ES IOM - Sussman Electric Boilers
Contents
1. SWITCH SOLENOID VALVE PUMP MOTOR 120V COM HIGH LIMIT OPERATING LIQUID PRESSURE PRESSURE LEVEL CONTROL CONTROL CONTROL PROPORTIONING PRESSURE CONTROL 135 OHM CONTACTORS COM SEQUENCER ES 100 and up with Element Cutoff Switches 120V 1PH INPUT L N CONTROL TERMINAL BLOCK L ON OFF SWITCH 9 PILOT LIGHT 09 o fo t s 1 PUMP MOTOR 2 2 T HIGH LIMIT PRESSURE LIQUID CONTROL a ELEMENT LEVEL e3 CUT OFF CONTROL OPERATING SWITCHES CONTACTORS PRESSURE CONTROLS FIELD WIRING FACTORY WIRING SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Wiring Diagram Control Circuit ES Electric Boilers with Automatic Blowdown System 120V 1PH INPUT FIELD WIRING FACTORY WIRING CONTROL TERMINAL BLOCK PILOT LIGHT 7 DAY 24 HR TIMER 3 mr AD MOTORIZED ON OFF BLOWDOWN SYSTEM TIME DELAY RELAY SWITCH PILOT _ LIGHT SOLENOID VALVE gt PUMP MOTOR x RELAY 2 D y 9 2 HIGH LIMIT OPERATING LIQUID PRESSURE PRESSURE SONTASTORS LEVEL CONTROL CONTROL CONTROL SUSSMAN Installation Operation amp Mainte2. 22 Power wiring shown in approximate factory installed location TORQUE VALUES Element Flange Bolts 22 lb ft Element Terminals 20 Ib in Contactor Terminals 50amp 25 16 45 Ib in SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Water Quality Information for Carbon Steel Boilers For optimum results the feedwater supply should be tested prior to initial start up If the mineral content exceeds the following recommended limits various external treatment processes water softener reverse osmosis etc may be used to correct the problem NOTE An analysis of the on site boiler feedwater must be made by a recognized and reliable water treatment company to ascertain the existing condition and treatment required RECOMMENDED FEEDWATER QUALITY HARDNESS ppm 8 85 0 5 5 gpg P ALKALINITY ppm 85 410 5 24 gpg T ALKALINITY ppm 200 500 7 0 gpg pH strength of alkalinity 8 0 11 4 SPECIFIC RESISTIVITY 50k Q cm 50 000 ohm centimeter Blow down the boiler on at least a once a day basis If boiler water or feed water are outside the above limits a more frequent blowdown is required Water quality can affect efficiency or result in boiler damage if neglected Boiler feedwater contains impurities in solution and suspension These impurities concentrate in the boiler since the steam generated is essentially pure The concentration of these impurities increases as mo
3. sate to the boiler can save a significant amount of energy The water returned is relatively free of corrosive minerals and carries a substantial amount of heat that does not have to be replenished A vacuum breaker is required whenever a condensate return system is used Each system consists of a vertical condensate return tank a motor and pump and support plumbing A 1 2 inlet is located on the tank to accept make up water A vent fit ting is located on the condensate tank top for atmospher ic air venting The return fitting is to be plumbed to the trapped condensate return line coming from the process A gauge glass and valve set are mounted on the side of the condensate tank The tank has a ball check valve internally mounted and a float arm and float ball assem bly that serve mechanically allowing make up water to enter the tank as the original supply is used The pump discharge outlet is to be plumbed to the boiler check valve The tank drain valve should be plumbed to a prop er drain line The motor is required to be wired to the boiler 14 SUSSMAN ELECTRIC BOILERS Installation Operation amp Maintenance Manual Optional Equipment cont VACUUM BREAKER SYSTEMS For model ES boilers PN ES89369 A vacuum breaker will prevent a boiler from flooding as a result of the steam condensing internally and creating a vacuum after boiler shutdown The breaker allows air to enter the boiler shell breaking the vacuum This syst
4. to select press OK When the timer is On press to manually turn lt en 5 Arrows for days 4 blinking the timer Off O and display arrow w will point to press or to select press OK Press again to go back to On and display 6 Go to step 8 to continue with programming or press arrow w will point to AUTO Menu to end When the timer is Off O press to manually turn the timer On and display arrow w will point to TO SET TIMER ON OFF TIMES OVR 7 Press Menu and press OK four times to go Press again to go back to Off O and display arrow current time day setting above v will point to AUTO 8 prog 01 blinking and ON symbol displayed press When the timer is in the override mode W on OVR or to select press OK timer will stay in that position until the next pro 9 Hour 12 00 blinking press or to select press OK grammed time at which time the arrow will point 10 Minute 12 00 blinking press or to select press to AUTO and continue in the automatic mode OK 11 Arrows for days 4 blinking press or to select HOURLY ON OFF SETTING FOR THE DAY press OK Hash marks on the upper and right edges of the dis 12 prog 02 blinking and OFF symbol O displayed play show the hourly On times for the day Absence press or to select press OK of hash mark on a specific hour indicates that the 13 Hour 12 00 blinking press or to select timer is Off on that hour press OK 14 Minute 12 00
5. Gauge Pressure Temperature Boiler Bhp Lbs Hr 3 Ph Chart Model No KW Rating Steam Volts Amps Gauge 208 34 Pressure s ES 12 12 12 362 240 29 PG F c 480 15 15 179 82 208 50 10 192 89 ES 18 18 1 84 54 2 ns a 5 203 95 208 67 0 212 100 ES 24 24 2 45 72 3 240 58 1 215 102 480 29 3 221 105 208 84 ES 30 30 3 06 90 4 240 73 pa M LA 480 37 9 237 114 208 100 11 241 119 ES 36 36 3 67 108 240 87 480 44 15 250 121 17 253 123 208 134 ES 48 48 4 90 145 240 116 19 257 125 480 38 21 260 127 60 60 6 12 D p ES 1 181 p b 25 267 131 208 200 27 270 132 ES 72 72 7 35 217 240 174 29 273 134 480 87 31 275 135 208 300 E100 108 112 325 240 260 Ed 480 130 35 281 138 208 400 37 283 139 ES 135 144 14 7 434 240 347 480 173 39 286 141 41 288 142 ES 160 158 162 475 45 290 143 I 240 434 45 292 144 ES 180 180 18 4 542 480 217 2 Sus 146 Single phase available 49 297 147 Steam at 212 F with 50 F feed water See page 19 for sizing 51 299 148 Other voltage available 53 300 149 55 303 151 60 308 153 65 312 156 70 316 158 75 320 160 80 324 162 85 327 164 90 331 166 95 335 168 100 338 170 18 SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Use the following Ta
