LG Boiler 30 User's Manual
Contents
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6. MAS MAOZ SYOLOVLNOD dWYSZ 690 Z Z 5 AObZ 5 062 6000 Jo 59 LINDUID dIVO9 31064 SET9Z Z SUYALVSH MAS 20007 SUYALVSH SOOOT SYALVSH 8 SUYALVSH 9 6 X079 TWNIWYAL dINVOOT T9OET 1 gt 1 dINVOS 9 T YOLODVLNOD 9 YOLOVINOD 690 YOLODVINOD dINVSZ 690 802 LINDUID 3104 ZET9Z T YAVIY LINDUID 3104 6192 LINDUID dWYOS 3104 9 LINDUID 31046 SET9Z 3 5 NOIST MAOT MASZ MAOZ SUALVSH SUALVSH AOEZ M1S 9 6000 10 10 SUYALVSH 8 SUYALVSH 6 46 SUYALVSH AOEZ MAS 25007 SYALVSH 5 SUYALVAH MAS 24007 jo SUYALVSH MAEE E VOOOT SYOLOVLNOD dWYSZ 690 2 SYOLOVINOD dWYSZ 690 2 5 SUYALVSH MAS 80007 lt 80 20001 SUYALVSH MAS 80007
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8. VIE 71 2 51 2 ADIAYAS 91342313 303 sJ10H 1 gt 2 1 61 GAVIN H 91 viva oD 5 JO 5 4 Ayed Aue q p sops p aq jou oD Joeu 5 Ayadoud SIUL 28 2 L OMO a 7 6 7181 U a 2876 6 2 1 7 SagOud 13437 YALVM 353 OL 1 5 Il 6 ox 0 Z 1 GTI ADIAYAS 3034
9. 18 32 SD PAR EGE NUNS 18 21 5 1 1 LG LOW PRESSURE 0 15PSD 2 1 18 5 1 2 LG LOW PRESSURE MAFD 0 15 81 19 5 1 3 LG HIGH PRESSURE 0 30 0 100 5 20 5 1 4 LG HIGH PRESSURE MAFD 0 30 0 100 5 0 21 5 2 INSTALLATION DATA SHEETS 22 25 5 2 1 LG LOW PRESSURE 0 15PSI 22 5 2 2 LG LOW PRESSURE MAFD 0 15 81 5 23 5 2 3 LG HIGH PRESSURE 0 30 0 100 81 06 24 5 2 4 LG HIGH PRESSURE MAFD 0 30 0 100 5 25 5 3 CONTROL WIRING SCHEMATICS 26 29 5 31 LG LOW PRESSURE O ISPSD 26 5 3 2 LG LOW PRESSURE MAFD 0 15PSI 27 5 3 3 LG HIGH PRESSURE 0 30 0 100 81 2 0020 000 0 00009 28 5 3 4 LG HIGH PRESSURE MAFD 0 30 0 100 5 29 5 4 HEATER WIRING SCHEMATICS 30 32 5 4 1 LG 10 30KW THREE PHASE 30 5 4 2 LG 10 30KW SINGLE PHASE 0060000000000900 00040933 31 5 4 3 LG 10 30KW THREE AND SINGLE PHASE 550 600 32 6 TERMS amp CONDITIONS 2 2222 2 2 2 0000000000000 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 1 INSTAL
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11. User Manual amp Installation Instructions LG 10 thru LG 30 IMPORTANT READ ALL INSTRUCTIONS BEFORE OPERATING e All steam boilers are built in accordance with ASME miniature boiler code NOTE It is the responsibility of the installer to conform to 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 gt www electrosteam com rev 12282009 ESTABLISHED 1952 WARNING The following labels have been placed this boiler for YOUR SAFETY Failure to observe these instructions could lead to PROPERTY DAMAGE SEVERE INJURY or even DEATH CAUTION HOT HIGH VOLTAGE AUTHORIZED PERSONNEL ONLY ALTO VOLTAJE SOLAMENTE PERSONAL AUTORIZADO CAUTION THROW OFF MAIN POWER SWITCH BEFORE WORKING ON ELECTRICAL CABINET MANUAL WAS SHIPPED WITH THIS BOILER IT IS IMPORTANT THAT YOU READ UNDERSTAND AND OPERATE THIS STEAM GENERATOR IN ACCOR DANCE WITH THE OPERATING INSTRUCTIONS CONTAINED IN THE MANUAL IF FOR ANY REASON YOU DO NOT HAVE A MANUAL CALL ELECRTO STEAM AT 800 634 8177 REPLACE GLASS EVERY SIX MONTHS RETIGHTEN SIGHT GLASS BEFORE USE FOR A MINIMUM OF 90 C 01 834 EXCEED 105 F PAR 4
12. dWVOOT 9 YOLOVLNOD dINVSZ 690 YOLOVLNOD dINVOS Z9OET LINDUID 41042 STT9Z T 41082 9 MAST NOIOT 696 696 es SUYALVSH 8 SYALYIH AOEZ lt 79 6000 SUYALVAH AOEZ MAS 25001 SYALVSH AVIZ 5 6 SUYALVSH MAS 80001 SYOLOVILNOD dWYSZ 690 2 SYOLODVINOD dWYSZ 690 Z SYOLDVLNOD dWYOS 490 2 lt 5 LINDUID 0 lt 31044 LETZ Z lt 5 LINDUID 3104 Z 5 93498 LINDUID dINWOE 3104 EET Z 32018 TWNINYAL dWYOOZ P9OET 32018 TWNIWYAL 9 32018 T9OET 2 MASZ MAOZ 2 MAST 2 MAOT 2 802 lt MASZ OT 2 802 MAOZ ST 2 802 MAOT SUYALVSH 70007 SUYALVAH 80 2
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16. 28 2 Kg hr 55 2 LB hr 25 0 Kg hr 51 8 LB hr 23 5 Kg hr LG 25 86 0 LB hr 39 0 Kg hr 77 4 LB hr 35 1 Kg hr 68 8 LB hr 31 2 Kg hr 64 5 LB hr 29 3 Kg hr LG 30 103 5 LB hr 47 0 Kg hr 93 2 LB hr 42 3 82 8 LB hr 37 6 Kg hr 77 6 LB hr 35 2 Kg hr 17 of 33 4OT 193 5 0 67 90 NHO OOTOO0 0E0 OTO TZE 31725 0 61 90 4 10 61 90 1 5 BEVO ELOO O d OS 933055334 10 67 90 33 0151 1 97 SLYVd LLL MAIA 10 3 5 Ox MAIA AQIS al lt 0 Le 2 ALS
