ES 24A 11.10 - Sussman Electric Boilers
Contents
1. Close steam outlet valve Boiler will build up to desired pressure and shut off automatically High Pressure Control This control will de energize the boiler should pressure within the boiler exceed the set pressure Slowly open steam outlet valve and use steam as needed Boiler should be blowndown daily see blowdown instructions on page 6 oum ES 24A Electric Steam Generator Installation Operation and Maintenance Manual Blowdown is an essential part of boiler operation It is one of the best preventative maintenance steps you can take Make sure a blow down schedule is established and followed regularly In hard water areas blowdown is necessary at least once a day In soft water areas once a week If there is a particular problem which applies to your own local water condition other than mineral content take this into consideration in determining which Schedule is to be followed 1 2 At the end of the working day while boiler is still operating turn switch to the OFF position and close water supply valve De energize wall mounted safety switch It is preferable to connect the blowdown valve directly into a drainage system when allowed by local codes If this is done the boiler can be discharged at operating pressure Consult local plumbing codes before doing so If blowing down into a receptacle allow pressure to decrease to 15 20 PSIG before opening blowdown valve When discharge is complete and boile2. M 4s N 2 O 8 ee P 24 Dimensional Table Model 24A Dimensional Table Model 24A Item Description Item Description 1 4 NPT Strainer 93806 8 4 NPT Pressure Gauge 99197 2 4 NPT 120V 60HZ Solenoid 4 OBIF 99042 9 Hi Limit Pressure Control 99066 3 NPT Check Valve 99162 10 operating Pressur Control 99966 4 4 NPT Drain Valve 99178B 11 Access Panel J 5 4 NPT Steam Outlet Nipple 100380 12 Main On Off Switch 92830 6A Gauge Glass Valve Set 99173C 13 Probe Isolator 100378 6B Gauge Glass Tube 99074 1 14 Probe Spark Plug 90229 7 4 NPT 100PSIG S Valve 99136 15 Probe 5 inch 99807F ES 24A Electric Steam Generator Installation Operation and Maintenance Manual Installation NaN Refer to National and all applicable Local Codes for specific installation requirements NOTE Reference heating element clearance requirements for particular boiler to allow for removal of elements Standard minimum suggested clearance is 21 inches 1 The boiler should be mounted on a solid level foundation 2 All piping should be installed by a licensed plumber 3 When any type water feed other than a pump feed is used the existing water supply pressure must be 10 PSIG greater than boiler operating pressure to assure water supply maintains proper water level in boiler Lack of water can result in improper boiler operation Keep feed water valves open at all times during normal operation 4 Connect ste
3. FL SUSSMAN ES 24A Electric ELECTRIC BOILERS Steam Generator Installation Operation and Maintenance Manual Model No Power Circuit Voltage Boiler Serial No Control Circuit Voltage National Board No Amps Phase Cy IMPORTANT This data file contains the National Board Registration Certificate approving your generator It must be kept near the generator at all times Products Covered by this Manual KW Design Max Work Model Range Steam Rate BHP Pressure Pressure 24A 24 73 Ibs hr 2 44 100 PSIG 90 PSIG Line water pressure must be a minimum of 10 PSIG higher than generator operating pressure or you will require high pressure water feed w motor and pump PN 101167 3 12 A Division of Sussman Automatic Corporation Fa SUSSMAN 43 20 34th Street Long Island City NY 11101 718 937 4500 1 800 238 3535 EC ELECTRIC BOILERS ax 718 937 4676 www sussmanboilers com Email seb sussmancorp com ES 24A Electric Steam Generator Installation Operation and Maintenance Manual Component Identification Dimensional Information 1 4 NPT Water Inlet Connection Electric Service Entrance LI Dimensional Table Item Models 24A A 257 s B 22 REP C 17 Ac REF D TA Hi Limit Operating E 16 s Control F As a es C G 2 s HE H 24 3 J 9 XD K 2X L 1074s
4. am line with customer supplied outlet valve to boiler steam outlet 5 During normal operation keep drain valve closed 6 If pump and boiler are plumbed within 30 ft pipe length a minimum of two check valves are required on boiler to avoid damage to pump NOTE THE SAFETY VALVE SHALL NOT BE PLUMBED WITH A DRAIN LINE SIZED LESS THAN THE OUTLET SIZE OF THE SAFETY VALVE Wiring JAR CAUTION Ground boiler according to National Electric Code requirements to avoid shock Use proper sized wire Power wiring to boiler should be in accordance with Local and N E C requirements following wiring diagram supplied Wire size specified adjacent to field wiring terminal block s Use 90 C copper wire only Purchaser should use a disconnect switch employing circuit breakers or fuses between the main power source and the boiler JAR CAUTION Boilers are susceptible to lightning damage because of plumbing water lines Industrial type lightning surge protectors should be installed according to the manufacturer s recommendation at your service entrance Consult your contractor or electrical dealer 1 The unit is pre wired and tested Connect control circuit voltage at the control circuit terminal block 2 With the main power off make sure that all wiring terminations are tight to avoid arcing carbonizing and or overheating of contacts JENIN Substitution of components or modification of wiring systems voids the warranty and may lead to dangerous