6. Glass Packing Fitting Drain Valve Safety glasses and gloves should be worn at all times when working with or examining water gauge glass and con nections Pressure in generator to be at zero before pro ceeding Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and or property damage 20 SUSSMAN ELECTRIC BOILERS Installation Operation amp Maintenance Manual Gauge Glass Installation Use and Care DO NOTS DO NOT use glass if it contains any scratches chips or any other visible signs of damage DO NOT reuse any tubular glass or glass packings DO NOT subject gauge glass to bending or torsional stresses DO NOT over tighten glass packing nuts DO NOT allow glass to touch any metal parts DO NOT exceed the recommended pressure of the gauge or gauge glass DO NOT clean the gauge or gauge glass while pressur ized or in operation DO s DO verify proper gauge has been supplied DO examine gauge glass and packings carefully for damage before installation DO install protective guards and utilize automatic ball checks where necessary to help prevent injury in case of glass breakage DO inspect the gauge glass daily keep maintenance records and conduct routine replacements DO protect glass from sudden changes in temperatures such as drafts water spray etc MAINTENANCE Ex
7. There is no subtractive differential scale with this type of control 2 All pressure controls are equipped with an adjusting screw allowing for setting of desired operational and high limit pressures To reduce pressure setting turn adjusting screw in direction that allows indicator to point to a lower pressure setting on the scale To increase pres sure setting turn adjusting screw in direction that allows indicator to point to a higher pressure on the scale NOTE It is recommended that the high limit control be set 10 psig above the desired normal operating pressure 3 Operating pressure controls except low pressure 15psig types have a separate differential scale Differential indi cates pressure below the main operating maximum pres sure the pressure control will re set The differential set point is adjusted in the same manner by turning the adjusting screw in the desired direction to increase or decrease the differential pressure value 6 valve supplied by customer and adjust operating pres sure control to 20psig and the differential to 10psig Set the high limit pressure control to 30psig Switch boiler on to allow steam pressure to build up Pressure gauge reading will increase and the operating pressure control will de energize the contactor s when the pres sure gauge indicates 20psig Open steam outlet valve to bleed off pressure When the pressure gauge read ing decreases below 10psig differential the operating
8. between boiler flange and element flange In doing this be careful to align flange holes so element wire connection terminals on element assembly are in line with previously disconnected wire leads to facilitate easy connections NOTE Observe markings on element flange Install element marking TOP on top 7 Use only new element flange bolts Tighten all 6 element flange bolts to a torque value of 22 lb ft each see illustration 8 Connect all wires to the terminals Tighten all element terminals to a torque value of 20 lb in each see illustration Make sure all wires are clean and bright to assure good electrical contact 9 Check that the wires are correctly connected to the contactor terminals and are tightened to a torque value of 45 Ib in see illustration Make sure all wires are clean and bright to assure good electrical contact 10 Open water valve to allow water supply to reach boiler feed mechanism Torque Wrench Element Flange Bolt 12 Contactor Terminals see Torque chart 11 As boiler automatically refills observe the new flange assembly for possible leaks If water For Illustrative Purposes Only is noticed the bolts must be re tightened Before doing this turn the boiler off at the main fuse safety switch 12 When boiler reaches working pressure check flange assembly again for leaks VAR CAUTION Follow maintenance instructions provided with the boiler
9. equalization column can be examined visually and manually to see if is clear and clean If there are signs of scale or mineral deposit buildup the float control must be disassembled and cleaned One of the lower heating elements should be removed If scale or mineral deposits have begun to form all elements should be removed cleaned and reinstalled using new element gaskets Operating and high limit pressure control operation should be checked Pressure controls should be removed and cleaned if necessary Water feed supply check valves should be inspected and replaced if necessary 8 If the boiler is equipped with an electronic auxiliary low water cut off every four months the probe should be removed and checked for deposits The probe should be cleaned and reinstalled 13 SUSSMAN ELECTRIC BOILERS Installation Operation amp Maintenance Manual Standard Equipment for ES amp HU Optional Equipment AUXILIARY LOW WATER CUT OFF e For model ES amp HU boilers PN ES81017MR with manual reset Senses water level electronically using a resistance probe When a low water condition is detected the contactor control voltage circuit is interrupted and the heating elements are de energized When water level returns to proper levels voltage is restored to the contactor coils and the elements are re energized For controls with a manual reset button voltage to the contactor coils is not restored until the water level has returned t
