User Manual - Whaley Food Service
Contents
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3. eene 14 4 2 AMPERAGE 8 4 24 4111000 14 15 4 3 ACTUAL POWER RATING CALCULATIONS eee 15 4 4 STEAM CAPACITY CALCULATIONS cete ettet 16 5 DRAWINGS amp WIRING SCHEMATICS 17 36 Sg PARTS LEGENDS rac depu 17 20 5 1 1 LB 100 240KW LOW PRESSURE 0 15 8 17 5 1 2 100 240KW LOW PRESSURE MAFD 0 15 5 18 5 1 3 LB 100 240KW HIGH PRESSURE 0 30 O 1OOPSI 19 5 1 4 LB 100 240KW HIGH PRESSURE MAFD 0 30 0 100 51 20 52 INSTALLATION DATA 8 62220 21 24 5 2 1 100 240KW LOW PRESSURE 0 15 8 2 21 5 2 2 LB 100 240KW LOW PRESSURE MAFD 0 15 5 22 5 2 3 LB 100 240KW HIGH PRESSURE 0 30 0 100 5 23 5 2 4 LB 100 240KW HIGH PRESSURE MAFD 0 30 0 100 5 24 5 3 CONTROL WIRING SCHEMATICS ettet 25 28 5 31 LBIEOWPRESSURE CISPSD 25 5 3 2 LB LOW PRESSURE MAFD 0 15 8 0 26 5 3 3 LB HIGH PRESSURE 0 30 0 100 5 27 5 3 4 LB HIGH PRESSURE MAFD 0 30 0 100 81 28 5 4 HEATER WIRING 5 22
4. 009 0 MYOS 35 of 37 Electro Steam Generator Corp LB 100 thru LB 240 User Manual gt ae 107 UTI S C490 aud Aue ud rou UF ee eq jou jo ye pue eur IT sis 0 97 SYLVA 2 08 36 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp Electro Steam Generator Corporation Terms and Conditions of Sale These terms and conditions apply to all goods or services Seller provides Seller recognizes no other terms and conditions unless approved in writing by Seller s authorized representative Seller rejects any additional terms and conditions that may be contained in any document provided previously or subsequently by your company CHANGES Changes made after fabrication has begun shall be submitted in writing signed by the purchaser Purchaser agrees to pay the cost of any changes The specifications and prices are subject to change without notice CLAIMS Title passes to the buyer upon delivery to the carrier unless otherwise indicated Safe delivery is the responsibility of the carrier Da
5. 60 F 90 of 212 F 80 of 212 F 75 of 212 F LB 100 345 0 LB hr 310 5 LB hr 276 0 LB hr 258 8 LB hr 156 5 Kg hr 140 8 Kg hr 125 2 Kg hr 117 4 Kg hr LB 120 414 0 LB hr 372 6 LB hr 331 2 LB hr 310 5 LB hr 187 8 Kg hr 169 0 Kg hr 150 2 Kg hr 140 8 Kg hr LB 150 518 0 LB hr 466 2 LB hr 414 4 LB hr 388 5 LB hr 235 0 Kg hr 211 5 Kg hr 188 0 Kg hr 176 2 Kg hr LB 180 621 0 LB hr 558 9 LB hr 496 8 LB hr 465 8 LB hr 281 7 Kg hr 253 5 Kg hr 225 3 Kg hr 211 3 Kg hr LB 240 828 0 LB hr 745 2 LB hr 662 4 LB hr 621 0 LB hr 375 6 Kg hr 338 0 Kg hr 300 5 Kg hr 281 7 Kg hr 16 of 37 1 02 001 91 QN3931 17 of 37 ou peus pue ac Senn AOS FU pu 072 001 817 9317 S1uvd dop uortsmuued Amd Aue ox UF 0 vou ur Duwanip su 18 of 37 ace 020000620011 mu 25S EEE JUGUM UJAPQS 0429 group Ad Aue ox ved 0 MOUM ur 967064000 OG SS p WEM 8 1 U Lue 072 001 91 0 3931 S1HVd 19 of 37 G4VW H 072 001 81 QN3931 SLYVd 20 of 37 1 02 001 81 MAIA dOL dop uortsm
6. 120 4 110000 29 36 5 4 1 LB 100 120KW THREE PHASE 208 240 29 5 4 2 LB 150 240KW THREE PHASE 208 240 30 5 4 3 LB 100 120KW THREE PHASE 380 425 22 22000 31 5 4 4 LB 150 180KW THREE PHASE 380 425 32 5 4 5 LB 240KW THREE PHASE 380 425 2000 seen 33 5 4 6 100 120KW THREE PHASE 440 600 34 5 4 7 150KW THREE PHASE 440 600V 35 5 4 8 LB 180 240KW THREE PHASE 440 600 0 36 6 TERMS amp CONDITIONS 1 eet tenens 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 1 INSTALLATION INSTRUCTIONS LITTLE BOILER LB SERIES The Electro Steam Generator design consists essentially of a high pressure chamber filled with water that is heated by one or more submerged resistance type electric heating elements Automatic controls are provided to maintain the pre set operating pressure and water level Safety features include automatic low water cutoff manual low water reset optional dual pressure controls safety valve and visible water level gauge All of our generators are built in accordance with A S M E Miniature Boiler Code and are individually inspected and stamped by an Authorized National Board Insurance Inspector IMPORTANT READ ALL INSTRUCTIONS BEFORE OPERATING Important Set unit perfectly level and as clos
7. LB 120 4 30 25 208 230 480 600 LB 150 6 25 30 208 230 480 600 LB 180 6 30 40 208 230 480 600 LB 240 6 40 4 2 AMPERAGE CALCULATIONS The INPUT VOLTAGE PHASE TOTAL POWER RATING and HEATER VOLTAGE RATING are used to calculate the amperage THREE PHASE AMPERAGE FORMULAS 208 240 amp 440 600 380 425V using 208 240V heaters lt 43 3 3 DEFINITIONS I Amperage Vi Input Voltage Pr Total Power Rating Vu Heater Voltage Rating 14 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 4 2 AMPERAGE CALCULATIONS Continued THREE PHASE AMPERAGE CALCULATIONS AMPS Input Voltage 208 220 230 240 380 400 415 425 440 460 480 550 575 600 LB 100 278 240 251 262 169 146 151 155 110 115 120 88 92 96 LB 120 333 288 301 314 203 175 181 186 132 138 144 106 111 115 LB 150 416 360 377 393 254 218 226 232 165 173 180 132 138 144 LB 180 500 432 452 471 304 262 272 278 198 207 217 159 166 173 LB 240 666 576 602 629 406 349 362 371 265 277 289 212 221 231 4 3 ACTUAL POWER RATING CALCULATIONS Because the HEATER VOLTAGE RATINGS only come in 4 different voltages and there are so many different voltages in the field the TOTAL POWER
