ES IOM a - Sussman Electric Boilers
Contents
1. 170 e eo MOTORIZED BLOWDOWN BLOWDOWN SYSTEM TIME DELAY RELAY VALVE LIGHT Cy soLtNoD VALE PROPORTIONING PUMP MOTOR PRESSURE CONTROL R RELAY Q HIGH LIMIT OPERATING fee PRESSURE PRESSURE CONTROL CONTROL CONTROL INPUT zl Neutral CONTROL TERMINAL BLOCK CONTACTORS ES and SSB Electric Boilers with Automatic Blowdown System 120V 1PH FIELD WIRING FACTORY WIRING SOLENOID VALVE ON OFF SWITCH 9 HIGH LIMIT PRESSURE CONTROL AUTOMATIC CONTACTORS PRESSURE CONTROL I GROUND LWCO H AUX LWCO BOARD BOILER SHELL Sussman Boilers installation Operation amp Maintenance Manual Wiring Diagram Control Circuit SSB Electric Boilers with Manual Reset Auxiliary Low Water Cutoff 120V 1PH INPUT Ll dn FIELD WIRING CONTROL FACTORY WIRING TERMINAL BLOCK HIGH LIMIT AUTOMATIC CONTACTORS LIQUID PRESSURE PRESSURE LEVEL CONTROL CONTROL CONTROL GUARD GROUND LWCO MANUAL RESET AUX LWCO BOARD BOILER SHELL Sussman Boilers installation Operation amp Maintenance Manual 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 b2. B 1 9 1 2 DIA COVER PLATE a 1 EASY ACCESS FOR MAINTENANCE i I VENT SAFETY __ 1 V s VENT WITH SAFETY BAR ESS CONDENSATE RETURN FLASH TUBE 1AA NENT ED FLOAT VALVE libel 7 ido qu C A o A Z o COLD WATER INLET 3901 0 F sayas OVERFLOW OUTLET i NPT farside V2 COLD WATER INLET COUPLING label OVERFLOW label WITH 100 MESH STRAINER 77 E LIMIT MAKEUP WATER PRESSURE mE TO TO 30 PSI MAXIMUM label x r SIMPLE RUGGED LINKAGE CONDENSATE RETURN label E V C CC 77 MM MU 1 Ya CONDENSATE 1 4 RETURN COUPLING SIGHT GLASS TOP VIEW WE S __ 5 DIA UPPER FLOAT BALL SITE GLASS ASSY 39011 FB PN 99173C A E n TA SIGHT GLASS L SHUTOFF GATE VALVE 99041 PUMP EASY ACCESS 1 STRAINER CLEANOUT p Notes 1 Motor Pump is closed Coupled design 2 Pump capacity as follows MODEL 38083V MODEL 38084V GPM 125 ft 225 ft Sussman Boilers installation Operation amp Maintenance Manual Blovedovvn Separator Tanks Models BDT ASME 36 42 48 54 Dimensions and Features Suggested Hook Up to Boiler T Vent to NND Pressure Gauge iaa c Q iri DET Pressure Gauge must be fullsize 2 optional optional Blowdown Separator r Blowdown Inlet AA Blowdown Separator
3. 15 Blowdown Separators 15 SSB Boilers have all wetted metal parts Stainless Steel and are Control Voltage Stepdown Transformer 15 required to be operated on distilled de ionized or RO type Multistage Load Progressive Sequencers 15 water having a minimum specific resistivity of 1 Megohm cm Condensate Return Systems 16 ES amp HU Boilers are of Carbon Steel construction and are not Or to be operated on distilled deionized or type water Specification Charts 18 SIZING ua sasan EE RR X REUS 19 Gauge Glass Installation 20 21 Element Replacement 22 Water Quality Information for Carbon Steel Boilers 23 Warranty ree nets 24 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 states a hazard which may signals a situation where IMPORTANT NOTE cause serious injury or death if minor injury or product damage This highlights information that is especial precautions are not followed may occur if you do not follow instructions ly relevant to a problem free installation A Division of Sussman Au
4. Water Gpuge optional Fon Boiler Water Gauge optional B Inlet Blowdown Outlets Blowdown Drain C Drain l A Temperature Gauge Temperature Gauge opt _ _ _ _ 1 3 3 4 Coupling Temperature Probe Handhole Assembl optional 3 x l N Handhole Assembly except 85 0 Y F gt Hm j IE Cold Water Inlet A amp Washout Drain F Cold Water Inlet amp Washout Drain rg Tempered Blowdown to Drain Cold Water Supply Y Y 1 Drain Valve closed during normal operation BDT ASME 48 26 59 BDT ASME 54 69 100 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 boiler steam blowdown in the separator This reduces the outlet temperature to a level that makes it safe for discharge If the separator is less than half full of water after the boiler is blown down cold tap water must be added to bring the water level to the halfway mark before the next blowdown Note 1 BHP is approximatley 10kW Maximum boiler working pressure 250 psi Maximum blowdown separator pressure 65 psi Blowdown Separators are sized in accordance with National Board Standard Equipment 0 100 Ib Pressure Gauge 0 200 Temperature Gauge Water Level Gauge 17 Sussman Boilers installation Operation amp Maintena