10. ft Bw e ae d e fie 16 SUSSMAN ELECTRIC BOILERS Installation Operation amp Maintenance Manual Blowdown Separator Tanks Specifications and Data Models BDT ASME 36 42 48 54 Dimensions and Features Suggested Hook Up to Boiler Vent to atmosphere must be full size Pressure Gauge we E Vent Blowdown Inlet Inlet CL a From Boiler Witer Gauge Blowdown Ouilets Handhole Assembly except BDT ASNE 36 F Cold Water Inlet amp Washout Drain Tempered Cold Water Su H NV H lt fo Drain 2 4 re 2 16 3 The Sussman Separator design incorporates a water seal at the outlet which permits the operator to introduce cold water from the bottom to mix with the hot water and boil er steam blowdown in the separator This reduces the out let temperature to a level that makes it safe for discharge NOTE 1BHP is approximately 10KW Drain Valve dosed during normal operator 2 2 Maximum Boiler Working Pressure 250 psi Maximum Blowdown Separator Pressure 65 psi Blowdown Separators are sized in accordance with National Board Standards Standard Equipment 0 100 Ib Pressure Gauge 0 200 Temperature Gauge Water Level Gauge Constructed in accordance with Section VII Division ASME Boiler amp Pressure Vessel Code 17 SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Specifications Steam
11. pressure control will re energize the contactor s High limit pressure control check FOR TEST PURPOSES ONLY Set the high limit pressure control 10psig lower than the operating pressure control Close the steam outlet valve and switch the boiler on to allow boiler to build pressure When the pressure gauge indicates the pressure at which the high limit pressure control is set the high limit pressure control re set button will pop up and the control will de energize the contactor s Open the steam outlet valve to bleed off pressure The contactor s should not re energize on pressure drop The contactor s should only re energize when the pres sure has dropped and the high limit pressure control reset button is depressed SUSSMAN ELECTRIC BOILERS Installation Operation amp Maintenance Manual With main disconnect OFF tighten all electrical connections before energizing boiler to prevent arcing carbonizing of contact and or overheating 1 Set the desired operating pressure and differential pressure on the operating pressure control 2 Set the high limit pressure control Recommended to be 10 psig above the operating pressure setting 3 Turn on water supply 4 Turn main disconnect switch on 5 Turn boiler control switch on The water feed will begin and continue until the water level reaches half way up the gauge glass The water feed will automatically shut off and the contactor s will energize 6 B
12. 8 2966 2982 2981 3007 3019 3025 3030 200 2878 2886 2906 2919 2937 2953 2962 2978 2989 2995 3001 Example Need a boiler to produce 450 Ibs steam hr at 75 psig with the available feedwater temperature 50 F From the chart above find 3417 KW Lb of steam 450 Ibs steam hr x 3417 153 8 KW boiler required Note Add 2096 to required kW for contingencies 19 SUSSMAN ELECTRIC BOILERS Installation Operation amp Maintenance Manual Gauge Glass Installation IMPORTANT NOTE Read all warnings and instructions before performing installation or maintenance Safety glass es and gloves should be worn at all times when working with or examining water gauge glass and connections Pressure in generator to be at zero before proceeding Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury and or property damage 1 Apply Teflon tape or pipe dope to pipe threads Install top gauge fitting fitting without a drain valve into the uppermost tapping Wrench tighten the fitting until it is snug and the glass outlet is pointing at five o clock about 1 8 turn from its final downward vertical posi tion 2 Install the bottom gauge fitting the fitting with a drain valve until it is snug and the glass outlet is pointing directly upward Verify top and bottom fittings are thread
13. FX Model No SUSSMAN ELECTRIC BOILERS and Maintenance Manual TABLE OF CONTENTS Boiler Serial No Dimensional Information and National Board No Dimensional amp Clearing Specifications Safety Valve Set Pressure PSIG Wiring Diagrams Power Circuit Voltage Installation can PIPING derer aed aah Ce a blade Control Circuit Voltage Wiririg ssc eave say Pee pakay ka Amps Phase HZ Pre Operation Check Steam Outlet Valve Size NPT Pressure Controls Operation amp Testing Operation Blowdown IMPORTANT This data file contains the National Board Registration Certificate approving your boiler It must be kept near the boiler at all times Products covered by this manual Digital Timer Operation Instructions Timing Switch Maintenance Standard Equipment Auxiliary Low Water Cut Off Line Pressure Water Feed System W Max Series Range Steam Rate BHP Optional Equipment Work p quip Pressure Design Pressure ES HU 12 180 36 542 Ibs hr 1 2 18 4 0 100 psig 85 psig Steam Rate Steam at 212 F with 50 F feed water ES and HU boilers are of Carbon Steel construction See page 23 for Water Quality Information Element Replacement Water Quality Information for Carbon Steel Boilers Component Identificati
14. TIONS 1 At the end of the working day while boiler is still operating turn boiler main switch to the OFF position close water supply valve and open disconnect switch 2 If blow down valve is plumbed into a blowdown tank the boiler can be discharged at operating pressure 3 If the blowdown valve is not plumbed into a blowdown tank consult with local plumbing codes regarding boiler discharge 4 When discharge is complete and boiler is drained close the blowdown valve open the water supply valve turn boiler main switch to ON position and close disconnect switch 5 When refilling is complete turn off the boiler unless further operation is needed 6 If boiler is equipped with a Manual Re set Auxiliary Low Water Cut off as required in some states the re set button must be pushed before the boiler will begin developing steam Do not push re set button until the boiler has refilled with water 11 AUTOMATIC BLOWDOWN INSTRUCTIONS PN ES81600 1 NPT Starts stops and blows down the boiler automatically utilizing a programmable time clock a time delay relay and motorized ball valve If the blowdown valve is plumbed into a blowdown tank the boiler can be discharged at operat ing pressure If the blowdown valve is not plumbed into a blowdown tank consult with local plumbing codes regarding boiler discharge NOTE The manual valves from the boiler drain and the lower float control equalization tube must be ful
