ES 30-36 IOM - Sussman Electric Boilers
Contents
1. NOTE THE SAFETY VALVE SHALL NOT BE PLUMBED WITH A DRAIN LINE SIZED LESS THAN THE OUTLET SIZE OF THE SAFETY VALVE INT WHEKE 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 INT CAKLE 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 WARNING Substitution of components or modification of wiring systems voids the warranty and may lead to dangerous 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 INI GUL b The water feed circuit should be wired to the junction box provi2. READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK INT WREKIN 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 and lower Boiler with _ 1 Steam Equalizing Pipe equalizer column of the MM control must be completely clear of McDonnell Miller 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 Pump and Low Water Control Normal Boiler Water Line All elements are thoroughly checked before shipment The manufac Cut Off Level is Arrow Mark turer cannot be responsible for burn outs caused by a faulty low water cut off Blowdown Valve The lower equalizer column can best be examined by breaking the 1 Water Equalizing Pipe 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 Close water supply valve on incoming water supply line Drain boiler completely of water Open boiler door to access heating element Disconnect wire electric leads connecting element to main power system of boiler Again note wire connections to facilitate re assembly Proceed to remove and
3. Contactor Terminals see Torque chart 10 Open water valve to allow water supply to reach boiler feed mechanism 11 As boiler automatically refills observe the new flange assembly for possible leaks Hustrative epum Only If water is noticed the bolts must be re tightened Before doing this turn the boiler off installed location at the main fuse safety switch 12 When boiler reaches working pressure check flange assembly again for leaks TORQUE VALUES Element Flange Bolts 22 lb ft Element Terminals 20 Ib in INEZ Follow maintenance instructions provided with the boiler Contactor Terminals 50amp 25 Ibin 60amp 45 lb in 75amp 75 lb in ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Gauge Glass Installation IMPORTANT NOTE Read all warnings and instruc tions before performing installation or maintenance Safety glasses and gloves should be worn at all times when working with or examining water gauge glass Top Gayge and connections Pressure in generator to be at zero SO 7 22 before proceeding Improper installation mainte nance of gauge glass and connections can cause Nm D J7172 diate or delayed breakage resulting in bodily injury and or property damage i Wiese A 1 Apply Teflon tape or pipe dope to pipe t
4. 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 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 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 UJ oum Boiler should be blowndown daily see blowdown instructions on page 6 ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and Main
5. discard 6 bolts from flange N IMPORTANT Note the wire connections to facilitate re assembly see wiring schematic fimt Flange Bolts 22 iof 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 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 2 NOTE Observe markings on element flange Install element marking 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 each see illustration Make sure all wires are clean and bright to assure good electrical contact a 9 Check that the wires are correctly connected to the contactor terminals and are tight AS Viet ened to a torque value of 45 Ib in see illustration Make sure all wires are clean and ES bright to assure good electrical contact
6. 99136 Safety Valve 100PSIG 1 2 NPT Component Identification Dimensional Information in inches ES 30A amp ES 36A HP 30A 47 7 178 2 NM EE 437 2 SIDE VIEW e b o 20 2 Q U 5 Item Description Item Description i O 1 Steam Outlet 8 Safety Valve EO ment 2 Gauge Glass Valves 9 Hi Limit Pressure Control 3 Gauge Glass Tube 10 Operating Pressure Control 26 i 4 Water Feed Strainer 11 Pressure Gauge FRONT VIEW 5 Water Solenoid Valve 12 On Off Switch 6 Check Valve 13 Control Circuit Fuse 7 Drain Valve 14 Access Panel PN 100600 5 12 A Division of S Automatic C ti FA SUSSMAN ivision of Sussman Automatic Corporation E ue 43 20 34th Street Long Island City 11101 718 937 4500 1 800 238 3535 ELECTRIC BOILERS 7189374676 www sussmanboilers com Email seb sussmancorp com
7. 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 MAKEUP WATER OF A LOWER CONCENTRATION ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Spare Parts List 90229 Probe Plug 99162 Check Valve 3 8 HP30A 92830 On Off Switch with Pilot Light 99167 Check Valves 1 2 ES30A 36A 93806A Strainer 1 4 HP30A 99173C Valve Set 99007 Contactor 60 AMP 3 Pole 240V 991788 Drain Gate Valve 1 2 ES30A 36A amp HP30A 99031 Water Solenoid 1 2 120V ES30A 36A 99197 Pressure Gauge 160 PSIG 2 1 2 NPT 99032 Water Solenoid 1 2 240V ES30A 36A 99807F 1 4 Probe Rod 5 Inch 99042 Water Solenoid 1 4 1201 HP30A 100706 8 amp Fuse 99042C Water Solenoid 1 4 240V HP30A 100378 Probe Isolator 99074 1 778 Gauge Glass w 2 99174C O Ring 100412A Liquid Level Control Board 120V 99075 Contactor 60 amp 3 Pole 120V 100412C Liquid Level Control Board 240V 99123 Strainer 1 2 ES30A 36A 102124 Ball Valve Steam 3 8 HP30A 99128R Pressure Control Operating 0 100 PSIG 103036 Ball Valve Steam 1 E530A 36A 991308 Pressure Control Hi Limit 0 100 PSIG 103540 Boiler Gasket Kit 99096 995478 99088 w Reset Button on Rise Gasket Bolts amp Compound
8. FL SUSSMAN E E HP30A X ELECTRIC BOILERS Electric Steam Generators Installation Operation and Maintenance Manual Model No Power Circuit Voltage Generator 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 ES 30A 30 90 Ibs hr 3 0 100 PSIG 85 PSIG ES 36A 36 108 Ibs hr 3 6 100 PSIG 85 PSIG HP30A 30 90 Ibs hr 3 0 100 PSIG 85 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 100600 5 12 FA SUSSMAN A Division of Sussman Automatic Corporation 43 20 34th Street Long Island City 11101 718 937 4500 1 800 238 3535 COY ELECTRIC BOILERS Fax 718 937 4676 www sussmanboilers com Email seb sussmancorp com ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Standard Features LIQUID LEVEL LWCO CONTROLLER The electronic controller automatically maintains proper water level and shuts off the generator when water supply in the boiler drops below a safe operating level WATER LEVEL SIGHT GLASS Allows constant observation of water level while boiler is in opera
