another way Loosen the top clamp on the air duct coupling and remove the gas balance line from the tee fitting Lift up the air induction elbow and twist it to the side so that air from the space around the heater can be drawn into the air duct coup
51. q096 85 V 10265 49100US e2uaJ9JeH JINO 44 LADDER DIAGRAM Time Delay Relay Pump CN1 28CN4 38CN5 30 TC 7 3 B20 B14 SCHEMATIC SAFETY A LIMIT Gor THERMOSTAT OPERATING PRESSURE CONTROL SWITCH 816 RECIRCULATION PUMP B2 B21 BOOSTER CONTROL CABINET PUMP THERMOSTAT gt 11 H o d EZ 13 STACK PRESSURE CONTROL CABINET COOLING FAN B1 AD cS POWER Be A bi 7 120V INPUT POWER GROUND nOn CONNECTION POINT b CONTROL CABINET RACK MACHINE CIRCUIT BREAKER 54 CONNECTION POINT X 2 D Ht DOOR MACHINE 9 m CONTROL CABINET TERMINAL LOCATED IN BLOCK HC1 DISHMACHINE CONTROL CABINET B EXHAUST FAN SIGNAL TO TURN ON EXHAUST B2 FAN WHEN BOOSTER IS GAS BURNER i VENTED INTO DISH POWER TE MACHINE VENT HOOD Figure 28 Electrical Diagrams 45 This Page Intentionally Left Blank REPLACEMENT PARTS REPLACEMENT PARTS Rack Conveyor Figure 29 Parts Diagram 48 REPLACEMENT PARTS CSS 130 PARTS LIST For machines built after 7 7 97 Fig 29 Part Part Description Qty Item No No 1 112197 Boiler assembly Includes Item 7 1 2 112009 Clamp eR en See 2 3 111950 Hose boot aur intake
52. r continue to run and the burner operates under the supervision of the boiler control If for any reason the full sequence is completed and the burner doesn t ignite the sequence will be repeated after a blower on time of 45 seconds 30 seconds post purge and 15 seconds prepurge for the next cycle During this part of the sequence the igniter remains on for 30 seconds and the balance of the sequence is unchanged If no ignition occurs again a third cycle will follow with the same sequence as the second After the third trial for ignition if the burner does not ignite the system will lockout and reset can only be accomplished by momentarily switching the power off At the end of a heating cycle after the gas valve is de energized the blower will continue to run for a 30 second post purge If normal burner operation during a heating cycle is interrupted by any of the limit controls the unit pump will continue to run and the blower will continue to operate for a 30 second post purge TROUBLESHOOTING DETAILED FLOW CHARTS ON PAGES 20 26 If the burner lockout for any reason the cause of failure will be displayed by the flashing of one of the lights CODE GREEN POWER Light flashing control failure no light no power RED PURGE Light flashing blower or stack switch failure or possible flue blockage RED VALVE FLAME Light flashing valve igniter or flame sense failure combustion related problem NOTE
53. re changing TDR INITIAL START UP AND SERVICE DELAYED IGNITION Possible Causes Time of occurrence a High lockups on LP occurs on start up b Gas valve regulation problem occurs on start up c Defective burner flameholder occurs primarily on burner shutdown d Natural gas orifice in LP unit occurs on startup a High lock up pressures on LP fuel systems are the most common cause of delayed ignitions on CSS 130 heaters The high LP supply pressure results from improper second stage regulator selection or a faulty regulator It can be detected by measuring the gas supply pressure to the unit at the inlet pressure tap on the gas valve Use a water manometer or pressure gauge with a scale reading of at least 25 w c Install the pressure tap in the 1 8 NPTF plugged port located above the gas inlet port on the gas valve The gas supply to the heater must be shut off before making this connection The CSS 130 heater is designed to operate with supply pressures of 4 14 w c If supply pressure exceeds 14 w c with the heater not operating it is likely that this is the cause of the delayed ignition Lock up pressures must be measured when the heater is not operating and preferably immediately after heater shutdown b Gas valve regulation problems can also cause delayed ignitions To detect gas valve regulation problems it is necessary to have an inclined manometer or a Magnehelic pressure gauge The normal gas valve
54. regulator setting is 0 2 w c It is measured between the 1 8 NPTF plugged port marked PRESS TAP on the gas valve and the barbed fitting above the air orifice coupling The pressure will be about 2 5 w c when the blower is running prepurge before the gas valve opens When the gas valve is energized and the solenoid opens the pressure should rise to 0 2 w c This should happen smoothly without allowing the pressure to go positive above 0 w c If the pressure spikes positive when the solenoid opens then the gas valve regulator is faulty and may be the cause of the delayed ignition assuming inlet tested OK C A defective burner flameholder can cause a delayed ignition however not often If the gas supply pressure and the gas valve are functioning properly and the air and gas orifices are correct the burner should be inspected To inspect remove the blower and the burner will drop out of the bottom of the chamber There should be no perforations other than the punched holes When replacing the burner the insulating pad must be on the top of it If none was on the burner when it was removed check to see if it fell off during burner removal and has stayed in the combustion chamber Never leave an insulating pad lying in the combustion chamber as this can cause burner overheating and perforation NOISY OPERATION There are two principal sources of noisy operation a Combustion high pitched noise whistle or hoot b Boilin