15. amine the gauge glass regularly for any signs of clouding scratching erosion or corrosion The glass should be inspected daily until the need for replace ment becomes apparent This will help establish the routine inspection and routine replacement schedules CLEANING Use commercial non abrasive glass cleaners to keep glass clean Use diluted acids such as Hydrochloric muriatic acid when regular cleaners do not seem to work Do not use wire brushes or any other abrasive materials which could scratch the glass INSPECTION Examine the surface of the glass for scratches corro sion chips cracks surface flaws or nicks To do this shine a very bright concentrated light at an angle of about 45 degrees A defective glass will glisten as the light strikes imperfections Glass which appears cloudy or roughened and will not respond to cleaning should be replaced STORING Keep gauge glass in original packaging until ready to install 21 SUSSMAN ELECTRIC BOILERS Installation Operation amp Maintenance Manual Element Replacement READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK IN PAKAO Before Installing your new elements be sure the McDonnell Miller low water cut off and aux low water cutoff if sup plied is operating properly The float chamber and lower equalizer col umn of the MM control must be completely clear of sludge or other for eign matter Failure to do this may cause the immediate burn out of the
16. ble to determine KW Boiler rating when steam load and feedwater temperatures are known ii d 0 2 10 15 25 40 50 75 100 125 150 40 3347 3355 3375 3388 3406 3422 3431 3447 3458 3464 3470 50 3318 3326 3345 3359 3376 3392 3401 3417 3429 3435 3441 60 3288 3296 3316 3329 3347 3363 3372 3388 3400 3407 3411 70 3259 3267 3287 3300 3318 3334 3343 3359 3370 3376 3382 80 3229 3238 3278 3271 3288 3305 3313 3329 3341 3347 3353 90 3200 3208 3238 3242 3259 3275 3284 3300 3312 3318 3324 100 3171 3179 3199 3212 3229 3246 3255 3271 3283 3288 3294 110 3142 3150 3170 3183 3200 3217 3225 3242 3253 3259 3265 120 3112 3210 3140 3154 3171 3287 3196 3212 3224 3230 3236 130 3083 3091 3111 3124 3142 3160 3167 3183 3195 3200 3206 140 3054 3062 3082 3095 3113 3129 3137 3154 3165 3171 3177 150 3025 3032 3052 3066 3083 3099 3108 3124 3136 3142 3148 160 2995 3003 3029 3036 3054 3070 3079 3095 3107 3113 3118 170 2966 2974 2994 3001 3025 3041 3050 3066 3077 3083 3089 180 2937 2945 2964 2978 2995 3011 3020 3036 3048 3054 3060 190 2907 2915 2935 294
17. blinking press or to select press DAYLIGHT SAVING TIME OK In the Run mode use a pencil point and press hr 15 Arrows for days lt blinking press or to select See for Daylight Saving Time and current time advances possible combinations below one hour and hr displayed To revert back to 16 Press Menu to end or press OK and repeat steps 8 to Standard Time press hr and current time falls back 15 to set more ON OFF times one hour and 4 hr display disappears PROGRAMMED DAY COMBINATIONS PROGRAMMING CONFLICTS Every day arrows 4 on all days Monday to Saturday Switch Off commands have priority over switch On Monday to Friday commends Saturday and Sunday NOTES Any individual day 1 The timer is set according to the boiler operation When the timer is ON the boiler is ON and the RUN MODE blowdown is OFF On Run mode display will show current time date on off status override automatic status hourly on off setting for the day and Daylight Saving Time 2 Timer must be powered up during programming to display On Off status 3 During programming if no button is pressed after 1 minute the timer will revert back to Run mode 12 SUSSMAN ELECTRIC BOILERS PROGRAMMING For electric steam boilers equipped with Automatic Blowdown Systems ES 81600 refer to the following instructions for time clock operation and settings Timer settings for blowdown operation are at the discretion of th
18. connect power voltage to line side of contactor 3 Power Fuses only on boilers rated 120 amperes and larger 4 See Parts List for contactor and heating element information SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Wiring Diagram Control Circuit ES Electric Boilers Basic Control Circuit 120V 1PH INPUT CONTROL FIELD WIRING TERMINAL FACTORY WIRING ON OFF SWITCH lt SOLENOID VALVE LIQUID HIGH LIMIT OPERATING CONTACTORS LEVEL PRESSURE PRESSURE CONTROL CONTROL CONTROL ES Electric Boilers with Manual Reset Auxiliary Low Water Cutoff 120V 1PH INPUT L IN FIELD WIRING BLOCK FACTORY WIRING ON OFF i 4 SWITCH 7 I e PILOT LIGHT m DX SOLENOID VALVE uh 1 5 4 I Wy PUMP MOTOR T RELAY 7 E i D ll HIGH LIMIT OPERATING CONTACTORS LIQUID 6 PRESSURE PRESSURE LEVEL CONTROL CONTROL CONTROL NC Q a t 622 com PILOT AUX LWCO LIGHT PC BOARD No MANUAL RESET SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Wiring Diagram Control Circuit nuin ES Electric Boilers with Sequencer CONTROL TERMINAL FIELD WIRING BLOCK FACTORY WIRING ON OFF
19. e owner operator The weekly program dial shows the seven days of the week and AM PM imprints for each day The time switch is set by pushing the captive trippers to the outer ring position for the entire period that the load is to be turned ON i e 2 hours to each trip per on the 7 day dial When the tripper is pushed to the inside the switch is in the OFF position SETTING TIME To set the current time and day of week turn the minute hand clockwise Do not set the time by rotating Outer Dial Turn the minute hand clockwise until the day of the week and the time of day on the outer dial is aligned with the triangle marker on the inner dial two o clock Example for 7 day program dial Monday 10 30 am Turn the minute hand clockwise until Monday 10 30 AM is aligned with the triangle on the inner dial The hour and minute hand will show exactly 10 30 FOR MANUAL OVERRIDE Manual override can be accomplished at the discretion of the owner operator as follows 3 WAY MANUAL OVERRIDE SWITCH permanent ON automatic 1 permanent OFF i IMPORTANT It is recommended that for periodic and effective blowdown the override switch be set in the automatic setting 24 Hour and 7 Day Time Switches Installation Operation amp Maintenance Manual HAZARD OF ELECTRIC SHOCK DISCONNECT ALL ELECTRICAL POWER BEFORE WORKING ON BOILER Sussman Electric Steam Boilers are designed for years