5. er cut out switches feed system will return water level to normal Boiler is now qualified for proper low water cut out and normal liquid level operating conditions PRESSURE CONTROLS OPERATION AND TESTING NOTE ALL ES STEAM BOILERS ARE PROVIDED WITH ONE HI LIMIT PRESSURE CONTROL AND ONE OPERATING PRESSURE CONTROL 1 All pressure controls are equipped with a screw allowing for setting of the desired operational and hi limit pressures To reduce pressure setting rotate screw in direction which allows indicator to point to a lower pressure setting NOTE IT IS RECOMMENDED THAT THE HI LIMIT CONTROL BE SET 10 PSIG ABOVE DESIRED NORMAL OPERATION PRESSURE 2 A differential pressure can be obtained on all automatic re setting operating pressure controls in the same manner as operating pressure control is set Differential indicated pressure below the main operating maximum pressure the pressure control will reset 3 Pressure Control Operating Check Close steam outlet valve by customer and adjust operating pressure control to a low pressure setting Set hi limit control at 10 PS1G above that setting Switch boiler on to allow for steam pressure build up Pressure gauge reading will build and the operating pressure control will shut off boiler at its pressure setting Re setting of operating pressure control is accomplished by bleeding off pressure through steam outlet valve by customer and allowing pressure to drop below set point 4 Hi limit Pre
6. itch 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 dicc IMPORTANT Note the wire connections to facilitate re assembly see wiring schematic Element Flange Bolts 22 Ibift Remove and discard six 5 16 18 bolts from flange Do not reuse these bolts NIRE 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 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 Ib in each see illustration Make sure all wires are clean and bright to assu
7. ning and replacing g p p g tne p g placing Every four months the heating elements should be removed If scale has begun to form the element should be cleaned and the boiler should be drained and flushed NOTE NEW BOLTS AND GASKET SHOULD BE USED WHEN RE INSTALLING THE ELEMENT TO ASSURE PROPER SEALING ES 24A Electric Steam Generator Installation Operation and Maintenance Manual Element Replacement READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK Before Installing your new elements be sure the McDonnell Miller low water cut off and aux low water cutoff if supplied is operating properly The float chamber Boiler with 1 Steam Equalizing Pipe and lower equalizer column of the MM control must be completely McDonnell Miller clear of sludge or other foreign matter Failure to do this may cause the immediate burn out of the new elements If the unit is probe equipped check condition of the probes and isolator All elements are thoroughly checked before shipment The manufactur er 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 Pump and Low Water Control Normal Boiler Water Line 1 Disconnect boiler from electric power supply at main safety switch or fuse panel Then turn boiler sw
8. operating conditions 3 Instructions for water feed control system i e motor and pump or solenoid feed a Check the voltage of the motor or solenoid before making electrical connection JAR WARNING b The water feed circuit should be wired to the junction box provided c Motors rated greater than 1 3HP or are not 120VAC single phase require the use of suitable motor starter d Amperage Wire Size For correct sizing refer to the label on the boiler located next to the field wiring terminals This label states the wire size AWG or MCM minimum temperature rating 90 C and conductor material copper only Deviation from this information may result in improper or unsafe boiler operation ES 24A Electric Steam Generator Installation Operation and Maintenance Manual Wiring Diagram Control Circuit ES 24A PRI Electric Boilers Typical Wiring Diagram 24A 3 PHASE POWER IMPUT CONTROL CIRT l INPUT l i l Facdory Wiring ai A cu HreaL Fiukl Wiring 3 rie z CONTACTOR a6 mom TL al F euer OO Ab HEATING STEH T j ELEMENT win arn FILET 5 ufu Liver n ROWE Exc Baller Fawrpisir l ha npu Aegeeceer t FUsE T kien ies Li Li l p Brome Lait PATAFE aen PUPP MOTOR Eh o I EERERETHR __ js 71 IT i BULEMOID VALVE WHT LEVEL rin EAE i 1 CONTROL E LL p Se S m x 1 t Ll CONTACTO SI ra t EIU 1 ix L