5. For model SSB boilers p n SSB81017 amp SSB81017MR w 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 to 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 e For model ES amp HU boilers P N ES99117 e For model SSB boilers P N SSB99117 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 For SSB boilers P N SSB99117 components are of stainless steel construction HIGH PRESSURE WATER FEED SYSTEM For model ES12 72 P N ES38002A For model ES100 180 P N ES38020A For model SSB12 72 P N SSB38002A For model SSB100 180 P N 55838020 Used to supply makeup water and to maintain constant water level when the boiler operating pressure is equal to or greater than incoming wat
6. e ES81600 Auto blowdown wiring diagram f Detailed sequencer package wiring diagram Wiring Diagram Control Circuit ES and SSB Electric Boilers 120V 1PH INPUT CONTROL FIELD WIRING TERMINAL FACTORY WIRING ON OFF SWITCH LIQUID HIGH LIMIT OPERATING CONTACTORS LEVEL PRESSURE PRESSURE CONTROL CONTROL CONTROL Sussman Boilers installation Operation amp Maintenance Manual Wiring Diagram Control Circuit ES and SSB Electric Boilers THREE PHASE FIELD WIRING SINGLE PHASE MAIN POWER FACTORY WIRING MAIN POWER SUPPLY SUPPLY uu TB 1 TERMINAL POWER BLOCK see note 1 1 6 TB i 1 Power Terminal Block only on boilers with two or more contactors 2 Power Fuses only on boilers rated 20 amperes and larger 3 See Parts List for contactor and heating element information 2 a e ss POWER FUSES L 4 1 4 tt tt ee elm ee qim e FB TRANSFORMER r ri optional C TO CONTROL CIRCUIT HEATING ELEMENTS NOTES H ES Electric Boilers with Manual Reset Auxiliary Low Water Cutoff 120V 1PH INPUT L Iy NE FIELD WIRING BLOCK FACTORY WIRING ON OFF SWITCH A SOLENOID VALVE COM NC HIGH LIMIT OPERATING CO
7. inches all around boiler for servicing Sussman Boilers installation Operation amp Maintenance Manual Dimensional amp Clearance Specifications High Limit Operating Pressure Pressure Pressure Gauge Steam Outlet Control 15 PSIG A Control E j Safety Valve On Off Switch Gauge Glass Height Assembly MM 150 Liquid Level Control D see note 3 Water Feed Inlet ile Drain Valve Y Left Front F lt Width 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 from Front of boiler Prefix C to numeral indicates acceptability for closet or alcove installations prefix acceptability for alcove installations but not for closet installations 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 Numeral indicates minimum clearance below suspended units to combustible floor Sussman Boilers installation Operation amp Maintenance Manual Typical Wiring Diagrams a Three phase power circuit with separate 120Volt control circuit With singe phase power circuit insert b Three phase power circuit with step down transformer c Detailed ES81017 81017MR auxiliary low water cut off wiring d Detailed SSB auxiliary low water cut off wiring
8. or to low water condi tions The foregoing is in lieu of all other express warranties Sussman Automatic Corporation does not assume or authorize any party to assume for it any other obligation or liability 24 TERMS AND CONDITIONS FOR RETURNS Merchandise Return Authorization To ensure processing of warran ty claim a Merchandise Return Authorization MRA must be obtained by the original purchaser and prominently shown on cor respondence and packages Returns made without an MRA will not be processed To obtain MRA call 1 800 238 3535 Authorized returns which after examination by Sussman are not covered by this warranty will be subject to a labor charge Freight Charges and Handling Fees The purchaser is responsible for all shipping charges All Boiler Product returned pursuant to this warranty must be shipped freight prepaid Proof of Purchase Proof of purchase original sales receipt identify ing the model number and serial number of Boiler Product must accompany warranty claim SUSSMAN AUTOMATIC CORP IS NOT LIABLE FOR LABOR AND OTHER COSTS INCURRED IN REMOVAL REINSTALLA TION OR UNAUTHORIZED REPAIR OF THE BOILER PRODUCT OR FOR DAMAGES OF ANY TYPE WHATSOEVER INCLUDING INCIDENTAL OR CONSEQUENTIAL DAMAGES THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION CONTAINED HEREIN AND SPECIFICALLY LIA BILITY FOR ANY BREACH OF ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PURPOSE IS EXCLUD ED THE DUR