20. eck valves are required to avoid damage to pump 3 Connect steam line with customer supplied outlet valve to boiler steam outlet NOTE For best performance a globe valve rated for steam service higher than the maximum boiler pres sure should be plumbed on the steam outlet line failure to do so can cause heating element breakdown See page 1 for steam outlet valve size 4 Provide for boiler drain connection a daily blowdown is required A Blowdown Separator Tank may be necessary check with local code 5 Safety valve shall be plumbed according to local code NOTE The safety valve shall not be plumbed with a line sized less than the outlet size of the safety valve SUSSMAN ELECTRIC BOILERS ALL ELECTRICAL WIRING MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN IN ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES Installation Operation amp Maintenance Manual Assure that the power voltage and phase being supplied to the boiler matches the power voltage and phase of the boiler Connecting incorrect power supply can damage boiler components or cause improper boiler operation If the boiler power requirements do not match the power to be supplied to the boiler the boiler must be returned to the factory for conversion Boilers cannot be field converted ALL BOILERS ARE PRE WIRED AND TESTED PRIOR TO SHIPMENT 1 2 Ground boiler according to National Electric Code requirements to avoid shock Power wiring to boile
21. ed into the tappings the same number of turns distance A distance B 3 Remove glass packing nut friction washer or packing gland depending upon the model and glass packing from the fittings and place them in the same order on to both ends of the gauge glass Push both packings about an inch up the gauge glass 4 Gently insert one end of the glass into the top gauge fit ting Keeping the glass inside the top fitting gently rotate the top gauge fitting clockwise until vertically aligned with the bottom gauge then insert glass into bottom fitting until glass bottoms out on the shoulder inside the bottom fitting 5 Carefully raise glass about 1 16 and slide lower glass packing down until the glass packing contacts the lower gauge fitting DO NOT allow the glass to remain in con tact with any metal 9 Carefully slide upper glass packing up as far as possible 7 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 lightly a quarter turn at a time checking for leakage after each turn IMPORTANT NOTE Read all warnings and instructions before performing instal lation or maintenance Top Gauge Fitting J ZZ En ag il ines T J Z TT 22 SS Gauge Glass Guard Rod _ y Glass Packing Friction Washer Nut or Packing Gland 74
22. em is a must for boilers connected to a condensate return tank The vacuum breaker consists of a spring loaded disc and associated piping and is factory plumbed to the boiler AUTOMATIC BLOWDOWN SYSTEM Extends life of boiler Saves labor costs Starts the boiler automatically every day e Shuts down the boiler every day Automatically blows down the boiler every day Completely programmable can skip days different start and shutdown times different operational durations ES81600 for all model boilers A stainless steel motor driven straight through self clean ing ball valve with Teflon seats handles particles and dirty fluid without the use of an up stream strainer or other Cleaning device A timer Standard analog time clock is set for two hour time intervals optional digital time clock can be programmed to one minute intervals and elec tronic time delay relay control the boiler and the blow down valve A pilot light indicates when the blowdown valve is open The valve shall be plumbed to a proper drain or recepta cle An automatic blowdown system can be installed on any boiler regardless of size operating pressure or operat ing duty cycle CONTROL VOLTAGE STEPDOWN TRANSFORMER Provides 120 Volt 220 Volt export from main power supply Factory wired and fused BLOWDOWN SEPARATORS see page 17 For models ES12 48 PN BDT ASME36 For models ES60 180 PN BDT ASME42 A separator accepts the flash stea
23. entification Models ES HU symeou Tem ES12 48 esza 72 5100 EST35 t80 WATER STEAM Overall Height 36 44 59 61 INLET OUTLET Length Overall Length 28 33 34 38 ES 12 18 HU 40 55 1 2 NPT 1 2 NPT Width Overall Width 20 22 26 30 ES 24 72 HU 75 205 1 2 1 NPT A Steam Outlet 6 1 4 10 8 1 4 9 ES 100 HU 310 1 2 NPT 1 1 2 NPT B Steam Outlet 10 1 4 17 1771 4 18 1 4 ES 135 180 HU 410 550 61 1 2 NPT 2 NPT 1 EHE Allow minimum 21 inches clearance in front of door for servicing of heating D M M Drain Valve 6 1 2 6 6 1 4 6 1 4 elements Recommended clearance 24 inches all around boiler for servicing E Check Valve 14 9 17 16 3 4 F PV Drain Valve 2 3 4 2 1 4 2 3 4 2 34 G PV Drain Valve 6 1 4 9 1 2 7 34 9 1 4 J Clearance 3 3 4 3 1 2 4 K Check Valve 2 1 2 2 3 4 3 M Door Width 8 3 4 14 Allow 24 inches all around for servicing SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Dimensional amp Clearance Specifications Operati High Limit Pressure Funa Pressure Gauge Front F Wdih gt lt Length gt Side Elevation Front Elevation Allow 24 all around for servicing Clearance from combustible surfaces A 1 Clearance above top of boiler B A Clearance fr