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18. 46 8 48 9 51 1 33 28 4 29 4 30 1 21 5 22 5 23 5 17 2 18 18 8 LG 25 65 6 69 3 57 6 60 1 39 9 42 34 7 35 5 27 6 28 8 30 1 22 1 23 1 24 1 LG 30 81 2 85 9 67 4 70 4 49 4 39 1 40 6 41 5 32 3 33 7 35 2 25 8 27 28 1 SINGLE PHASE AMP DRAW CALCULATIONS AMPS Input Voltage 208 220 230 240 380 400 415 425 440 460 480 550 575 600 LG 10 48 1 50 9 39 9 41 7 19 1 20 20 8 15 3 16 16 7 LG 15 72 1 62 4 65 2 68 1 28 6 29 9 31 3 22 9 24 25 Not possible with odd LG 20 93 8 81 1 84 8 88 5 numberof heaters 37 2 38 9 40 6 29 8 31 1 32 5 LG 25 114 120 99 8 104 47 7 49 9 52 1 38 2 39 9 41 7 LG 30 141 149 117 122 55 9 58 4 60 9 44 7 46 7 48 8 16 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 4 4 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 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 FORMULAS TO CA
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20. 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 brush and reinstalled using a new gasket If you are replacing or cleaning your heater elements 1 Place Toggle Switch 2 and Main Disconnect Box in OFF position 2 Make sure generator is cool and the Pressure Gauge 15 reads 0 PSI 3 Remove heater wires from heater s using an 11 32 or 3 8 Socket 4 Unbolt and remove heater s using a 1 2 Socket NOTE Heater s may be difficult to get out you may need to use some sort of pry bar to get them loose 5 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 NOTE If you are replacing a heater because of a heater failure you must also clean the probes and clean out the chamber or you may have another heater failure within 48 hours 7 of 33 LG 10 thru LG 30 User Manual Electro Stea
21. 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 equipment and service supplied shall conform to the description in the quotation and agrees to repair or replace 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
22. with the 6 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 e The chamber will continue to fill with water until 1 second after the water makes contact with the C probe causing the Water Solenoid 7 and Pump 8 if high pressure to turn off e If the contactor s still have not engaged at this time you may need to press the Safety Reset 13 on the Safety Pressure Control 12 If your generator is equipped with a Manual Low Water Reset MLWR 3 it must be pressed at this time to engage the 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 the contactor s to reengage causing the pressure to rise again The contactor s will continue to cycle on and off during operation The Generator is now fully operational and will produce steam until it is turned off As steam is exhausted the water level will drop until 3 seconds after it breaks contact
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24. SUYALVAH 80 20007 lt 5 LINDUID 3104 46192 Z 5984 48 LINDUID dWYOY 3104 SETQ Z 1 gt 1 dINVSZ 690 YOLOVINOD dINVSZ 690 301291405 9 YOLDV LNOD 9 X079 TWNIWYAL T9OET T X079 TWNIWYAL dINVOOT T9OET LINDUID 3104 LET9Z YAVIY LINDUID dWVOr 3104 SET9Z YAVIY LINDUID 31046 EET9Z LINDUID 31046 TET9Z 2 802 2 802 2 802 MOIST 2 802 085 MOIST 082 MAOT 2 802 8 MAOE OT HdE 2 802 MAST OT HdE 10 SIONS 4 1 5 aos OOOTSZ OVOOLOTE __ lt 55 Ayed Aue q ped 0 22080 0 4 2 OS e gt lt uY 5 41 00290194709 3
25. 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 3 Remove Safety Valve 18 WARNING There MUST be NO PRESSURE in the chamber when removing the Safety Valve 18 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 18 is removed 10 of 33 LG 10 thru LG 30 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 5 Insert funnel into coupling where Safety Valve 18 used to be 6 Pour a 1 2 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 HOU