9. warnings and instructions before performing installation or maintenance Top Gauge A fl Fitting OY fee aM pc 27 assets E ee m Ea ey 1 p T 2 d Vessel Wall EN EN NC Hol Gauge Glass i N S Guard Rod gt L m k 4 Friction Washer es Packing or Packing Gland Ra vAIILT Ly L L 3 Glass Packin Ing H E SU l u E ET VEE Fe i ia Ie ui FERA Bottom Gauge n Fitting Drain Valve RNI Safety glasses and gloves should be worn at all times when working with wA 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 20 23 Sussman 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 w
10. 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 ALKALIN1TY ppm 200 500 7 0 gpg pH strength of alkalinity 10 4 11 4 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 S105 ppm 125 SULFITE SO3 ppm 25 50 PHOSPHATE ppm 30 60 P ALKALINITY AS CaCO3 ppm 900 IRON ppm 2 WATER QUALITY CAN AFFECT EFFICIENCY OR RESULT IN BOILER DAMAGE IF NEGLECTED BOILER FEEDWATER CONTAINS IMPURI TIES IN SOLUTION AND SUSPENSION THESE IMPURITIES CONCENTRATE IN THE BOILER SINCE THE STEAM GENERATED IS ESSEN TIALLY 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 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 W
11. ATION OF ANY WARRANTIES WHICH MAY BE IMPLIED BY LAW NOTWITHSTANDING THE PREVIOUS SEN TENCE INCLUDING THE WARRANTIES OF MERCHANTABILI TY AND FITNESS IS LIMITED TO THE TERM OF THIS WARRAN TY IN NO EVENT SHALL SUSSMAN AUTOMATIC CORPORA TION BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUEN TIAL DAMAGES ARISING FROM OWNERSHIP OR USE OF ANY BOILER PRODUCT OR FOR ANY DELAY IN THE PERFOR MANCE OF ITS OBLIGATIONS UNDER THIS WARRANTY DUE TO CAUSES BEYOND ITS CONTROL SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRAN TY LASTS AND OR DO NOT ALLOW THE EXCLUSION OR LIM ITATION OF CONSEQUENTIAL DAMAGES SO THE ABOVE LIM ITATIONS AND EXCLUSIONS MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS YOU MAY HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE
12. CAL 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 facility maintenance person or engineer familiarize themselves with these simple rules 1 The use of chemical boiler cleaning compounds voids all warranties and should not be used Some compounds can will damage the incoloy sheathing of the heating elements A reputable water treatment engineering firm should be consulted regarding pre treating or conditioning the boiler feed water 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 The sight glass should be checked frequently to assure the boiler has adequate water 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 N AUL 5 A monthly inspection should be made of the internal wiring Open the access door and check all electrical con nections for tightness Replace any wires that show signs of damage NOTE The electrical power MUST be shut off during this maintenance proced
13. ITH MAKEUP WATER OF A LOWER CONCENTRATION 23 Limited Warranty Sussman Boilers installation Operation amp Maintenance Manual THIS WARRANTY SUPERCEDES ALL PRIOR WARRANTY COVERAGE Sussman Automatic Corporation hereby extends to the original purchaser of its Industrial Steam and Hot Water Boilers Steam Superheaters and Heat Exchanger products Boiler Products a warranty against defects in materials and workmanship for the period indicated below NO OTHER EXPRESS OR IMPLIED WARRANTY WRITTEN OR ORAL APPLIES INCLUDING WITHOUT LIMITATION WARRANTIES OR MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE NO PERSON IS AUTHORIZED TO GIVE ANY OTHER WARRANTY OR ASSUME ANY OTHER LIABILITY EXCEPT BY WRITTEN STATEMENT SIGNED BY AN OFFICER OF SUSSMAN AUTOMATIC CORPORA TION LONG ISLAND CITY NY The warranty is only valid on Boiler Products purchased and used in the United States of America and Canada WARRANTY WARRANTY PERIOD The warranty on Boilers Products extends for one 1 year from the date of first purchase by the original pur chaser The ASME pressure vessel used on Boiler Products extends for five 5 years from the date of first purchase by the original pur chaser Sussman Automatic Corporation will repair or replace at its sole option a Boiler Product if it fails to conform to this warranty In the event a Boiler Product is to be repaired pursuant to this warranty such repair work will be performed by Sussman Auto