55. rized 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 blocks pulse vanes and auger brush roo ho 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 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 t
56. roubleshooting Check stack switch troubleshooting 39 Checking Blower Complete General Troubleshooting First Reset boiler control by switching power off for 15 seconds and then on again With a call for heat hot water after two 2 seconds does green power light come o Yes Blower starts Connect manometer to pressure tap on gas valve pressure during blower operation without gas flow valve flame light not lit is 2 5 in w c Natural or LP Gas Yes No Blower OK Check for flue obstructions Obstruction Clear Clear remove obstruction Replace blower 40 No Refer to general trouble shooting section Check for voltage 120 VAC at blower wire connector within 5 minutes after green light 0 Volts 120 VAC Check output Replace blower thermostat OK Check stack switch Check limit switch Replace boiler control Checking Stack Switch Complete General Troubleshooting First Turn off boiler switch Remove both tubes from stack switch and disconnect electrical wires Check for continuity across switch terminals Continuit No continuity 0 OHMS CO OHMS Attach tubes disconnected from stack switch to U tube Replace stack manometer switch Turn on boiler to operate blower Manometer indicates 1 5 w c or greater Reconnect stack switch tubes and check for continuity between stack switch terminals with blower operating Check for vent obst
57. ructions Clear Obstructed Clear obstructions amp Check blower reconnect tubes amp electrical wires to No continuity Continuity 0 OHMS CO OHMS stack switch start boiler amp thriugh Replace stack switch NOTE Check tubes on stack switch for proper connections 41 Red Valve Flame Light Flashing Complete General Troubleshooting First Are gas valves and gas meter turned on Is there gas in the LP tank LP units Reset boiler by interrupting power for Turn on valves fill LP tank on LP 15 seconds when valve flame lite unit Reset boiler by switching lights is there 24 VAC between orange power off for 15 seconds Run and yellow wires on gas valve and or through two to three cycles does gas valve click Does burner ignite and appear to run properly Check wires to gas valve No Yes Nuisance lockout caused flashing Check igniter Replace Correct light Check combustion igniter OK integrated wiring 50 200 OHMS boiler control no cracks Yes No Check for gas flow Is Replace meter moving Gas igniter pressure is OK Yes Check gas and air orifice for proper size Incorrect Correct No Replace gas valve Install correct Boiler cycles through three cycles after resetting and valve flame lite flashes Replace integrated boiler control orifices 42 Checking Pump With a call for heat reset boiler control by switch
58. sting motion to spread the adhesive completely between the sections of pipe 7 When the two sections of pipe have bottomed out inspect the joint for a complete seal Additional sealant may be required for a complete seal It takes 24 hours of curing time to develop full joint strength N Caution Do not drill holes through pipe or fittings Do not use sheet metal screws or rivets 15 INSTALLATION INSTALLATION CONT D Vent Installation Horizontal Through the Wall Venting Cont d Locating the Vent Opening in the Outside Wall It is essential to follow the National Fuel Gas Code ANSI Z223 1 Latest Edition and these instructions for proper venting and condensate disposal For Canada the installation of this unit must conform to all Canadian local codes as appli cable or in the absence of local codes to the Canadian installation code CAN CGA B149 The vent termination must be located at least 12 inches above grade or the normally expected snow accumulation level Snow level may be higher on walls exposed to prevailing winds If adjacent to public walkways the vent termination must be located 7 feet above grade 3 Do not locate termination close to shrubbery The termination must be located at least 10 feet from any forced air inlet into the building and at least 4 feet horizontal and in no case above or below any other building opening gas meter electrical meter service regulator reliefs or other equ
59. tained in public water systems which accumulate in the coil over long periods of time may be removed when necessary by flushing the coil with cleaner These products are also effective in cleaning a coil that is fouled by magnesium Flush entire system thoroughly after demineralizing process Failure to do so will result in contaminated rinse water and severely shorten unit life HIGH GAS CONSUMPTION SEE ALSO CROSS CONTAMINATION Improper burner operation caused by incorrect air fuel ratio CO or 0 out of the specified range will cause high gas consumption It is most noticeable on LP fired units with low CO or high 0 however units operating on LP or natural gas with incorrect air fuel ratios will not provide their best effi ciency If no combustion analyzing equipment CO or 0 is available an indication of the air fuel ratio can be gotten by briefly sniffing the flue gases When running properly the CSS 130 s flue gases should have little smell If they have a strong piercing smell the gas orifice is probably too small Do not attempt to do reorificing without an 0 or CO kit 34 SHORT CYCLING SEE ALSO CROSS CONTAMINATION The result of low flow is very rapid temperature rise in the heater Sometimes the rise is so fast that the operating control will not operate before the safety limit operates The heater will lockout and can only be restarted by resetting the manual reset button on the safety limit switch Where a
