Technical Manual - Champion Industries
Technical ManualGas FiredBoilerModelCSS-130CAUTIONRead all instructions carefully before starting the installation.Save this manual for future referenceJuly, 1997Manual P/NP. O. Box 4149Winston-Salem, North Carolina 27115-4149336/661-1556Fax: 336/661-1660111995REV. A2674 N. Service RoadJordan Station, Ontario, Canada LOR 1SO905/562-4195Fax: 905/562-4618Champion Industries, Inc.
Complete the information below so it will be available for quick reference.Model NumberCSS-130Voltage and Phase115/60/1Serial NumberChampion Parts DistributorPhoneChampion Service AgencyPhoneIn the United States Call:Champion Industries Service: 1-800-858-4477 Champion Service Fax: 1 (336) 661-1660In Canada Call:Champion Industries Service: 1-800-263-5798 Champion Service Fax: 1 (905) 562-4618NOTE: 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 LOCATORTO THE INSTALLER:BEFORE YOU BEGINIt is important for you to read all Installation and Operating sections of this manual before you begininstallation. This will avoid mistakes and confusion when installing and operating the unit.1.2.3.4.5.6.7.8.9.Gas BurnerAir IntakeOutside Vent WallExhaust AirDishwasher Water SupplyWater Return From DishwasherGas SupplyGas ValveStack Switch10.11.12.13.14.15.16.17.18.19.Blower Motor and HousingControl CabinetTank VentCoil Air Bleed OffCirculation PumpExpansion TankTerminal StripBoiler ControlTransformer 24VCopper Coil Heat Exchanger4Front ViewLeft Side ViewGas Flue (Rear of CSS-130)Gas Flue (Left end of CSS-130)Gas Flue (Right end of CSS-130)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 1Component Locatori
REVISIONSRevision HistoryRevisionDate7/7/97iiRevisedPagesSerial NumberEffectivityCommentsAll—Reissue of manual and replacement parts lists
CONTENTSCONTENTSLIMITED WARRANTY . 1INTRODUCTION . 2Unpacking the Gas Fired Boiler .Installation Codes .Locating the Gas Fired Boiler .Clearance to Combustibles .Air for Combustion and Ventilation .33345INSTALLATION . 6VENT INSTALLATION . 6General . 6Existing Boiler Removal . 6Common Venting . 7Vertical Venting . 8Chimney Venting . 10Horizontal Through-the-Wall Venting . 14Pipe Cutting and Joining Procedures . 15Locating the Vent Opening in the Outside Wall . 16Installing the Horizontal Venting and Termination . 17GAS SUPPLY CONNECTIONS. 18Gas Fuel Requirements . 18Gas Pressure Requirements. 18Gas Piping Installation . 19Pressure Testing the Gas Piping Installation . 20Field Conversion of Gas Orifice . 21ELECTRICAL CONNECTIONS . 22PLUMBING CONNECTIONS . 24Water and Drain Connections . 24INITIAL START-UP AND SERVICE . 25Instructions for Setting Air Pressure in Expansion Tank . 26Instructions for Manually Venting Air from Boiler Water System . 27Gas Valve Operating Instructions . 28Check Test, and Start-up . 29Sequence of Operation Explained . 36TROUBLESHOOTING FLOW CHARTS. 37ELECTRICAL SCHEMATICS . 45REPLACEMENT PARTS LIST . 48iii
CONTENTSLIST OF FIGURESFigure 1Figure 2Figure 3Figure 4Figure 5Figure 6Figure 7Figure 8Figure 9Figure 10Figure 11Figure 12Figure 13Figure 14Figure 15Figure 16Figure 17Figure 18Figure 19Figure 20Figure 21Figure 22Figure 23Figure 24Figure 25Figure 26Figure 27Figure 28Figure ��–––––––––––––Component Locator . iMinimum Clearance to Combustibles (Top View) . 4Minimum Clearance to Combustibles (Front View) . 4Clearance Dimensions Chart . 4Vent Pipe Slope and Horizontal Support . 8Vertical Through-the-Roof Vent Installation with Fire Stops . 9Vertical Vent Configuration . 9Type B-1 Vent Chimney Venting Detail . 11Type B-1 Chimney Vent Connection without Elbows . 12Type B-1 Chimney Vent Connection with Elbows . 12Horizontal Through-the Wall Venting . 14Horizontal Vent (Exit Through Rear Wall) . 16Horizontal Termination Clearance . 16Horizontal Vent Termination (Window and Grade Level) . 17Horizontal Vent (Exit Through Side Wall) . 17Pipe Sizing Table . 19Gas Supply Piping (Drip Leg) . 19CSS-130 Manual Gas Shut-off Valve . 20CSS-130 Gas Connection Point (Side View) . 20CSS-130 Gas Connection Point (Top View) . 20Gas Orifice Union Location . 21Gas Orifice Union . 21LP Gas Orifice Kit P/N 111993 . 21Electrical Connections (Right side of CSS-130) . 22Electrical Schematic Detail . 23CSS-130 Control Panel Power Connections (Inside right front side) . 23Plumbing Connections (Right side of CSS-130) . 24Electrical Diagrams. 46Parts Diagrams . 48