14. NTACIORS LIQUID PRESSURE PRESSURE LEVEL C H 10 CONTROL CONTROL CONTROL TT AUX LWCO PCROARD lt a MANUAL RESET PROBE Sussman Boilers installation Operation amp Maintenance Manual Wiring Diagram Control Circuit ES Electric Boilers with Manual Reset Auxiliary Low Water Cutoff 120V 1PH INPUT Ll Iy amp CONTROL TERMINAL FIELD WIRING FACTORY WIRING ON OFF SWITCH HIGH LIMIT OPERATING LIQUID PRESSURE PRESSURE LEVEL CONTROL CONTROL CONTROL PROPORTIONING PRESSURE CONTROL 135 OHM CONTACTORS COM SEQUENCER ES Electric Boiler with Auxiliary Low Water Cutoff 120V 1PH INPUT FIELD WIRING 1 du FACTORY WIRING CONTROL TERMINAL ON OFF SWITCH DA SOLENOID VALVE ll 12 GOM NC NO HIGH LIMIT OPERATING E TT tme CONTACTORS MUI C HL CONTROL CONTROL CONTROL qe AUX LWCO PCBOARD TO PROBE Sussman Boilers Installation Operation amp Maintenance Manual Wiring Diagram Control Circuit ES and SSB Electric Boilers with Automatic Blowdown System 120V 1PH INPUT CONTROL TERMINAL BLOCK FIELD WIRING FACTORY WIRING 7 DAY 24 HR TIMER ON OFF PILOT LIGHT e SWITCH 581600 AUTOMATIC
15. ONS 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 operating 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 fully 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 When the time clock turns the boiler off the blowdown 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 N Blowdown program can be overridden to allow for unscheduled blowdown or operational cycles Refer to the time clock instruction insert 12 Maintenance Sussman Boilers installation Operation amp Maintenance Manual HAZARD OF ELECTRIC SHOCK cA DISCONNECT ALL ELECTRI
16. Sussman Bowers Es SSE amp HU Installation Operation and Maintenance Manual Model No TABLE OF CONTENTS Boiler Serial No Dimensional Information National Board No amp Component Identification 2 Dimensional amp Clearing Specifications 3 Safety Valve Set Pressure PSIG w Wiring 4 8 Power Circuit Voltage EM Installation Control Circuit Voltage PIPING 9 Amps ____ Phase HZ Wiring 9 10 Pre Operation 10 IMPORTANT This data file contains the National Pressure Controls Operation amp Testing 11 Board Registration Certificate approving your boiler 11 It must be kept near the boiler at all times Blowdown 12 Maintenance 13 Products covered by this manual Optional Equipment 14 Auxilliary Low Water Cut 14 Series KW Range Steam Rate BHP Design Pres Were Line Pressure Water Feed System 14 High Pressure Water Feed System 14 ES HU 12 180 36 542 165 1 2 18 4 0 100 psig 85 psig Condensate Return System 14 SSB 12 180 36 542 lbs hr 1 2 18 4 0 100 psig 85 psig Vacuum Breaker Systems 15 Steam Rate Steam 212 F with 50 F feed water Automatic Blowdown System
17. er line pressure and condensate is not returned to the boiler e ES38002A amp SSB38002A Range is 0 100 psig 1 2 NPT size consisting of strainer solenoid valve and 1 3 HP 120 1 60 motor and pump e ES38020A amp SSB38020A 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 SSB38002A and SSB38020A pump components are of stainless steel construction CONDENSATE RETURN SYSTEM see page 17 For model ES12 72 p n ES38083V for model ES85 180 p n ES38084V These systems are used whenever condensed steam can be collected for reuse in the boiler Returning the conden sate to the boiler can save a significant amount of energy The water returned is relatively free of corrosive miner als 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 fitting is located on the condensate tank top for atmospheric 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 ta
18. ext blowdown 0 30 psig pressure gauge 0 200F temperature gauge water sight gauge glass and valve set assembly are included CONTROL VOLTAGE STEPDOWN TRANSFORMER Provides 120 Volt 220 Volt export from main power supply Factory wired and fused MULTISTAGE LOAD PROGRESSIVE SEQUENCERS Accurate control is provided by automatic progressive sequencing in the use of energy and minimizing wear on electrical components The sequencers are designed to apply power progressively to larger KW boilers A factory installed pressure sensitive sequential control reacting to steam boiler pressure progressive energizes or de energizes heating elements through power contactors A delay between sequencer steps before start up and between each subsequent step elimi nates power surges Each sequencer is matched and factory pre set to boiler 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 resump tion of power the control will re stage the loads one at a time 15 Condensate Return Systems Sussman Boilers installation Operation amp Maintenance Manual Models 38083V amp 38084V