8. NO PVC 3 Remove Safety Valve 18 WARNING There MUST be NO PRESSURE in the chamber when removing the Safety Valve make sure the steam out and drain are open to assure chamber will remain depressurized Be cautious of escaping steam from chamber while Safety Valve is removed 9 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 5 CHAMBER CHEMICAL ACID TREATMENT Continued 4 Close Manual Drain 19 and Steam Out 16 turn generator on until Sight Glass 10 shows that it is 1 2 full and then shut off Insert funnel into coupling where Safety Valve 18 used to be Pour a 1 Gallon of hydrochloric acid inhibited solution NON FOOD APPLICATIONS into funnel very slowly being careful of fumes and venting while pouring NOTE Solution can be obtained from any industrial chemical dealer FOR FOOD APPLICATIONS Use FDA approved chemicals 7 Remove funnel reinstall Safety Valve 18 and verify Steam Out 16 is closed let solution set in generator for 1 HOUR 8 Turnon generator allowing pressure to climb to 5 PSI on Pressure Gauge 415 and then shut off 9 Allow the pressure to drop to 0 PSI on Pressure Gauge 15 naturally DO NOT open Steam Out 16 or Manual Drain 19 until pressure is down 10 Remove Safety Valve 418 11 Reinsert funnel and fill generator completely to the top with clean water let stand for an additional 1 2 HOUR NOTE Turning on the generator wi
9. brush and reinstalled using a new gasket If you are replacing or cleaning your heater elements Place main disconnect box es and the Toggle Switch 2 in the OFF position Make sure generator is cool and the Pressure Gauge 15 reads 0 PSI Remove heater wires from heater s using a 3 8 Socket Unbolt and remove heater s using a 1 1 16 Socket NOTE Heater s may be difficult to get out you may need to use some sort of pry bar to get them loose Clean heater s with wire brush If replacing dispose of old heater s Reinstall heater s with new gasket s 7 Attach heater wires assuring proper wiring Refer to Heater Wiring Schematics attached i ad icd NOTE If you are replacing heater because of heater failure you must also clean the probes and clean out the chamber or you may have another heater failure within 48 hours 6 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 4 REPLACING GLASS GAUGE amp RUBBER WASHERS OR GLASS PACKINGS The Sight Glass 10 gives the operator the ability to easily monitor the actual water level inside the chamber If the Sight Glass 10 gets clogged or is no longer functional it can be very difficult to troubleshoot a problem 3 4 1 BRASS SIGHT GLASS STANDARD GLASS GAUGE and RUBBER WASHERS MUST be replaced EVERY SIX MONTHS INSTALLATION Only properly trained personnel should install and maintain water gauge glass and connections
10. down aa GLAND e GLASS PACKING NUT facing down e GLASS PACKING NUT facing up GLASS PACKING GLAND facing up PACKING e GLASS PACKINGS inch down from top SS e PACKING WASHER f 4 Gently insert GLASS GAUGE into GAUGE FITTINGS TOLL You may need to rotate GAUGE FITTINGS until I vertically aligned after GLASS GAUGE is in lt gt i L 5 Carefully raise GLASS GAUGE about 1 16 from bottom and slide lower GLASS PACKINGS down until it makes C contact with the BOTTOM GAUGE FITTING DO X NOT allow GLASS GAUGE to remain in contact with any BOTTOM metal yH GAUGE 6 Carefully slide upper GLASS PACKINGS as far as mm FITTING possible DRAIN 7 Hand tighten both GLASS PACKING NUTS then tighten VALVE 1 2 turn more by wrench Tighten only enough to prevent leakage DO NOT OVER TIGHTEN If any leakage should occur tighten slightly a quarter turn at a time checking for leakage after each turn 8 Reinstall GUARD RODS 8 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 5 CHAMBER CHEMICAL ACID TREATMENT All Electric Steam Generator should be cleaned regularly The following is the least amount of times recommended to clean out your chamber NORMAL WATER AREAS Should be done ONCE A YEAR BAD WATER AREAS Should be done TWICE A YEAR If equipped with Motorized Auto Flush amp D