9. G as standard 15PSIG trim also available Incoming water line pressure must be 10 PSIG greater than generator operating pressure If not a motor pump must be used Specify Sussman ES 38002A high pressure water feed motor pump system When ordering specify Model No KW Volts PH and motor pump if required Water Connection is 1 4 NPT ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Installation JING 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 steam 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
10. MENDED 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 cm 50 000 ohm centimeter BLOW DOWN BOILER ON AT LEAST A ONCE A DAY BASIS IF BOILER WATER OR FEEDWATER ARE OUTSIDE THE ABOVE LIMITS A MORE FREQUENT BLOWDOWN IS REQUIRED RECOMMENDED LIMITS WITHIN A BOILER TOTAL DISSOLVED SOLIDS ppm 3500 TOTAL ALKALINITY ppm 850 SUSPENDED SOLIDS ppm 300 SILICA Si05 ppm 125 SULFITE SO3 ppm 25 50 PHOSPHATE ppm 30 60 P ALKALINITY AS ppm 900 IRON ppm 2 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 MORE 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 INTERNAL SURFACES THIS DEPOSIT CAN INTERFERE WITH PROPER
11. ROL 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 water 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
12. ded 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 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Wiring Diagram ES 30A ES 36 A HP Electric Boilers FACTORY WIRING FIELD WIRING NOTE SEE BOILER NAMEPLATE FOR INPUT REQUIREMENTS 480V 3PH OR 208V OR 240V 3PH PROBES BOILER SHELL CONTROL CIRCUIT INPUT CONTROL TERMINAL BLOCK ORN contactor LIQUID PUMP MOTOR Pump LEVEL SOLENOIO 1 5 VALVE BLK CONTROL T BLU 1 HIGH LIMIT PRESSURE CONTROL P2 OPERATING PRESSURE CONTROL CONTACTOR COIL o OPTIONAL 28 AUX 1 MANUAL RESET 59 PILOT LIGHT ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Pre Operation Check All Boilers LWCO PUMP CONT
13. essure Do not push reset until boiler has filled with water Maintenance INEZ niley 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 UJ 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 cleaning and replacing 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 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Element Replacement
14. hreads 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 position 2 Install the bottom gauge fitting the fitting with a drain valve until it is snug and the glass outlet is Guard Rod s pointing directly upward Verify top and bottom fit tings are threaded into the tappings the same num ber of turns distance A distance B 3 Remove glass packing nut friction washer or pack ing gland depending upon the model and glass packing from the fittings and place them in the Glass Packing 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 fitting Keeping the glass inside the top fit ting 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 Drain Valve remain in contact with any metal 6 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
15. jury 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 Examine the gauge glass regularly for any signs of clouding scratching erosion or corrosion The glass should be inspected daily until the need for replacement 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 corrosion 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 ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and Maintenance Manual Water Quality Information for Carbon Steel Boilers FOR OPTIMUM RESULTS THE FEEDWATER SUPPLY SHOULD BE TESTED PRIOR TO INITIAL STARTUP IF THE MINERAL CONTENT EXCEEDS THE FOLLOWING RECOM
16. pre vent leakage DO NOT OVER TIGHTEN If any leakage should occur tighten lightly a quarter turn at a time checking for leakage after each turn Glass Packing Friction Washer Nut or Packing d i Fitting IMPORTANT NOTE Read all warnings and instructions before performing installation or maintenance Safety glasses 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 ES 30A ES36A HP 30A Electric Steam Generator Installation Operation and 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 pressurized 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 in
17. 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 Pressure 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 JING AUTION TO AVOID IMPROPER OR UNSAFE CONDITIONS INSURE OPERATING PRESSURE CONTROL IS RESET TO PROPER DESIRED BOILER OPERATING
18. tenance 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 boiler 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 pr
19. tion ON OFF SWITCH Complete with pilot light for switching on the generator INTEGRAL ELECTRICAL CONTROL Magnetic contactors energize the elements and are integrally mounted in the control unit BLOWDOWN DRAIN VALVE Facilitates emptying the pressure vessel during blowdown drain sequence J BOX for motor pump connection LONG LIFE HEATING ELEMENTS Industrial grade heavy duty stainless steel heating elements equipped with one piece resistance welded terminations for added strength and safety OPERATING PRESSURE CONTROL Operates automatically to maintain steam pressure within generator MANUAL RESET PRESSURE CONTROL Provides high limit pressure cut out with manual reset STEAM SAFETY VALVE ASME Code valve automatically opens to reduce pressure should excessive steam cause pressure build up STEAM PRESSURE GAUGE Allows visual observation of steam pressure over full range ENERGY SAVING AND MINIMUM MAINTENANCE Fully insulated pressure vessel minimizes heat loss and maximizes energy savings EASY CONTROL MAINTENANCE All controls and components are easily accessible Fully louvered openings avoid component heat build up e RUGGED CONSTRUCTION Performance is insured for all typical industrial applications Meeting Code Requirements Pressure vessel rated at 100PSIG to ASME Section Code M and National Board registered UL listed cUL certified built to NEC Units are trimmed at 100PSI
Download Pdf Manuals
Related Search