19. fferential 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 pressure gauge indicates 20psig Open steam outlet valve to bleed off pres sure When the pressure gauge reading decreases below 10psig differential the operating 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 pres sure 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 out let valve to bleed off pressure The contactor s should not re energize on pressure drop The contactor s should only re energize when the pressure has dropped and the high limit pressure control reset button is depressed een With main disconnect OFF tighten all electrical connections before energiz cA ing boiler to prevent arcing carbonizing of contact and or overheating Set the desired operating pressure and differential pressure on the operating pressure control Set the high limit pressure control Recommended to be 10 psig abo
20. hen steam load and feedwater temperatures are known 10 15 25 40 50 75 100 125 150 0 2 ame se ss ss se pam sae sss 325 som sm ume e pam sus sme sss zm ue sme 3284 e pae ae 302 sms sus ae smi fer s as 3056 sum sus ams sur sns fare m pass ase son s ame soe 3054 s ass pus se zur zer amr sss jams 3090 _ 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 lbs steam hr x 3417 153 8 KW boiler required Feed Water F 19 Sussman Boilers installation Operation amp Maintenance Manual Gauge Glass Installation 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 andlor property damage 1 Apply Teflon tape or pipe dope to pipe threads Install top gauge fitting fitting without a drain valve into the uppermost tap ping Wrench tighten the fitting unt
21. hile 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 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 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 21 rej Before Instal
22. ical cleaning compounds Follow maintenance instructions provided with the boiler A SUMON ELECT OLERE Division of Sussman Automatic Corporation READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK p 1 Steam Equalizing Pipe Pump anil Low Waler ontral 7 cC r 9 To arque o Wrench Eee Element Flange Bolts 22 ib ft s s f Mess o 96 Torque Wrench o Element Terminals 20 Ib in RE o o N e o Torque Wrench L Contactor Terminals 45 b in For lllustrative Purposes Only Power wiring shown in approximate factory installed location TORQUE VALUES Element Flange Bolts 22 Ib ft Element Terminals 20 bjn Contactor Terminals 45 103923 Rey 6 04 43 20 34th Street Long Island City NY 11101 718 937 4500 1 800 238 3535 Fax 718 937 4676 www sussmanboilers com Email seb sussmancorp com Sussman Boilers installation Operation amp 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 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
23. il 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 pointing directly upward Verify top and bottom fittings are threaded into the tap pings 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 fitting 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 contact with any metal 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 9 IMPORTANT NOTE Read all
24. isible 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 allow ing the low water cut 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 ele ments 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 Boilers equipped with an auxiliary low water cut off control with a manual re set button required as mandatory equipment is some states once the correct operating water level has been reached it will be necessary to depress the reset button in order for the contactors to re energize Note For boilers equipped with an automatic blowdown 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 necessary to cyc
25. le the time clock from the run to off mode several times Pressure Controls Operation and Testing Sussman Boilers installation Operation amp Maintenance Manual 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 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 pressure setting turn adjusting screw in direction that allows indi cator to point to a higher pressure on the scale Note It is recommended that the high limit control be set 10psig 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 pressure 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 A Operating pressure control check Close steam outlet valve supplied by customer and adjust operating pressure control to 20psig and the di