11. run generator are marked on name plate of generator NOTE Check tightness of ALL connections periodically Disconnect box and wire gauges should be sized and installed by a licensed electrician in accordance with your local codes 3 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 2 OPERATION amp SEQUENCE OF EVENTS IMPORTANT READ INSTALLATION INSTRUCTIONS BEFORE OPERATING 1 Turn on water supply from the source to the Generator OPEN all valves on the Generator except for the Manual Drain 19 Place main disconnect box in ON position gt gt B Place ON OFF Switch 2 in ON position Water Solenoid 7 and Pump 8 if high pressure will engage and the chamber will begin to fill with water As the water level rises it will make contact with OR D and A probes indicating the heaters are safely submerged At this time the contactor s will engage supplying power to the heaters causing steam pressure to accumulate The chamber will continue to fill with water until 3 seconds after water makes contact with the C probe causing the Water Solenoid 7 and Pump 8 if high pressure to turn off If the contactor s still have not engaged at this time you may need to press Safety Reset 13 on the Safety Pressure Control 12 If your generator is equipped with a Manual Low Water Reset ML WR 3 it must be pressed at this time to engage t
12. way down from the top CONTROL 7 Somewhere t 3 Adjust the PRESSURE ADJUSTMENT DIAL on the Between 7 SAFETY so that the BLACK INDICATOR LINE is somewhere between 1 4 and 2 of the way down from top 4 Close the Steam Out 16 and turn on generator When the contactor s click on the pressure will rise If contactor s do not gt click on right away you may need to press SAFETY RESET Continue to watch the Pressure Gauge 15 until you hear the Between contactor s click off This may take up to 20 minutes WARNING DO NOT allow the pressure to exceed the rating on the Safety Valve 18 If contactor s do not turn off before the pressure limit is exceeded manually shut off generator open the Steam Out 16 and DECREASE the pressure setting on the SAFETY pressure control Repeat step 4 12 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 7 SETTING THE PRESSURE CONTROLS Continued 5 At this point the contactor s should be clicked off and you should be able to click them on and then off again by pressing the SAFETY RESET This is a way to test if the SAFETY is still controlling the pressure and not the CONTROL While setting the SAFETY and the contactor s are off if the SAFETY RESET does not cause the contactor s to click on and off again INCREASE the setting on the CONTROL th
13. PAIR OR REPLACEMENT SHIPPING POINTS OF DEFECTIVE PARTS UNDER NO CIRCUMSTANCES SHALL ELECTRO STEAM GENERATOR CORPORATION BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES THE PRICE STATED FOR THE EQUIPMENT IS A CONSIDERATION IN LIMITING ELECTRO STEAM GENERATOR CORPORATION S LIABILITY NO ACTION REGARDLESS OF FORM ARISING OUT OF THE TRANSACTIONS OF THIS AGREEMENT MAY BE BROUGHT BY PURCHASER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED THE WARRANTY FOR THIS EQUIPMENT OR SERVICE PROPOSED IN THIS QUOTATION IS AS STATED IN THE AFOREMENTIONED PARAGRAPHS IT IS NOT RESTATED NOR DOES IT APPEAR IN ANY OTHER FORM This warranty supersedes all prior verbal or written warranties INSURANCE Buyer represents that they have a program of Insurance which adequately protects their interest and that of their employees and agents including damage to plant property and equipment personal injury of any kind directly or indirectly related in any way to the equipment service repair or parts supplied by Seller Accordingly Buyer waives any claim against Seller for the foregoing and on behalf of its Insurance Company any right of subrogation in connection therewith LAW This Agreement shall be governed by the internal laws of the State of New Jersey USA and any claims arising hereunder shall be prosecuted in the United States District Court having jurisdiction of causes of action arising in the District in which Seller
14. RATING is only completely accurate if the VOLTAGE IN is exactly equal to the HEATER VOLTAGE RATING This means in most cases the TOTAL POWER RATING is not completely accurate The AMERAGE and INPUT VOLTAGE can be used to calculate the ACTUAL POWER RATING THREE PHASE ACTUAL POWER RATINGS FORMULA DEFINITIONS I Actual Power Rating Vi Amperage Input Voltage ACTUAL POWER RATING CALCULATIONS KW Input Voltage 208 220 230 240 380 400 415 425 440 460 480 550 575 600 LB 100 100 91 5 100 109 111 101 109 114 84 91 8 100 84 91 8 100 LB 120 120 110 120 131 134 121 130 137 101 110 120 101 110 120 LB 150 150 137 150 163 167 151 163 171 126 138 150 126 138 150 LB 180 180 165 180 196 200 182 195 205 151 165 180 151 165 180 LB 240 240 220 240 261 267 242 261 273 202 220 240 202 220 240 15 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 4 4 STEAM CAPACITY CALCULATIONS Steam Capacity Calculations are based on the impossible feed water temperature of 212 F WARNING Anything above 140 F will cause damage to water solenoid and pump NET STEAM CAPACITY CALCULATIONS MODEL Feed Water Feed Water Feed Water Feed ve UNIT 212 2 140 2 100