24. ers are susceptible to lightning damage due to water line connections An industrial type lightning surge protector should be installed according to the manufacturer s recommendation at the service entrance Consult your contractor or electrical dealer Jw Substitution of components or modifi cation of wiring system voids the warranty and may lead to dangerous operating conditions Installation Operation amp Maintenance Manual SUSSMAN ELECTRIC BOILERS Pre Operation Check All Boilers LWCO PUMP CONTROL OPERATION AND TESTING Boilers equipped with an auxiliary low water cut off control with a manual re set button required as 1 All valves for incoming water supply are to be fully opened Main disconnect switch is to be in the on position Boiler main switch is to be in the on position Since boiler will be empty the pump or solenoid will be energized allowing the boiler to fill with water Control will automatically fill boiler to proper operating water level and the pump solenoid will be de ener gized Contactors will then energize applying voltage to the heating elements Pump switch operation at this point water should be visible approximately half way up the sight glass Slowly open the drain valve located at the bottom of the boiler Water level in the sight glass will begin to drop allowing the low water cut mandatory equipment is some states once the correct operating water level has bee
25. ly open for the automatic blowdown to be effective 1 Program time clock by setting the time boiler is to turn on and off daily Refer to instructions in time clock insert 2 When the time clock turns the boiler off the blow down is activated A red pilot light over the time clock will come on and remain on while the motorized ball valve is open The time duration the valve is open is set by an adjustable potentiometer built into the time delay board The water level in the boiler after blowdown is complete will be approximately at the lower gauge glass valve Elements are not exposed to air between operations 3 Boiler will automatically refill at next programmed on cycle Blowdown program can be overridden to allow for unscheduled blowdown or operational cycles Refer to the time clock instruction insert SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Digital Timer Operation Instructions 0 2 4 6 8 10 12 TO SET TIME amp DAY OF 14 CLOCK C4hRM 1 1 Press Menu ON OFF STATUS wee 2 24h AM or PM blinking press e R 5 or to select press OK ON symbol displayed when timer is on and OFF su fe no 3 Hour 12 00 blinking press symbol displayed when timer is off m 9 or to select press s0 50 4 Minute 12 00 blinking press OVERRIDE AUTOMATIC o is e or
26. m and effluent from the boiler blowdown and reduces the temperature and pressure to insure a safe discharge of water and sludge Steam flash and pressure are absorbed and pass harmlessly to the out side via a vent The separator design utilizes a water seal at the outlet which permits the operator to introduce cold water from the bottom to mix with the hot water and boiler steam in the blowdown separator This reduces outlet tem perature to a safe discharge level These separators require specific plumbing from the boiler blowdown valve and require connection to a cold water sup ply If the separator is less than half full of water after the boiler is blown down cold water must be added to bring the water level to the halfway mark before the next blowdown 0 30 psig pressure gauge 0 200F temperature gauge water sight gauge glass and valve set assembly are included MULTISTAGE LOAD PROGRESSIVE SEQUENCERS Accurate control is provided by automatic progressive sequenc ing in the use of energy and minimizing wear on electrical components The sequencers are designed to apply power pro gressively to larger KW boilers A factory installed pressure sen sitive sequential control reacting to steam boiler pressure pro gressive energizes or de energizes heating elements through power contactors A delay between sequencer steps before start up and between each subsequent step eliminates power surges Each sequencer is matched and factory pre se
27. n reached it will be nec essary to depress the reset button in order for the con tactors to re energize NOTE For boilers equipped with an automatic blow down system For test 1 the blowdown time clock must be in the run mode before the boiler will automatically fill For test 2 and 3 in order for the drain valve to open the blowdown clock must be in the off mode See blowdown time clock insert The automatic blowdown indicator light will be on when the valve is open This light will remain on for the duration of the blowdown cycle a few seconds It may be nec essary to cycle the time clock from the run to off mode several times off pump control to energize the feed water system Close valve for proper operation 3 Low water cutout switch performance open the drain valve completely Maintain this condition until water level falls within the gauge glass enough to cause the low water cutout switch to de energize the heating elements All of the contactors will be in a de energized or open state at this time Close the drain valve water feed system will automatically refill the boiler and the contactors will re energize Pressure Controls Operation and Testing 4 Operating pressure control check Close steam outlet NOTE All boilers are provided with one high limit pressure control and at least one operating pressure control 1 The high limit pressure control is equipped with a manual reset feature
28. nance Manual ELECTRIC BOILERS Installation REFER TO NATIONAL AND ALL APPLICABLE LOCAL CODES FOR SPECIFIC INSTALLATION REQUIREMENTS 1 The boiler should be mounted on a solid level foundation 2 The boiler should be located with suitable clearances refer to page 3 and Code requirements NOTE Allow minimum of 21 inches clearance in front of door for servicing of heating elements 3 Do not install boiler in any location where water could freeze 4 Do not install boiler outdoors 5 Do not install boiler near flammable or corrosive materials 6 Do not install boiler in a location where leakage from the boiler tank or piping can damage to adjacent areas or to lower floors of the structure Provide a floor drain and properly sloped floor from the boiler towards the drain or install a suitably plumbed drain pan under the boiler NOTE Allow a minimum of 36 inches of clearance in front of door for servicing of heating elements ALL PIPING SHOULD BE INSTALLED BY A QUALIFIED LICENSED PLUMBER IN ACCORDANCE WITH NATIONAL AND LOCAL CODES 1 When water feed is other than pump type the water supply pressure must be 10 psig greater than boil er operating pressure to assure water supply maintains proper water level in the boiler Insufficient water levels can result in improper boiler operation Keep feed water valves open at all times during normal operation 2 If pump and boiler are plumbed within 30 feet pipe length a minimum of 2 ch