9. r is drained 1 Close the blowdown valve 3 Put boiler switch in the ON position 2 Open water supply valve 4 Close wall mounted safety switch When refilling is complete turn off the boiler switch unless further operation is desirable If you have been supplied with a Manual Reset Low Water Control as required in some states the reset button on the control must be pushed before boiler will begin developing pressure Do not push reset until boiler has filled with water Maintenance J Ween HAZARD OF ELECTRICAL SHOCK DISCONNECT ALL POWER BEFORE WORKING ON BOILER Sussman Electric Steam boilers are designed for years of trouble free performance To establish a good preventative maintenance program we suggest that the building maintenance person or engineer familiarize themselves with these simple rules 1 2 The sight glass should be checked daily to ensure that boiler has adequate water A monthly inspection should be made of the internal wiring All electrical connections should be checked for tightness A check for water leaks should also be made and any loose fittings immediately tightened Every four months the low water cut off and pump control should be checked to insure that it is functioning properly Every four months the probe and isolator should be checked for deposits and cleaned if necessary This is accomplished by remov ing the inspection plate removing the probe with a standard socket wrench clea
10. re good D e electrical contact Pg UE 9 Check that the wires are correctly connected to the contactor terminals and are tight ened to a torque value of 45 Ib in see illustration Make sure all wires are clean and bright to assure good electrical contact For Illustrative Purposes Only 10 Open water valve to allow water supply to reach boiler feed mechanism Power wiring shown in approximate 11 s boiler automatically refills observe the new flange assembly for possible leaks factoryinstalled location If water is noticed the bolts must be re tightened Before doing this turn the boiler off at the main fuse safety switch TORQUE VALUES 12 When boiler reaches working pressure check flange assembly again for leaks Element Flange Bolts 22 lb ft Contactor Terminals see Torque chart Element Terminals 20 Ib in J Wee Follow maintenance instructions provided with the boiler Contactor Terminals 45 b in m PN 101167 3 12 Fa S Jc NEA A Division of Sussman Automatic Corporation j 43 20 34th Street Long Island City NY 11101 718 937 4500 1 800 238 3535 em C ELECTRIC BOILERS Fax 718 937 4676 wwwsussmanboilers com Email seb sussmancorp com
11. s HHH LIMIT IHR E eo E PRESSURE PRESSURE ci RMOL CONTIOL EXILEH SHELL l I I E inis df 123 FE Ea3 Boon PIHT UHT Tn MANUAL HESET Replacement Heating Elements PN Description Models 39243B 24kw 208 3 24A 39243C 24kw 24003 24A 39243F 24kw 48003 24A ES 24A Electric Steam Generator Installation Operation and Maintenance Manual Pre Operation Check All Boilers LWCO PUMP CONTROL OPERATION AND TESTING 1 All valves for incoming water supply are to be fully opened Main disconnect switch to be in ON position Boiler switch to be in ON position Since boiler will be empty pump or solenoid will be energized allowing boiler to fill with water Control will allow for automatic reaching of proper water level Contactors will be energized applying voltage to heating elements 2 Pump Switch Operation At this point water should be visible approximately halfway up sight glass Slowly open drain valve located at bottom of boiler Water level will fall allowing low water cutoff pump control to energize feed water system Close drain valve for proper operation 3 Low Water Cut Out Switch Performance Open drain valve completely Maintain this condition until water level falls within gauge glass enough to cause low water cut out switch to de energize heating elements Contactor will be in the de energized state at this time Close the drain valve For automatic resetting type low wat
12. ssure Control Check See item 3 above but in doing so assure for this test purpose only that the operating control is Set above the pressure setting of the hi limit control The hi limit trip will de energize the contactors Resetting of the hi limit occurs after bleeding steam to reduce pressure inside the boiler 4 CAUTION TO AVOID IMPROPER OR UNSAFE CONDITIONS INSURE OPERATING PRESSURE CONTROL IS RESET TO PROPER DESIRED BOILER OPERATING PRESSURE CAUTION ONLY WITH MAIN DISCONNECT OFF TIGHTEN ALL ELECTRICAL CONNECTIONS BEFORE ENERGIZING BOILER TO PREVENT ARCING CARBONIZING OF CONTACTS AND OR OVERHEATING 1 Turn on water supply Turn main switch on Turn boiler switch to ON position When water appears approximately halfway up the gauge glass the pump or solenoid feed will automatically shut off and the contactors will switch on 2 Operation of Low Water Cut Off The boiler is equipped with a probe type liquid level control which is coupled to an electronic controller pc board 3 The automatic reset operating pressure control has a visual pressure adjustment The top screw of the control adjusts the scale in the large indicator window By turning the screw the pressure setting can be adjusted Selection of desirable pressure is very easily made Some pressure controls have an additional screw for adjustment of pressure differential OFF ON pressure operating range which is factory set at the maximum allowable rating
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