15. RESSURE CONTROL This pressure control should be the only one controlling the operating pressure of the generator SAFETY PRESSURE CONTROL This pressure control is only used if the Control fails It is always set higher than the Control if the operating pressure is passed The Safety will turn the heaters off SAFETY RESET This reset is tripped when the Safety turns the heaters off It must be manually pushed to turn the heaters back on This lets the user know there was a problem If it is tripped the Control most likely failed PRESSURE ADJUSTING DIAL These dials adjust the set pressure at which each pressure control will turn the heaters off DIFFERENTIAL ADJUSTING DIAL This dial is only on the Control When the Control turns the heaters off the amount of pressure that is dropped before it turns the heaters back on the differential can be adjusted by this dial This dial should never have to be adjusted unless desired PRESSURE GAUGE This tells the user what pressure is in the chamber The pressure controls are set to this gauge 5 PSI PRESSURE CONTROL Only used with MAFD Motorized Auto Flush amp Drain this control prevents the MAFD from opening when there is more than 5 pounds off pressure in the generator 11 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 7 SETTING THE PRESSURE CONTROLS WARNING The pressure controls must be set while all circui
16. Remember to wear safety gloves and glasses during installation Before installing make sure all parts are free of chips and debris Uninstall GUARD RODS GLASS GAUGE and RUBBER WASHERS you may need to rotate one of the GAUGE FITTINGS to remove GLASS GAUGE Slip anew RUBBER WASHER on the new GLASS GAUGE about an inch from the bottom Now slip the following items through the top of GLASS GAUGE in the following order e FRICTION WASHER GLASS PACKING NUT facing down GLASS PACKING NUT facing up FRICTION WASHER RUBBER WASHER inch down from top Gently insert GLASS GAUGE into GAUGE FITTINGS You may need to rotate GAUGE FITTINGS until vertically aligned after GLASS GAUGE is in Carefully raise GLASS GAUGE about 1 16 from bottom and slide lower RUBBER WASHER down until it makes contact with tte BOTTOM GAUGE FITTING DO NOT allow GLASS GAUGE to remain in contact with any metal Carefully slide upper RUBBER WASHER up as far as possible Hand tighten both GLASS PACKING NUTS then tighten 1 2 turn more by wrench Tighten only enough to prevent leakage DO NOT OVER TIGHTEN If any leakage should occur tighten slightly a quarter turn at a time checking for leakage after each turn Reinstall GUARD RODS 7 of 37 m TOP GAUGE FITTING ALA twm 1 Ha T GLASS i GAUGE ROD GLASS PACKING c LLL FRIC
17. TION 1 WASHER RUBBER mE WASHER ba d 47 TR 1 Em 4 TTT BOTTOM DRAIN VALVE LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 4 REPLACING GLASS GAUGE amp RUBBER WASHERS OR GLASS PACKINGS Continued The Sight Glass 10 gives the operator the ability to easily monitor the actual water level inside the chamber If the Sight Glass 10 gets clogged or is no longer functional it can be very difficult to troubleshoot a problem 3 4 2 BRASS SIGHT GLASS SEISMIC GLASS GAUGE GLASS PACKINGS 77773 ermine MUST be replaced EVERY SIX MONTHS The Seismic Sight Glass is equipped with BALL CHECKS in each GAUGE FITTING La INSTALLATION Only properly trained personnel should install and maintain water gauge glass and connections PACKING Remember to wear safety gloves and glasses WASHER during installation Before installing make sure all parts are free of chips and debris GUARD GLASS ROD GAUGE 1 Uninstall GUARD RODS GLASS GAUGE and GLASS PACKINGS you may need to rotate one of the GAUGE FITTINGS to remove GLASS GAUGE 2 Slip a new GLASS PACKINGS on the new GLASS GLASS 4 GAUGE about an inch from the bottom PACKING 3 Now slip the following items through the top of GLASS NUT GAUGE in the following order ___ PACKING PACKING GLAND facing