26. 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 12 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 3 7 SETTING THE PRESSURE CONTROLS SETTING PRESSURE CONTROLS INSTUCTIONS WARNING The pressure controls must be set while all circuits 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 Control Box 1 click on and off Familiarize yourself with this sound order in which the pressure controls must be set is the SAFETY and then the CONTROL In order 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 To DECREASE the pressure setting turn the
27. 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 1 second 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 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 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 or outside 5 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 3 CLEANING amp MAINTENANCE The following cleaning procedures 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 A WEEK BAD WATER AREAS Should be done ONCE A D
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31. 416 CAUTION USE ELECTRICAL TERMINALS ARE SUITABLE AMBIENT TEMPERATURE SUPPLY CONDUCTORS RATED FOR COPPER WIRE ONLY AROUND UNIT NOT TO LG 10 thru LG 30 User Manual Electro Steam Generator Corp TABLE OF CONTENTS 1 INSTALLATION INSTRUCTIONS 4 2 OPERATION amp SEQUENCE OF EVENTS 222 2222 22211 5 3 CLEANING amp 22 2 2222 4 1 202020202000001 6 14 3 1 MANUAL BLOW 6 3 2 CLEANING WATER LEVEL PROBES ssssesssssssssessssssssessssssssessssssseesssssseveeees 6 7 3 3 CLEANING OR REPLACING HEATERS 8 3 4 REPLACING GLASS GAUGE AND RUBBER WASHERS 8 9 3 4 1 BRASS SIGHT GLASS STANDARD 8 3 4 1 BRASS SIGHT GLASS SEISMIC 9 3 5 CHAMBER CLEANING amp CHEMICAL TREATMENT 10 11 3 6 PRESSURE CONTROL DATA SHEET 12 3 7 SETTING THE PRESSURE CONTROLS 13 14 4 CALCULATIONS amp DATA SHEETS 15 17 4 1 HEATER POWER amp VOLTAGE RATINGS 15 4 2 TOTAL POWER RATING CALCULATIONS 15 4 3 AMPERAGE CALCULATIONS 16 4 4 ACTUAL POWER RATING CALCULATIONS 17 4 5 STEAM CAPACITY CALCULATIONS 17 5 DRAWINGS amp WIRING 68
32. ATER SUPPLY Connect city water line to Y Strainer 6 Purity NOT to exceed 26 000 OHMS per CM Temperature Range 32 140 F or 0 C 60 Pressure Range 20PSI 150PSI CAUTION The Pump 8 requires clean tap water If the water is not free of foreign matter 5 micron cartridge filter should be installed in the water supply line STEAM OUTLET Connect Steam Outlet Valve 16 to piece of equipment vessel room or area to be operated by the Electro Steam Generator SAFETY VALVE amp DRAIN Separately route the Safety Valve 18 amp Drain 23 to a high temperature drain PVC Discharging pipe of the Safety Valve 18 should never be smaller than the valve outlet and should be rigidly supported placing no weight on the safety valve itself If equipped with Motorized Auto Flush amp Drain MAFD 20 it should be routed with the Drain 23 4 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 2 OPERATION amp SEQUENCE OF EVENTS IMPORTANT READ INSTALLATION INSTRUCTIONS BEFORE OPERATING 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 switch in ON position Place ON OFF Switch 2 in ON position e The 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
33. AY NORMAL WATER AREAS WITH MAFD Should be done TWICE A MONTH BAD WATER AREAS WITH 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 and Main Disconnect Box 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 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 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 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 To