26. ling your new elements be sure the CAUTI McDonnell Miller low water cut off and aux low water cutoff if supplied is operating properly The float chamber and lower equalizer column of the MM control must be completely 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 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 Boiler with McDonnell Miller 1 Disconnect boiler from electric power supply at main safety switch or fuse panel Then turn boiler switch to OFF position 2 On automatic feed units close valve on incoming water 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 certai
27. matic Corporation or at its direction Under no circumstances will Sussman Automatic Corporation make reimbursement for repair costs without written authorization by Sussman Automatic Corporation See Merchandise Return Authorization under Terms and Conditions for returns LIMITATIONS EN BOILER PRODUCTS MUST BE INSTALLED OPERATED AND MAINTAINED IN ACCORDANCE WITH ALL INSTRUCTIONS PROVIDED BY SUSSMAN AUTOMATIC CORPORATION FAILURE TO FOLLOW OUR INSTALLATION OPERATING OR MAINTE NANCE PROCEDURES AND OR USE OF UNAUTHORIZED PARTS AUTOMATICALLY VOIDS THIS WARRANTY Purchasers and or Users are responsible for the suitability of the products for their application This warranty does not apply to i repairs or replacements necessi tated by any cause beyond the control of Sussman Automatic Corporation including but not limited to any malfunction defect or failure caused by or resulting from unauthorized service or parts installation operating or maintenance contrary to furnished instruc tions local water conditions handling shipping or transit accidents modification or repair by the user abuse misuse neglect accident incorrect power line voltage power line surge lightening damage or fire flood or other Acts of God ii repair or replacement in the ordinary course of expendable Boiler Products part and iii heating elements and boiler controls whose damage or failure is attributable to corrosion scale or dirt accumulations
28. n 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 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 11 As boiler automatically refills observe the new flange assembly for possible leaks If water 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 FR Avoid use of chem
29. nce Manual Specifications Steam Gauge Pressure Temperature Boiler Bhp Lbs Hr 3 Ph Chart Model No KW Rating Steam Volts Amps Gauge 208 34 Pressure ES 12 12 122 36 2 240 29 PG F C 480 15 15 179 82 208 50 10 192 89 es ES 18 18 1 84 54 2 n 3 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 73 227 311 480 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 58 21 260 127 ES 60 60 6 12 181 2 Vs E Ee I 180 73 25 267 131 ES 72 72 7 35 217 240 174 29 273 134 480 87 31 275 135 208 300 ES 100 108 112 325 240 260 33e 27813 480 130 35 281 138 208 400 37 283 139 ES 135 144 14 7 434 240 347 480 173 39 286 141 240 379 41 288 142 ES 160 158 16 2 475 me 43 289 1 333 240 434 45 292 144 ES 180 180 18 4 542 480 217 47 395 846 Single phase available 49 297 147 212 F 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 Boilers installation Operation amp Maintenance Manual Sizing Use the following Table to determine KW Boiler rating w
30. nk The tank has a ball check valve internally mounted and a float arm and float ball assembly 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 proper drain line The motor is required to be wired to the boiler 14 Sussman Boilers Installation Operation amp Maintenance Manual Optional Equipment cont VACUUM BREAKER SYSTEMS For model ES boilers P N ES89369 For model SSB boilers P N SSB89369 A vacuum breaker will prevent a boiler from flooding as a result of the steam condensing internally and creating a vacu um after boiler shutdown The breaker allows air to enter the boiler shell breaking the vacuum This system is a must for boilers connected to a condensate return tank The vacuum breaker consists of a spring loaded disc and associated pip ing and is factory plumbed to the boiler The SB89369 is of stainless steel construction AUTOMATIC BLOWDOWN SYSTEM Extends life of boiler Saves labor costs Starts the boiler automatically every day 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 cleaning ball valve with Teflon seats handle