18. User Manual LB 100 thru LB 240 steam boilers built in accordance with ASME miniature boiler code NOTE It is the responsibility of the installer to conform with any state or local codes If further inspection following modification by installer is required under state or local codes that is the responsibility of the local installer www electrosteam com lectro Steam rev 10062008 LB 100 thru LB 240 User Manual Electro Steam Generator Corp TABLE OF CONTENTS 1 INSTALLATION INSTRUCTIONS 2 2 22 2 2 2222 3 2 OPERATION amp SEQUENCE OF EVENTS 2 eee 4 3 CLEANING amp 5 11 31 MANUALE t tilt etu a de ete 5 3 2 CLEANING WATER LEVEL PROBES cette 5 6 3 3 CLEANING OR REPLACING HEATERS eerte 6 3 4 REPLACING GLASS GAUGE AND RUBBER WASHERS 7 8 3 4 1 BRASS SIGHT GLASS 5 7 3 41 BRASS SIGHT GLASS SEISMIC 00000000100000 enses serere ea 8 3 5 CHAMBER CLEANING amp CHEMICAL TREATMENT es 9 10 3 6 PRESSURE CONTROL DATA SHEET cette 11 3 7 SETTING THE PRESSURE CONTROLS 12 13 4 CALCULATIONS amp DATA SHEETS 7 c 14 15 4 1 HEATER POWER amp VOLTAGE RATINGS
19. al wool or Scotch Brite Wire wheel works the best You may also want to try some sort of chemical like CLR remover or LIME A WAY 8 Reinstall probes assuring each probe s length is assigned to its proper letter 9 Reconnect wires to probes assuring each color is also assigned to its proper letter NOTE DO NOT make wires too tight Just tighten enough to make contact Over tightening can cause probe plugs to pull apart over time 10 Reinstall cover plate Water Level Probe Specifications Letter Assignment on Chamber A B C D G Water Level Probe Length 51 572 Wire Color Assignment RED Not Used BLACK GREEN Assignment on Dual Function Board LLCO Not Used H G NOTE The B Probe is not used It is a spare probe that can be cut and used to replace any one of the other probes WARNING There MUST be NO PRESSURE in the chamber when removing probes If you must change probes while chamber is HOT make sure the steam out and drain valves are open to assure chamber will remain depressurized DO NOT touch probes with your bare hands while HOT and be cautious of escaping steam from probe holes while probes are removed 3 3 CLEANING OR REPLACING HEATERS Heaters are located inside the Control Panel 1 below the insulation barrier bolted into the chamber If 3 5 Chamber Chemical Acid Treatments are not regularly done heaters must be taken out at least ONCE A YEAR cleaned with wire
20. and STEAM under HIGH PRESSURE can lift drain pipes right off the ground and cause SERIOUS INJURY Make sure drain pipe is SECURELY STRAPPED and CANNOT move The drain must be directed into a HIGH TEMPERATURE drain NO PVC 3 2 CLEANING WATER LEVEL PROBES Water Level Probes are the heart of your generator Almost all steam generator malfunctions are caused by dirty water level probes CLEANING your PROBES is by far the MOST IMPORTANT maintenance step to keep your generator running properly The following is the LEAST amount of times recommended to clean your probes NORMAL WATER AREAS Should be done TWICE A YEAR BAD WATER AREAS Should be done 3 4 TIMES A YEAR NOTE The best time to clean your probes is before you turn your generator on while it is still cool 1 Place main disconnect box and the Toggle Switch 2 in the OFF position 2 sure generator is cool and the Pressure Gauge 15 reads 0 PSI 3 Find the water level probes 5 located in the blue box on top of generator 4 Unscrew the four Philips head screws and remove cover plate exposing the water level probes 5 5 5 16 Socket to remove wires from probes 6 Use 13 16 Spark Plug Socket to remove probes from chamber 5 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 2 CLEANING WATER LEVEL PROBES Continued 7 Clean probes to remove rust and scaling NOTE To clean probes you may use wire wheel wire brush ste
21. e as possible to the steam vessel or appliance it will operate For generator measurements refer to Installation Data Drawing attached For interpretation of numbered items refer to Parts Legend Drawing attached NOTE Ambient temperature around this unit must not exceed 105 F Water Supply Connect city water line to Y Strainer 6 Supply pressure not to exceed 150 PSI If you have a low pressure generator water supply pressure must be at least 10 PSI higher than the operating pressure CAUTION The Pump 48 requires clean tap water If the water is not free of foreign matter a 5 micron cartridge filter should be installed in the water supply line NOTE If treatment is used purity should NOT exceed 26 000 ohms Steam Outlet Connect Steam Outlet Valve 16 to piece of equipment vessel room or area to be operated by Electro Steam Generator Safety Valve Connect Safety Valve 18 separately than Drain 19 to a high temperature drain NO PVC Discharging pipe should never be smaller than the valve outlet and should be rigidly supported placing no weight on the safety valve itself Drain Connect Drain 19 separately than Safety Valve 18 to a high temperature drain PVC If equipped with Motorized Auto Flush amp Drain 20 MAFD should also be connected to drain Electrical A fused disconnect box of proper size should be installed close to Generator Voltage s KW and Phase s required to