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35. DEFINITIONS Total Power Rating FH Pu Heater Power Rating Number of Heaters MODEL UNIT LG 10 LG 15 LG 20 LG 25 LG 30 Heater Power Rating Watts 3 333 5 000 6 500 8 333 9 750 Number of Heaters 3 3 3 3 3 Total Power Rating Watts 10 000 15 000 19 500 25 000 29 250 15 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 4 3 AMPERAGE CALCULATIONS The INPUT VOLTAGE PHASE TOTAL POWER RATING and HEATER VOLTAGE RATING are used to calculate the amperage NOTE 380 425V heaters are not usually rated for 380 425V They are usually 208 240V heaters that have been re stamped 380 425V and wired in series FORMULAS TO CALCULATE AMPERAGE THREE PHASE SINGLE PHASE 380 425V 208 240V amp 380 425V using 208 240V heaters 440 600V using 208 240V Vi _ Not possible with 2 Le gt odd number of 43 208 240V amp 440 600V i DEFINITIONS I Amperage Input Voltage Total Power Rating Vu Heater Voltage Rating THREE PHASE AMP DRAW CALCULATIONS AMPS Input Voltage 208 220 230 240 380 400 415 425 440 460 480 550 575 600 LG 10 27 8 29 4 23 1 24 1 16 9 134 13 9 14 2 11 11 5 12 8 82 9 22 9 62 LG 15 41 6 36 37 7 39 3 25 4 21 8 22 6 23 2 16 5 17 3 18 13 2 13 8 14 4 LG 20 54 1
36. 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 REPAIR 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 writt
37. LATION INSTRUCTIONS LITTLE GIANT LG 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 close 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 CONNECTIONS Periodically check all plumbing and electrical connections for tightness this should also be done before initial start up ELECTRICAL This generator must be connected to a disconnect switch protected by fuses or circuit breakers with the proper size wire by a licensed electrician in accordance with N E C and your local codes Voltage KW and Phase requirement are marked on the nameplate W
38. LCULATE ACTUAL POWER RATINGS THREE PHASE SINGLE PHASE P I V 3 DEFINITIONS Pa Actual Power Rating I Amperage Input Voltage ACTUAL POWER RATING CALCULATIONS KW Input Voltage 208 220 230 240 380 400 415 425 440 460 480 550 575 600 LG 10 10 11 2 9 18 10 11 1 9 26 9 97 10 5 84 9 18 10 8 4 9 18 10 LG 15 15 13 7 15 16 3 16 7 15 1 16 3 17 1 12 6 13 8 15 12 6 13 8 15 LG 20 19 5 17 8 19 5 21 2 21 7 19 7 21 2 22 2 164 17 9 19 5 164 17 9 19 5 LG 25 23 6 26 4 23 25 26 3 29 1 24 9 26 1 21 23 25 21 23 25 LG 30 29 3 32 7 26 9 29 3 32 5 27 1 29 2 30 6 24 6 26 9 29 3 24 6 26 9 29 3 4 5 STEAM CAPACITY CALCULATIONS Steam Capacity Calculations are based on the impossible feed water temperature of 2127 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 Water UNIT 212 F 140 F 90 of 212F 100 F 80 of 212F 60 F 75 of 212 F LG 10 34 5 LB hr 15 7 Kg hr 31 1 LB hr 14 1 Kg hr 27 6 LB hr 12 5 Kg hr 25 9 LB hr 11 8 Kg hr LG 15 51 7 LB hr 23 5 Kg hr 46 5 LB hr 21 1 Kg hr 41 4 LB hr 18 8 Kg hr 38 8 LB hr 17 6 Kg hr LG 20 69 0 LB hr 31 3 Kg hr 62 1 LB hr
39. R 8 Turn on generator allowing pressure to climb to 5 PSI on Pressure Gauge 15 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 18 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 will not completely fill it to the top Filling must be done manually through the safety valve coupling 12 Open Manual Drain 19 to drain generator 13 Close Manual Drain 19 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 r
40. ROLS 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 WARNING DO NOT allow the pressure to 1 Setti exceed the rating on the Safety Valve 18 ressure Contro ettings If contactor s do not turn off before the Control Safety pressure limit is exceeded manually shut High Pressure off generator open the Steam Out 16 0 100 PSI 80 PSI 85 PSI and DECREASE the pressure setting on Hich Pressure the SAFETY pressure control If you 0 30 PSI 25 PSI 27 PSI cannot get the SAFETY to control the Low Pressure pressure it may need to be replaced 0 15 PSD 11 PSI 13 5 PSI 6 Open 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 pr