29. new elements If the unit is probe equipped check condition of the Boiler vith MDonnell Miller 1 Steam Equalizing Pipe Pump and Low Water Control Normal Boiler Water Line probes and isolator All elements are thoroughly checked before shipment The manufacturer cannot be responsible for burn outs caused by a faulty low water cut off The lower equalizer column can best be examined by breaking the unions on either side and then visually and manually examining the piping with your finger or probes to see if it is clear and clean 1 Disconnect boiler from electric power supply at main safety switch or fuse panel Then turn boiler switch to OFF position 2 Close water supply valve on incoming water supply line Drain boiler completely of water 3 Open boiler door to access heating element 4 Disconnect wire electric leads connecting element to main power system of boiler Again note wire connections to facilitate re assembly Proceed to remove and discard 6 bolts from flange IMPORTANT Note the wire connections to facilitate re assembly see wiring schematic Remove and discard six 5 16 18 bolts from flange Do not reuse these bolts 5 Thoroughly clean boiler flange of all foreign material Be certain no part of old gasket remains on flange 6 Apply Slic Tite Gasket Compound or equal to both surfaces of new gasket supplied with replacement element Proceed to install element flange assembly with gasket
30. o proper operating levels and the reset button is pushed Do not depress the reset button before the correct water level is achieved LINE PRESSURE WATER FEED SYSTEM For model ES amp HU boilers PN ES99117 Water feed system used to supply makeup water to the boiler when incoming water line pressure is 10 psig greater than the operating pressure of the boiler Completely factory plumbed and wired 0 100psig range 1 2 NPT size Consists of strainer solenoid valve 120 1 50 60Hz and check valve for automatic feed HIGH PRESSURE WATER FEED SYSTEM For model ES12 72 PN ES38002A For model ES100 180 PN ES38020A Used to supply makeup water and to maintain constant water level when the boiler operating pressure is equal to or greater than incoming water line pressure and conden sate is not returned to the boiler ES38002A Range is 0 100 psig 1 2 NPT size consisting of strainer solenoid valve and 1 3 HP 120 1 60 motor and pump ES38020A Range is 0 125 psig 3 4 NPT size consisting of strainer solenoid valve and 1 2 HP 120 1 60 motor and pump These assemblies are mounted on rubber shocks and secured to a steel base mounting plate These units require field plumbing and wiring to the boiler CONDENSATE RETURN SYSTEM see page 16 For model ES12 72 PN ES38083V for model ES85 180 PN ES38084V These systems are used whenever condensed steam can be collected for reuse in the boiler Returning the conden
31. of trou ble free performance To establish a good preventative mainte nance program we suggest that the facility maintenance per son or engineer familiarize themselves with these simple rules 1 Daily blowdown at pressure is essential for ideal boiler performance Extended periods of operation may require more frequent blowdown If the boiler is not equipped with an automatic blowdown in order to safeguard the heating elements it is recommended to turn both the main disconnect switch and the boiler switch to the off position before manually blowing down the boiler 2 The sight glass should be checked frequently to assure the boiler has adequate water 3 The sight glass should be checked daily for damage i e scratches erosion leaks etc The sight glass should be replaced if damaged See insert 4 A monthly inspection should be made of the internal wiring Open the access door and check all electrical connections for tightness Replace any wires that show signs of damage NOTE The electrical power MUST be shut off during this maintenance procedure 5 Heating element mounting bolts should be checked and tightened to a torque of 22 ft Ibs If there are indications of steam leaks from an element replace the element gasket 6 A monthly check for leaks should be made any loose or damaged fittings should be tightened or replaced 7 Every four months the boiler float control should be checked for proper operation The lower
32. oiler steam pressure will gradually increase to the operat ing pressure control set point at which time the con tactor s will de energize 7 With steam demand the boiler steam pressure will decrease When the boiler pressure has dropped below the operating pressure control differential set amount the contactor s will re energize Note Adjust steam outlet valve such that the boiler pres sure does not drop more than 20 below reset 8 The boiler is equipped with float type liquid level con trols employing micro switches They are extremely sensitive and reliable and will maintain the proper water level within the boiler pressure vessel automati cally during boiler operation 9 The boiler should be blown down daily See blow down instructions A daily blowdown is an essential part of boiler operation It is the best and most important part of preventative maintenance you can give your boiler and will add years of life to the unit Make sure a blowdown schedule is established and followed regularly In extremely hard water areas blowdown may be necessary more than once a day If there is a particular problem that applies to your local water condition i e high concentra tions of minerals etc we recommend a consultation with a reputable local water treatment engineering firm Pre treating the boiler feed water may reduce mineral accumulation enough to allow a daily blowdown to be sufficient MANUAL BLOWDOWN INSTRUC