22. e rating on the Safety Valve Pressure Control Settings contactor s do not turn off before the pressure Control Safety open the Steam Out 616 and DECREASE 0 100 Ps SOPSI 85 PSI control cannot SAFETY to 25 PSI 27 PSI control the pressure it may need to be replaced 11PSI 13 5 PSI 6 the Steam Out 16 to exhaust some pressure Continue pressing the SAFETY RESET until the contactor s click on and remain on The pressure should eventually begin to rise If it doesn t throttle the Steam Out 16 somewhere between closed and open until it does 7 Pay attention to what the pressure reads when the contactor s click off If the pressure stopped BELOW the SAFETY PRESSURE SETTING then INCREASE the pressure setting on the SAFETY If the pressure stopped ABOVE then DECREASE the pressure setting 8 Continue to watch the pressure go up and down while adjusting the SAFETY and pressing the SAFETY RESET until the pressure stops at the proper SAFETY PRESSURE SETTING 9 At this point the SAFETY should be set to the proper SAFETY PRESSURE SETTING and the CONTROL should be set somewhere above the SAFETY 10 Let the pressure drop below the OPERATING PRESSURE SETTING and then press the SAFETY RESET so that the contactor s click on DECREASE the pressure setting on the CONTROL until the contactor s c
23. he contactor s If your generator is equipped with a Motorized Auto Flush amp Drain MAFD 20 you must wait until it closes before the contactor s will engage approximately 3 minutes Steam pressure will continue to rise until is reaches its set operating pressure This may take up to 25 minutes At this time the Control Pressure Control 12 will cause the contactor s to disengage The pressure will drop approximately 2 8 PSI until the Control Pressure Control 12 causes contactor s to reengage causing the pressure to rise again The contactor s will continue to cycle on and off during operation 5 Generator is now fully operational and will produce steam until it is turned off As steam is exhausted water level will drop until 3 seconds after it breaks contact with the C probe At this time the Water Solenoid 7 and Pump 8 if high pressure will engage and the chamber will again fill with water The chamber will continue filling until 3 seconds after the water makes contact with the C probe The Water Solenoid 7 and Pump 8 if high pressure will continue to cycle on and off during operation 6 To shut off the Generator place ON OFF Switch 2 in OFF position Pressure will drop naturally as the chamber cools or the Generator may be drained manually through Manual Drain 19 See Manual Blow Down 3 1 WARNING HOT WATER and STEAM under HIGH PRESSURE can lift drain pi
24. ipment and service supplied shall conform to the description in the quotation and agrees to repair or replace F O P shipping points any parts excepting expendable items that fail due to defects in material or workmanship The pressure vessel steam chamber are warranted to the original Purchaser for a period of five years from the date of shipment from our factory Mechanical and electrical components along with accessories and hoses are warranted for a period of one 1 year from date of shipment from our factory INNO EVENT SHALL ELECTRO STEAM GENERATOR CORPORATION S WARRANTY BE EXTENDED BEYOND THE WARRANTY LIABILITY PROVIDED BY THE SUPPLIER OR MANUFACTURER OF COMPONENT PARTS INCORPORATED IN THIS EQUIPMENT THERE ARE NO OTHER WARRANTIES OF ANY KIND EXPRESSED OR IMPLIED AND SPECIFICALLY EXCLUDED BUT NO BY WAY OF LIMITATION ARE THE IMPLIED WARRANTIES OF FITNESS FOR PARTICULAR PURPOSE AND MERCHANTABILITY All claims for incorrect products or replacement must be made and settled prior to installation Electro steam Generator Corporation assumes no liability for the expense of repairs made outside its factory Any claims for labor and or parts will be denied unless written authorization is given by Electro Steam Generator Corporation prior to work being done IT IS UNDERSTOOD AND AGREED THAT ELECTRO STEAM GENERATOR CORPORATION S LIABILITY WHETHER IN CONTRACT IN TORT UNDER ANY WARRANTY IN NEGLIGENCE OR OTHERWISE SHALL EXCEED THE COST OF RE