60. temperature plastic pipe alternative venting provided that no other equipment is vented into the chimney The chimney may have an approved liner installed into the flue 3 Two 2 or more vent connectors from either power or natural draft units may enter a common gas vent provided that they conform to the provisions and tables of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Latest Edition or applicable provisions of local building code For Canada the installation of this unit must conform to all Canadian local codes as applicable or in the absence of local codes to the Canadian installation code CAN CGA B149 4 None of the vent connectors may be connected to equipment with a positive vent pressure 5 The unit must be located as close to the chimney as possible to provide the shortest vent connector Installation Refer to Fig 8 on page 11 and note the dimensions H L D and A These dimensions are taken in to consideration when determining the vent and vent connector requirements Follow the procedure below to size the venting Determine the height of the chimney or Type B 1 vent and the length of the lateral run Select the proper vent connector diameter from Table 11 2 Table 11 2a or Table 11 3 shown on pages 12 13 These tables were derived from Tables 11 2 and Table 11 3 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 Latest Edition Install and adaptor at the flue outlet of the boiler to step up to the diameter of
61. the vent connector Install elbows for the vent connector if required All elbows should be the full size of the vent connector Caution Do Not install a three inch 3 elbow between the flue outlet on the boiler and the adaptor Install the vent connector between the elbows if used and the chimney Slope the vent connector upwards toward the chimney 1 4 minimum per foot of lateral run Secure all joints in accordance with the vent manufacturer s instructions for Type B 1 vent material INSTALLATION Chimney Venting Figure X below shows the dimensions that must be taken into consideration when sizing the vent and the vent connector H Height of the chimney or Type B vent L Total lateral length of the vent connector D Required diameter of vent connector Refer to Tables on pages X X Minimum maximum size limits of internal area of the chimney Slope up a 1 4 min per foot CSS 130 Figure 8 Type B 1 Vent Chimney Venting Detail Vent Connection without Elbows Shown Lateral slopes up 1 4 min per foot Refer to Vent Tables 11 2 11 2a and 11 3 on the next page for vent and vent connector diameter sizes 11 INSTALLATION Vent Installation Cont d Chimney Venting Cont d Refer to Table 11 2 11 2a or 11 3 and select the vent and vent connector diameter that meets the requirements for your installation For example For Type B venting into a masonry chimney refer to T
62. tion and Ventilation General An adequate supply of air for combustion and ventilation must be supplied in accordance with Section 5 3 of the National Fuel and Gas Code ANSI Z223 1 Latest Edition or applicable provisions of the local building codes for gas utilization equipment installed in buildings that require air for combustion ventilation and the dilution of flue gases from within the building For Canada the installation of this unit must conform to all Canadian local codes as applicable or in the absence of local codes to the Canadian installation code CAN CGA B149 Install the equipment in a location where the ventilation facilitates the satisfactory combustion of gas proper venting and maintenance of ambient temperature at safe limits under normal conditions of use Equipment should be located so as not to interfere with proper air circulation When normal infiltration does not provide the necessary air outside air must be introduced In addition to air needed for combustion process air must be provided as required for cooling of equipment or material controlling the dew point heating drying oxidation or dilution safety exhaust odor control and air for compressors In addition to air needed for combustion ventilation air must also be supplied including all air required for comfort and proper working conditions for personnel Unconfined Space An unconfined space such as an open basement must have a minimum volume