33. om Front of boiler Prefix C to numeral indicates acceptability for closet or alcove installations prefix acceptability for alcove installations but not for closet installations D 1 Clearance from back of boiler EL 1 Clearance from left side of boiler ER 16 Clearance from right side of boiler F C indicates type of flooring NC for non combustible C for combustible G Total minimum free area in square inches of close ventilating openings SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Typical Wiring Diagrams Three phase power circuit with separate 120Volt control circuit With singe phase power circuit insert Three phase power circuit with step down transformer Detailed ES81017MR auxiliary low water cut off wiring ES81600 Auto blowdown wiring diagram Detailed sequencer package wiring diagram Q n gt o Wiring Diagram Power Circuit ES Electric Boilers Power Circuit THREE PHASE FIELD WIRING SINGLE PHASE MAIN POWER FACTORY WIRING MAIN POWER SUPPLY SUPPLY uu 6 TERMINAL POWER BLOCK E see note 1 EMEN lj Tm T POWER FUSES L 4 L 4 tt FB a TRANSFORMER EXE optional C TO CONTROL CIRCUIT HEATING H7 ELEMENTS H H8 NOTES 1 Power Terminal Block only on boilers with two or more contactors 2 On boilers with only one power contactor
34. on High Pressure Water Feed System Condensate Return System Vacuum Breaker Systems Automatic Blowdown System Control Voltage Stepdown Transformer Blowdown Separators Multistage Load Progressive Sequencers Condensate Return Systems Blowdown Separator Tanks Specification Charts ES amp HU Installation Operation IMPORTANT NOTE As you follow these instructions you will notice warning and caution symbols This blocked information is important for the safe and efficient installation and operation of electric boilers These are two types of potential hazards that may occur during this installation and operation DEN DIESE states hazard which may cause serious injury or death if precautions are not followed YN CAUTION signals a situation where minor injury or product damage may occur if you do not follow instructions IMPORTANT NOTE This highlights information that is especial ly relevant to a problem free installation SUSSMAN ELECTRIC BOILERS FA A Division of Sussman Automatic Corporation 43 20 34th Street Long Island City NY 11101 718 937 4500 1 800 238 3535 e Fax 718 937 4676 email seb sussmancorp com www sussmanboilers com C US LISTED PUR 101137 4 13 SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Dimensional Information amp Component Id
35. r should be in accordance with National and Local Electrical Code requirements fol lowing wiring diagram supplied Use proper size wire Wire size is specified adjacent to field wiring terminals This label states the wire size AWG or MCM mini mum temperature rating 90 C and conductor material copper only Deviation from these requirements may result in improper or unsafe boiler operation A disconnect switch employing circuit breakers or fuses should be installed between the main power source and the boiler This disconnect switch should be located near the boiler and clearly marked for easy access and identification should the boiler need to be turned off due to an emergency Boiler control circuit is 120 Volt Unless boiler has an optional step down transformer a separate 120 Volt power feed wiring is required to be connected to the control circuit terminal block A 15 Amp circuit is required for all boilers If a 3 4 HP feed water motor and pump assembly is connected to the boiler then a 20 Amp circuit is required 5 f a separate control circuit is used it should be con nected to the control circuit terminal block 6 Remote mounted water feed systems i e condensate return motor and pump should be connected to the junction box provided on the outside of the boiler jacket 7 With main power off make sure all wiring termina tions are tight to avoid arcing carbonizing or over heating of contacts Boil
36. re feedwater is introduced into the boiler and steam is produced If the suspended solids are allowed to concentrate beyond certain limits a deposit or scale will form on the boiler s internal surfaces This deposit can interfere with proper boiler operation and cause boiler failure The concentration of these impurities is generally controlled by the feedwater quality and by blowdown Blowdown refers to removing a portion of the boiler water with high solids concentration and replacing it with make up water of a lower concentration 23 cL ISSMAN A Division of Sussman Automatic Corporation FA 43 20 34th Street Long Island City NY 11101 e 718 937 4500 MT 1 800 238 3535 e Fax 718 937 4676 email sebGsussmancorp com Us ELECTRIC BOILERS www sussmanboilers com LISTED PUR 101137 4 13
37. t to boil er system requirements Electronic progressive sequencers give accurate control of multi stage loads of the type used in steam boilers Features include progressive sequencing first on first off that equalizes the operating time of each load Integral solid state light emitting diodes show active stages Should a power interruption occur all elements are instantly de energized for safety Upon resumption of power the control will re stage the loads one at a time 15 SUSSMAN Installation Operation amp Maintenance Manual ELECTRIC BOILERS Condensate Return Systems Models 38083V amp 38084V B 9 V DIA COVER PLATE EASY ACCESS FOR MAINTENANCE i VENT WITH SAFETY BAR lt VENT SAFETY BAR l p Lures od ie 3 CONDENSATERETURNFLASHTUBE ae ALLA ao FLOAT VALVE _ 1 2 COLD WATER INLET COUPLING label 39010 F OVERFLOW OUTLET 1 NPT farside 1 OVERFLOW label CONDENSATE RETURN label N Ee poe CNN 1 14 CONDENSATE Dye SIMPLE RUGGED LINKAGE RETURN COUPLING E JL MN TOP VIEW SIGHT GLASS 99074 1 5 DIA UPPER FLOAT BALL SITE GLASS ASSY GHO 991738 T 3018 E H VA DRAIN VALVE SHUTOFF GATE VALVE PUMP EASY ACCESS STRAINER CLEANOUT Notes 1 Motor Pump is closed Coupled design 2 Pump capacity as follows MODEL 38083V MODEL 38084V GPM 125 ft 225
Download Pdf Manuals
Related Search