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26. lick off 11 Repeat Step 10 until you no longer need to press the SAFETY RESET for the contactor s to click on 12 Continue to watch the pressure go up and down while adjusting the CONTROL until the pressure stops at the proper OPERATING PRESSURE SETTING 13 The Pressure Controls are now set NOTE If at anytime the SAFETY RESET needs to be pressed after the pressure controls are set either one of the controls are bad the SAFETY is set too low or the CONTROL is set too high 13 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 4 CALCULATIONS AND DATA SHEETS 4 1 HEATER POWER amp VOLTAGE RATINGS LB 100 thru 240 Model units use 4 or 6 heaters to meet the required KW POWER from the customer s specified INPUT VOLTAGE Each heater comes 3 different KW POWER RATINGS and 4 different VOLTAGE RATINGS HEATER VOLTAGE RATINGS per INPUT VOLTAGE VOLTS Input Voltage 208 220 230 240 380 400 415 425 440 460 480 550 575 600 LB 100 240 208 230 230 230 208 230 230 230 480 480 480 600 600 600 NOTE 380 425V heaters are not usually rated for 380 425 They are usually 208 240V heaters that have POWER RATINGS per MODEL been re stamped 380 425V and jumpered in series MODEL UNIT QUAN KW AVAILABLE HEATER RATINGS 4 KW VOLTAGES
27. ll not completely fill it to the top Filling must be done manually through the safety valve coupling 12 Open Manual Drain 419 to drain generator 13 Close Manual Drain 719 refill generator completely to the top with clean water and open Manual Drain 19 to flush out generator completely 14 Reinstall Safety Valve 18 and close Manual Drain 19 15 Turn on generator allowing pressure to climb to 10 to 20 PSI on Pressure Gauge 15 and then shut off 16 Blow Down Open Manual Drain 19 slowly allowing HOT WATER and STEAM to blow out into the drain NOTE You may Blow Down your generator at any pressure you feel comfortable with 10 to 20 PSI is only a recommendation You may go higher or lower but higher is always better WARNING HOT WATER and STEAM under HIGH PRESSURE can lift drain pipes right off the ground and cause SERIOUS INJURY Make sure drain pipe is SECURE and CANNOT move The drain must be directed into a HIGH TEMPERATURE drain NO PVC 17 Your generator is now ready for normal use and operation 10 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 6 PRESSURE CONTROL DATA SHEET RESET CONRTOL SAFETY PRESSURE PRESSURE PRESSURE CONTROL SAFETY GAUGE CONTROL PRESSURE ADJUSTMENT PRESSURE ADJUSTING DIAL DIFFERENTIAL ADJUSTING DIAL 5 PSI FACTORY SET NC PRESSURE CONTROL ONLY USED WITH MAFD DEFINITIONS CONROL P
28. maged merchandise if accepted should be noted on the delivery receipt and on the freight bill before acceptance of shipment Make claim promptly CONTINGENCY contracts are contingent upon fire strikes accidents delays in transit acts of God or other causes beyond our control LOCAL CODES All steam boilers are built in accordance with ASME miniature boiler code NOTE It is the responsibility of the installer to conform with any state or local codes If further inspection following modification by the installer is required under state and local codes that is the responsibility of the local installer FREIGHT TERMS FACTORY NO FREIGHT ALLOWED All charges for unloading and transportation to job site are at the buyer s expense INSTALLATION No installation or job supervision charges are included ORDERS orders resulting from this quotation are subject to acceptance by the factory No production will begin until receipt of purchaser s signed order and credit approval PAYMENT TERMS Within Continental U S A net 30 days with approved credit from the date of invoice not date of arrival of goods Payment in full without retainer and or any unauthorized sums deducted is expected RETURNS OF MATERIAL No goods will be accepted for return without a return authorization number from the factory A 25 restocking fee is charged on returns freight prepaid TAXES No taxes of any kind are included All prices herein and or c
29. ontracts shall be subject to increase without notice by the amount of present or future sales or excise tax levied or charged either by Federal State or any other assessing agency PATENTS Seller agrees to indemnify Purchaser against any proven claim and assessed liability for infringement of any United States patent arising from the manufacture or sale of any apparatus furnished by Seller to Purchaser THE FOREGOING STATES SELLER S ENTIRE LIABILITY FOR CLAIMS OR PATENT INFRINGEMENT Seller shall have no liability whatsoever if the claim of infringement arises out of the Sellers compliance with Purchasers specifications Seller shall have no liability whatsoever if a claim of infringement is based upon the Purchasers use of the equipment as part of a patented combination where the other elements of the combination are not supplied by Seller or in the practice of a patented process Where the specifications process design are supplied by Purchaser then Purchaser agrees to indemnify the Seller in like manner of the claim or suit and c purchaser provides all information and assistance to Electro Steam Corporation at purchaser s expense as is reasonably necessary for the defense of the claim or suit Electro Steam Generator Corporation may at its option intervene in any suit or action brought against the purchaser on such claim ELECTRO STEAM GENERATOR CORPORATION LIMITED WARRANTY Electro Steam Generator Corporation fully warrants that all equ