WARRANTYLIMITED WARRANTYChampion 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 L0R 1S0 warrants machines, and parts,as set out below.Warranty of Machines: Champion warrants all new machines of its manufacture bearing the name"Champion" and installed within the United States and Canada to be free from defects in material and workmanship for a period of one (1) year after the date of installation or fifteen (15) months after the date of shipment byChampion, whichever occurs first. [See below for special provisions relating to glasswashers.] The warrantyregistration card must be returned to Champion within ten (10) days after installation. If warranty card is notreturned 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 arejurisdictional problems with local trades or unions.If a defect in workmanship or material is found to exist within the warranty period, Champion, at its election,will either repair or replace the defective machine or accept return of the machine for full credit; provided, however, as to glasswashers, Champion's obligation with respect to labor associated with any repairs shall end(a) 120 days after shipment, or (b) 90 days after installation, whichever occurs first. In the event that Championelects to repair, the labor and work to be performed in connection with the warranty shall be done during regularworking hours by a Champion authorized service technician. Defective parts become the property of Champion.Use of replacement parts not authorized by Champion will relieve Champion of all further liability in connectionwith its warranty. In no event will Champion's warranty obligation exceed Champion's charge for the machine.The following are not covered by Champion's warranty:a.b.c.d.e.f.g.h.i.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.Examples of the defects not covered by warranty include, but are not limited to: (1) Damage to the exterior orinterior 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 fromchemicals dispensed in excess of recommended concentrations, (6) Failure of electrical components due toconnection of chemical dispensing equipment installed by others, (7) Leaks or damage resulting from suchleaks caused by the installer, including those at machine table connections or by connection of chemicaldispensing equipment installed by others, (8) Failure to comply with local building codes, (9) Damage caused bylabor dispute.Warranty of Parts: Champion warrants all new machine parts produced or authorized by Champion to be freefrom defects in material and workmanship for a period of 90 days from date of invoice. If any defect inmaterial and workmanship is found to exist within the warranty period Champion will replace the defectivepart without charge.DISCLAIMER OF WARRANTIES AND LIMITATIONS OF LIABILITY. CHAMPION'S WARRANTYIS ONLY TO THE EXTENT REFLECTED ABOVE. CHAMPION MAKES NO OTHER WARRANTIES,EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED, TO ANY WARRANTY OFMERCHANTABILITY, OR FITNESS OF PURPOSE. CHAMPION SHALL NOT BE LIABLE FORINCIDENTAL OR CONSEQUENTIAL DAMAGES. THE REMEDIES SET OUT ABOVE ARETHE EXCLUSIVE REMEDIES FOR ANY DEFECTS FOUND TO EXIST IN CHAMPION DISHWASHINGMACHINES 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 dishwashingmachines to change this warranty or create any other obligation in connection with Champion Dishwashing Machines.1
INTRODUCTIONINTRODUCTIONWelcome to Champion.and thank you for allowing us to take care of your dishwashing needs.This manual 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 andthe rack conveyor dishwasher model 44-WS and 66-WSThe CSS-130 is a low pressure gas fired boiler capable of supplying hot water to the dishwasherwash 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 factorybefore it was shipped to your installation site.This manual contains: Installation InstructionsOperation InstructionsMaintenance InstructionsService InstructionsReplacement Parts ListsElectrical SchematicsAll information, illustrations and specifications contained in this manual are based upon thelatest product information available at the time of publication. Champion constantly improvesits products and reserves the right to make changes at any time or to change specifications ordesign 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 distributoror authorized service agency. When ordering parts, please supply the model number, serialnumber, voltage, and phase of your machine, the part number, part descriptions and quantity.2
INTRODUCTIONUnpacking the Gas Fired Boiler! 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 CodesThe 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 authorityhaving jurisdiction, the installation also must conform to the Standards for Controls and SafetyDevices 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 C22.1Canadian Electrical Code Part 1.Locating the Gas Fired BoilerLocate 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 combustionchamber.The location of the boiler should be chosen with regard to venting dimensions, convenient access topiping, 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(dripping, spraying, rain, etc.) during appliance operation and servicing procedures such as pumpreplacement, burner cleaning and the like.When the unit is located in an unconfined space of a building, air infiltration may be adequate to provideair for combustion and ventilation. Where normal infiltration does not provide the necessary air, outsideair must be introduced.In buildings of unusually tight construction, or when locating the unit in a confined space, additional airmust 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 appliancesin the area, but not less than 100 square inches. These openings shall freely connect with areas havingadequate infiltration from outside.The boiler should be placed beside the Champion dishwasher model that it serves so that all plumbing andelectrical 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 orleakage of water. The boiler pressure relief valve and back-flow preventor should be piped to adrain to protect from the occasional discharge of water.3