41. dial COUNTER CLOCKWISE causing the indicator line to move UP the scale BLACK INDICATOR LINE PRESSURE ADJUSTMENT DIAL To INCREASE pressure setting tum dial CLOCKWISE causing dial and indicator line to move DOWN SETTING INSTRUCTIONS 1 Open the pressure control covers as shown on page 12 2 Adjust the PRESSURE ADJUSTMENT DIAL on the Adjust the CONTROL so that the BLACK INDICATOR LINE is CONTROL somewhere between and 34 of the way down from the top gene i ween 3 Adjust the PRESSURE ADJUSTMENT DIAL on the SAFETY so that the BLACK INDICATOR LINE is somewhere between 1 4 and 2 of the way down from the top ul Adjust th 4 Close the Steam Out 16 and turn on generator When the ab contactor s click on the pressure will rise If contactor s do not Somewhere __ o click on right away you may need to press SAFETY RESET Continue to watch the Pressure Gauge 15 until you hear the 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 13 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 3 7 SETTING THE PRESSURE CONT
42. eady for normal use and operation 11 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 3 6 PRESSURE CONTROL DATA SHEET oe PRESSURE PRESSURE PRESSURE SAFETY CONTROL CONTROL GAUGE ajepsyeg DIFFERENTIAL PRESSURE PRESSURE ADJUSTING eee ADJUSTMENT DIAL DIAL 5 PSI FACTORY SET NC PRESSURE CONTROL ONLY USED WITH MAFD DEFINITIONS CONTROL PRESSURE 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
43. en 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 is located rev 06042007 33 of 33
44. essure 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 click 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 14 of 33 LG 10 thru LG 30 4 CALCULATIONS AND DATA SHEETS 4 1 HEATER POWER amp VOLTAGE RATINGS LG Model units use 3 Heaters to meet the required KW POWER from the customer s specified INPUT VOLTAGE Each heater comes in 5 different KW POWER RATINGS and 4 differen
45. fety gloves and glasses during installation WASHER Before installing make sure all parts are free of chips and debris GUARD ROD 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 anew GLASS PACKINGS on the new GLASS GLASS GAUGE about an inch from the bottom PACKING 3 Now slip the following items through the top of GLASS NUT GAUGE in following order PACKING PACKING GLAND facing down GLAND GLASS PACKING NUT facing down GLASS PACKING NUT facing up PACKING GLAND facing up GLASS PACKINGS inch down from top PACKING WASHER 7 4 Gently insert GLASS GAUGE into GAUGE FITTINGS You may need to rotate GAUGE FITTINGS until vertically aligned after GLASS GAUGE is in 5 Carefully raise GLASS GAUGE about 1 16 from bottom and slide lower GLASS PACKINGS down until it makes contact with BOTTOM GAUGE FITTING DO NOT allow GLASS GAUGE to remain in contact with any GLASS PACKING _ BOTTOM metal GAUGE 6 Carefully slide upper GLASS PACKINGS as far as FITTING possible lt 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 Reins
46. ggle Switch 2 and Main Disconnect Box in OFF position 2 Make sure generator is cool and the Pressure Gauge 15 reads 0 PSI 3 Remove cover plate exposing the Water Level Probes 5 4 Use 5 16 Socket to remove wires from probes 5 Use 13 16 Spark Plug Socket to remove probes from chamber 6 of 33 LG 10 thru LG 30 User Manual Electro Steam Generator Corp 3 2 CLEANING WATER LEVEL PROBES Continued 6 Clean probes to remove rust and scaling NOTE To clean probes you may use wire wheel wire brush steal 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 7 Reinstall probes assuring each probe s length is assigned to its proper letter 8 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 9 Reinstall cover plate Water Level Probe Specifications Letter Assignment on Chamber A B C D G Water Level Probe Length 4157 4 3 4 Wire Color Assignment RED Not Used BLACK GREEN Assignment 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
47. ion 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 contracts 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