30. pes right off the ground and cause SERIOUS INJURY Make sure drain pipe is SECURE and CANNOT move The drain must be directed into a HIGH TEMPERATURE drain NO PVC or outside 4 of 37 LB 100 thru LB 240 User Manual Electro Steam Generator Corp 3 CLEANING amp MAINTENANCE The following cleaning procedures are HIGHLY RECOMMENDED in order to keep your Steam Generator in the best operating condition at all times 3 1 MANUAL BLOW DOWN A Manual Blow Down is an easy way to GREATLY extend the life of your Steam Generator Using a Motorized Auto Flush amp Drain MAFD of course helps but is not a Cure all The following is the LEAST amount of times recommended to blow down your generator NORMAL WATER AREAS Should be done ONCE WEEK BAD WATER AREAS Should be done ONCE A DAY NORMAL WATER AREAS WITH MAFD Should be done TWICE A MONTH BAD WATER AREAS WITH MAFD Should be done ONCE A WEEK NOTE The best time to Blow Down your generator is after it has been running for some time while it is still hot 1 Place Toggle Switch 2 in OFF position 2 Allow pressure to drop between 10 and 20 PSI 3 Open Manual Drain 19 slowly allowing HOT WATER and STEAM to blow out into the drain cleaning out the generator NOTE Blow Down your generator at any pressure you feel comfortable with 10 to 20 PSI is only a recommendation You may go higher or lower but higher is always better WARNING HOT WATER
31. rain 20 locate the MAFD TIMER RELAY in the Control Panel 1 and do steps 1 3 before the chamber treatment and steps 4 5 after chamber treatment is done WARNING Before opening Control Panel 1 TO AVOID ELECTRICAL SHOCK place main disconnect box and the Toggle Switch 2 in the OFF position BEFORE TIME 1 Dial TIME ADJUSTMENT MAFD ADJUSTMENT TIMER RELAY all the way down to 15 seconds MAFD Make sure MAFD 20 in the closed position TIMER RELAY Disconnect the orange wire from the normally open NO terminal on the MAFD TIMER RELAY 2 AFTER 4 Reconnect the orange wire to the normally open COM NO terminal on the MAFD TIMER RELAY Input 5 Dial TIME ADJUSTMENT on MAFD 120V TIMER RELAY up to the desired flush time Most commonly 3 minutes Chamber Treatment Instructions 1 Turn on generator allowing pressure to climb to 10 to 20 PSI on Pressure Gauge 15 and then shut off 2 Blow Down Open Manual Drain 19 slowly allowing WATER and STEAM to blow out into the drain NOTE You may Blow Down your generator at any pressure you feel comfortable with 10 to 20 PSI is only a recommendation You may go higher or lower but higher is always better WARNING HOT WATER and STEAM under HIGH PRESSURE can lift drain pipes right off the ground and cause SERIOUS INJURY Make sure drain pipe is SECURE and CANNOT move The drain must be directed into a HIGH TEMPERATURE drain
32. ts are live TO AVOID ELECTRICAL SHOCK DO NOT TOUCH the wires or the terminals in which they connect while setting the pressure controls NOTES Setting the pressure controls greatly relies on your ability to tell whether the contactor s are turning the heaters on or off You should be able to hear the contactor s located inside the Electrical Box 1 click on and off Familiarize yourself with this sound The order in which the pressure controls must be set is the Safety and then the Control norder to set the Safety you must keep the Control at a higher pressure setting than the Safety Once the Safety is set then you can lower the Control to its correct setting To INCREASE the pressure setting when looking down on pressure control using your two index fingers turn the PRESSURE ADJUSTMENT DIAL CLOCKWISE causing the BLACK INDICATOR LINE to move DOWN the scale BLACK INDICATOR LINE PRESSURE ADJUSTMENT DIAL To DECREASE the pressure setting turn the dial COUNTER CLOCKWISE causing the indicator line to move UP the scale To INCREASE pressure setting turn dial CLOCKWISE causing dial and indicator line to move DOWN SETTING INSTRUCTIONS 1 Open the pressure control covers as shown on previous page Sh 2 Adjust the PRESSURE ADJUSTMENT DIAL on the CONTROL so that the BLACK INDICATOR LINE is Adjust the somewhere between 1 2 34 of the
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