63. ture sealant Refer to the specific venting installation section for detailed instructions Vent installation must be in compliance with Part 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 Latest Edition In Canada to the Canadian installa tion code CAN CGA B149 local codes or ordinances these instructions and good trade practices Existing Boiler Removal When an existing boiler is removed from a venting system serving other appliances the venting system is likely to be too large to properly vent the remaining attached appliances Perform the following steps individually with each appliance that remains connected to the common vent system placed in operation with the other appliances remaining connected to the common venting system but not in operation If improper venting is observed during any of the following tests the common venting system must be corrected 1 Seal any unused openings in the common venting system 2 Visually inspect the vent system for proper size and horizontal pitch and determine that there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition 3 As far as practical close all building doors and windows plus all doors between the space which the appliances remain connected to the common vent system are located and the other spaces of the building INSTALLATION Existing Boiler Removal Cont d 4 Turn on clothes
64. ure 16 Pipe Sizing Table 6 Install a manual shut off valve in Capacity of Pipe in MBTU HR accordance with state and local Based on 6 Specific Gravity of Gas requirements if required The CSS 130 is equipped with a manual shut off valve 7 A one eighth inch 1 8 plugged tap accessible for test gauge connection must be installed immediately upstream of the CSS 130 gas supply connection Gas Supply Li 8 Install a trap and drip leg in the last vertical run before entering the CSS 130 CSS 130 9 Support all piping with straps or hangers DripEeg Cap p Figure 17 Gas Supply Piping Drip Leg 19 INSTALLATION INSTALLATION CONT D Gas Supply Connections Gas Piping Installation Cont d Refer to Figs 18 19 and 20 9 Connect the gas supply piping to the CSS 130 at the lower left side of the unit 10 Gas connection point is 1 2 NPT See A Fig 18 11 The unit comes equipped with a 1 2 manual shut off valve 12 All threaded joints in the gas piping should be coated with piping compound The compound must be resistant to the action of liquefied petroleum gases LP gas even if your unit uses natural gas Pressure Testing the Gas Piping Installation 1 The CSS 130 and its manual gas shut off valve must be disconnected from the gas supply piping system during any pressure testing of the system at test pressures in excess of 1 2 psig Figure 18 CSS 130 Manual Gas Shut off
65. use of the fixed regulator setting gas flow must be adjusted by changing the gas orifice To remove the gas valve shut off 120 volt power and the master gas cock in gas line loosen the nut on the gas orifice union and remove the orifice union plus piping to the gas valve Disconnect the wires from the gas valve The valve may now be unscrewed from the inlet piping After the valve has been removed replace with a new valve in the reverse order in which the old valve was removed Do not over tighten the fittings into the valve body as this may cause damage to the valve NOTE When fueled by LP gas the CSS 130 performs best with 9 10 w c supply pressure If no other appliances are being supplied by the LP supply set the low pressure regulator to 9 10 w c 3l INITIAL START UP AND SERVICE SAFETY LIMIT SWITCH The Safety Limit Switch has a fixed set point at 240 F It will reset automatically To replace the switch shut off the 120 volt power and close gas valve drain water from the heater and remove the nut which holds the safety limit bulb in the heater discharge fitting Remove the bulb from the fitting and remove the 2 screws which hold the switch assembly to the electrical control box Discon nect the 2 wires from the quick connects at switch and remove the safety limit assembly To replace perform the same operations in reverse Push the sensing bulb as far into the fitting as possible before tightening sealing nut No more
66. utside Vent Wall 12 Tank Vent 4 Exhaust Air 13 Coil Air Bleed Off 5 Dishwasher Water Supply 14 Circulation Pump 6 Water Return From Dishwasher 15 Expansion Tank 7 Gas Supply 16 Terminal Strip 8 Gas Valve 17 Boiler Control 9 Stack Switch 18 Transformer 24V 19 Copper Coil Heat Exchanger 3 lt 4 Left Side View Front View Gas Flue Rear of CSS 130 Gas Flue Left end of CSS 130 Gas Flue Right end of CSS 130 gt NOTE The CSS 130 is available in 3 venting configurations rear left or right direction Gas flue venting configurations are specified at the time of order Figure 1 Component Locator REVISIONS Revision History Revision Revised Date Pages 7 7197 Serial Number Effectivity Comments Reissue of manual and replacement parts lists CONTENTS CONTENTS LIMITED WARRANTY 1 INTRODUCTION 2 Unpacking the Gas Fired Boiler tee eene eet etie 3 Installation Codes n unte eee reed Hid 3 Locating the Gas Fired Boiler 2n ener aei b 3 Clearance to Combustibles iie reel e tee edet 4 Air for Combustion and Ventilation 5 INSTALEA TION ani e een an prep enda e det 6 VENT INSTALLATION ene perte p tete E HR e po Ep ete 6 General
67. 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 period Champion at its election will either repair or replace the defective machine or accept return of the machine for full credit provided how ever 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 autho

CSS-130 - Champion Industries

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