INTRODUCTIONINTRODUCTION (CONT'D)Locating the Gas Fired Boiler (Cont'd)Clearance to CombustiblesThe 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.NOTE:DO NOT INSTALL THE GAS FIRED BOILER ON CARPETING.Refer to Fig. 2-4 below for the minimum allowable clearances to combustibleand noncombustible materials.DABCDishwasherAFigure 2Minimum Clearanceto CombustiblesCSS-130Top View(Horizontal Vent Arrangement Shown)ABFigure 3Minimum Clearanceto CombustiblesCSS-130Front ViewABDishwasher(Horizontal Vent Arrangement Shown)CLEARANCE TO COMBUSTIBLES(Dimensions in Inches)LocationItemMinimum ClearanceBoiler to Top, Back, & Side Walls1 inchDouble wall Type B-1 Vent1 inchBSingle Wall SST orGalvanized Vent6 inchesCHot Water Pipes3 inchesDThrough Combustible Wall2 inchesAFigure 4Clearance Dimensions Chart(See Fig. 2-3 above)4
INTRODUCTIONClearance to Combustibles (Cont'd)The clearances listed in the Clearance Chart (See Fig. 4) are minimum clearances. Clearances for serviceaccessibility to the gas fired boiler must take preference over the fire protection clearances. The installershould allow a minimum of 12" for servicing at the sides and back of the boiler if possible.! WARNING:Provide a screen or other type of protective barrier around exposed vent pipe to reduce burnhazards where inadvertent contact with hot vent surfaces by personnel can occur.Air for Combustion and VentilationGeneralAn adequate supply of air for combustion and ventilation must be supplied in accordance withSection 5.3 of the National Fuel and Gas Code, ANSI Z223.1-Latest Edition or applicableprovisions of the local building codes for gas utilization equipment installed in buildings thatrequire 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 ofgas, proper venting and maintenance of ambient temperature at safe limits under normal conditionsof 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, safetyexhaust, odor control, and air for compressors.In addition to air needed for combustion, ventilation air must also be supplied, including all air requiredfor comfort and proper working conditions for personnel.Unconfined SpaceAn unconfined space (such as an open basement) must have a minimum volume of 50 cubic feet per1,000 BTU/HR input of the total of all appliances in the area. Adjoining rooms may be counted as onearea only if there are no doors between the rooms.Air ContaminantsCompounds bearing contaminants such as chloride, fluoride, iodide, and bromide, when present in certainconcentrations in the air supplied for combustion to the boiler, can result in an accelerated and severecorrosion condition in the heat exchanger and/or the venting systems. Avoid storing or using chemicalscontaining 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 damagethe heat exchanger in the boiler.5
INSTALLATIONINSTALLATION! WARNING:Read all of the instructions included with your machine beforeattempting any installation. Faulty vent installation can causeimproper operation of the gas fired boiler.Vent InstallationGeneralThe CSS-130 gas fired boiler is approved as a Category I Boiler when the following ventinstallations are used:1. Common vent installation2. Vertical through-the-roof vent installation3. 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 ventinstallation is used. This installation is a positive pressure venting system and requires thatall connections be sealed with an approved high temperature sealant.Refer to the specific venting installation section for detailed instructions.Vent installation must be in compliance with Part 7 "Venting of Equipment", of theNational Fuel Gas Code; ANSI Z223.1-Latest Edition, (In Canada, to the Canadian installation code, CAN/CGA-B149), local codes, or ordinances, these instructions, and goodtrade practices.Existing Boiler RemovalWhen an existing boiler is removed from a venting system serving other appliances, theventing 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 thecommon vent system placed in operation with the other appliances remaining connected tothe common venting system but not in operation.If improper venting is observed during any of the following tests, the common venting systemmust 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 thatthere is no blockage or restriction, leakage, corrosion, and other deficiencies which couldcause an unsafe condition.3. As far as practical, close all building doors and windows plus all doors between the spacewhich the appliances remain connected to the common vent system are located and theother spaces of the building.6