48. m 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 TOP GAUGE MUST be replaced EVERY SIX MONTHS FITTING INSTALLATION T Only properly trained personnel should install f maintain water gauge glass and connections nan ee 4 Remember to wear safety gloves and glasses during installation Before installing make sure all parts are free of chips and debris 1 Uninstall GUARD RODS GLASS GAUGE and RUBBER WASHERS You may need to rotate one of the GAUGE FITTINGS to remove GLASS GAUGE 2 Slip anew RUBBER WASHER on the new GLASS GUARD _ GAUGE about an inch from the bottom ROD 3 Now slip the following items through the top of GLASS T GAUGE the following order GLASS FRICTION WASHER PACKING g FRICTION GLASS PACKING NUT facing down NUT WASHER GLASS PACKING NUT facing up FRICTION WASHER RUBBER WASHER inch down from top GLASS GAUGE RUBBER 4 Gently insert GLASS GAUGE into GAUGE FITTINGS f WASHER You may need
49. ro 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 Damaged 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 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 transportat
50. t VOLTAGE RATINGS User Manual Electro Steam Generator Corp AVAILABLE HEATER RATINGS POWER RATINGS per MODEL KW VOLTAGES MODEL UNIT QUAN KW 3 33 208 240 480 600 LG 10 3 3 33 5 00 208 230 480 600 LG 15 3 5 00 6 50 208 230 480 600 LG 20 3 6 50 8 33 214 240 480 600 LG 25 3 8 33 9 75 208 240 480 600 LG 30 3 9 75 HEATER VOLTAGE RATINGS per INPUT VOLTAGE VOLTS Input Voltage 208 220 230 240 380 400 415 425 440 460 480 550 575 600 LG 10 208 208 240 240 208 240 240 240 480 480 480 600 600 600 LG 15 208 230 230 230 208 230 230 230 480 480 480 600 600 600 LG 20 208 230 230 230 208 230 230 230 480 480 480 600 600 600 LG 25 214 214 240 240 214 214 240 240 480 480 480 600 600 600 LG 30 208 208 240 240 208 240 240 240 480 480 480 600 600 600 NOTE 380 425V heaters are not usually rated for 380 425V They are usually 208 240V heaters that have been re stamped 380 425 V and wired in series 4 2 TOTAL POWER RATING CALCULATIONS The HEATER POWER RATING and NUMBER OF HEATERS are used to calculate the TOTAL POWER RATING Since the HEATER POWER RATINGS are in Kilowatts they must be multiplied by 1000 to convert them to Watts
51. tall GUARD RODS 9 of 33 LG 10 thru LG 30 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 Drain MAFD 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 on MAFD TIMER RELAY all the way down to 15 seconds ADJUSTMENT 2 Make sure MAFD 20 in the closed position MAFD 3 Disconnect the orange wire from the normally open TIMER RELAY NO terminal on the MAFD TIMER RELAY z 5 AFTER p 4 Reconnect the orange wire to the normally open COM NO terminal on the MAFD TIMER RELAY 5 Dial TIME ADJUSTMENT on MAFD TIMER RELAY up to the desired flush time Most commonly 3 minutes Input 120V 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 HOT WATER and STEAM to blow
52. to rotate GAUGE FITTINGS until vertically aligned after GLASS GAUGE is in 5 Carefully raise GLASS GAUGE about 1 16 from bottom 77 and slide lower RUBBER WASHER down until it makes l contact with the BOTTOM GAUGE FITTING DO NOT allow GLASS GAUGE to remain in contact with any metal 6 Carefully slide upper RUBBER WASHER up as far as possible 7 Hand tighten both GLASS PACKING NUTS then tighten BOTTOM 1 2 turn more by wrench Tighten only enough to prevent GAUGE DRAIN VALVE leakage DO NOT OVER TIGHTEN If any leakage FITTING should occur tighten slightly a quarter turn at a time checking for leakage after each turn 8 Reinstall GUARD RODS 8 of 33 LG 10 thru LG 30 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 and GLASS PACKINGS MUST be TOP GAUGE replaced EVERY SIX MONTHS _ FITTING The Seismic Sight Glass is equipped with BALL CHECKS each GAUGE FITTING INSTALLATION Only properly trained personnel should install maintain water gauge glass and connections Remember PACKING to wear sa
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