INSTALLATIONExisting Boiler Removal (Cont'd)4. Turn on clothes 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 operateat 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 inoperation. Adjust the thermostat so the appliance operates continuously.6. After five minutes of main burner operation, test for air spillage at the draft hood reliefopening. 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 ventsystem 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 asdetermined 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-B149.The boiler should not be connected to a chimney flue serving a separate appliance that is designedto burn solid fuel.No portion of the venting system can 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 tocombustible materials and be fire stopped according to local codes.Common VentingVent connectors serving Category I appliances shall not be connected to any portion of the mechanicaldraft systems operating under positive pressure such as Category III 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 orclearance to combustible material.Vent connectors shall be firmly attached to draft hood outlets or flue collars by sheet metal screws orother approved means, except vent connectors of listed Type B-1 vent material (which shall be assembledin accordance with the vent manufacturer's instructions). Fasten joints between sections of single-wallconnector piping with sheet metal screws or other approved means.7
INSTALLATIONINSTALLATION (CONT'D)Vent InstallationCommon Venting (Cont'd)Horizontal portions of the venting system must be supported at least every 5 feet with metalstraps to prevent sagging. All horizontal sections of the vent connection must slope upwards1/4 inch per foot from the boiler to the vent termination (See Figure 5 below).Upward slope 1/4" minimum per footVent ConnectorSupport horizontal sectionsevery 5 feet with metal strapsFigure 5Vent Pipe SlopeandHorizontal SupportThe 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 VentingThe CSS-130 is certified for use with up to 50 equivalent feet of 3" diameter pipefor vertical vent installations. A 90 elbow equals 5 equivalent feet of pipe.Vent pipe and fittings must be securely supported horizontal sections require supportsevery 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 steeland is approved for use in the United States and Canada.8
INSTALLATIONVertical 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 tomake an offset in the attic, the horizontal run should slope upwards minimum of 1/4 inch per footand be supported by metal straps.Vent pipe passing through floors, ceilings, or framed walls must be 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 stormcollar to the pipe using a high temperature sealant. Terminations must be used in all installationsabove 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.VentTerminationStorm collarand flashingMaintainminimumair spaceChaseFigure 6Vertical Through-the -RoofVent Installation with Fire StopsFire stopTo CSS-130CSS-130Top ViewTo roofFigure 7CSS-130Vertical Vent ConfigurationSlope up 1/4" min. per footCSS-130Front ViewDishwasher9
INSTALLATIONVent Installation (Cont'd)Chimney VentingThe CSS-130 is certified as a Category I Boiler and approved for venting in a masonrychimney 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 temperatureplastic pipe alternat
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
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Upright 29" Conveyor Dual Rinse Dishwashing Machine EUCCW SERIES Due to an ongoing value analysis program at Champion, specifications contained in this catalog are subject to change without notice. Champion Industries, Inc., 3765 Champion Boulevard, Winston-Salem, NC 27105 336/661-1556 Fax: 336/661-1979 www.championindustries.com
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Champion Spas is a Non-Exclusive product line available through Imperial Distribution with Manufacturer direct Technical and Customer Service provided to support Champion Dealer Network. Purchase of a Champion Spas model may not constitute eligibility for: » Champion Spas Programs, Merchandising and Marketing Materials
Champion Spas is a Non-Exclusive product line available through Imperial Distribution with Manufacturer direct Technical and Customer Service provided to support Champion Dealer Network. Purchase of a Champion Spas model may not constitute eligibility for: » Champion Spas Programs, Merchandising and Marketing Materials
Investigating Chemistry through Inquiry 11 - 1 S PRELIMINARY ACTIVITY FOR . Beer’s Law Investigations . Guided Inquiry Version . The primary objective of this Preliminary Activity is to determine the concentration of an unknown copper (II) sulfate solution. You will use a Colorimeter (a side view is shown in Figure 1). In this device, red light from the LED light source will pass through the .