31. oiler 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 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 boiler 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 If pump and boiler are plumbed within 30 feet pipe length a minimum of 2 check valves are required to avoid damage to pump Connect steam line with customer supplied outlet valve to boiler steam outlet 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 N Aw NOTE The safety valve shall not be plumbed with a line sized less than the outlet size of the safety valve VViring ALL ELECTRICAL WIRING MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN IN ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES Assure that the power voltage and phase being supplied to the boiler matches the power voltage cA and phase of the boiler Connecting incorrect power supply can damage boiler components or cau
32. on amp Maintenance Manual Installation VViring cont 5 If a separate control circuit is used it should be connected to the control circuit terminal block 6 Remote mounted water feed systems i e condensate return motor and pump should be connected to the junc tion box provided on the outside of the boiler jacket Z With main power off make sure all wiring terminations are tight to avoid arcing carbonizing or overheating of contacts Leen Boilers are susceptible to lightning damage due to water line connections An industrial type lightning surge protector should installed according to the manufacturer s recommendation at the service entrance Consult your contractor or electrical dealer wA Substitution of components or modification of wiring system voids the warranty and may lead to dangerous operating conditions 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 is to be in the on posi tion 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 energized Contactors will then energize applying voltage to the heat ing elements 2 Pump switch operation at this point water should be v
33. our local water condition i e high concentrations of minerals etc we recommend a consultation with a reputable local water treatment engineering firm Pre treating the boiler feed water may reduce mineral accu mulation enough to allow a daily blowdown to be sufficient MANUAL BLOWDOWN INSTRUCTIONS 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 N If blow down valve is plumbed into a blowdown tank the boiler can be discharged at operating pressure If the blowdown valve is not plumbed into a blowdown tank consult with local plumbing codes regarding boiler discharge Ww A 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 When refilling is complete turn off the boiler unless further operation is needed 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 NOTE THE USE OF CHEMICAL BOILER CLEANING COMPOUNDS IN THESE BOILERS VOIDS ALL WARRANTIES SOME COMPOUNDS CAN WILL DAMAGE INCOLOY SHEATHED HEATING ELEMENTS AND SHORTEN THE LIFE OF THE ELE MENTS AUTOMATIC BLOWDOWN INSTRUCTI
34. s 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 electronic time delay relay control the boiler and the blowdown valve A pilot light indicates when the blowdown valve is open The valve shall be plumbed to a proper drain or receptacle An automatic blowdown system can be installed on any boiler regardless of size operating pressure or operating duty cycle BLOWDOWN SEPARATORS see page 18 For models ES12 48 and SSB12 48 p n BDT ASME36 For models ES60 180 and SSB60 180 p n BDT ASME42 A separator accepts the flash steam 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 outside 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 tempera ture 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 n
35. se 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 Ground boiler according to National Electric Code requirements to avoid shock 2 Power wiring to boiler should be in accordance with National and Local Electrical Code requirements following 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 minimum 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 boil ers If a 3 4 HP feed water motor and pump assembly is connected to the boiler then a 20 Amp circuit is required Ww A Sussman Boilers installation Operati
36. tomatic Corporation E cA U HAMAN 43 20 34th Street Long Island City NY 11101 718 937 4500 c r 1 800 238 3535 Fax 718 937 4676 email seb sussmancorp com Up www sussmanboilers com LISTED PUR 101137 06 04 Sussman Boilers installation Operation amp Maintenance Manual Dimensional Information amp Component Identification Models ES HU SSB 44 59 Height Overall Height 36 61 Length Overall Length 28 33 34 38 Width Overall Width 20 22 26 30 A Steam Outlet 6 1 4 10 8 1 4 9 B Steam Outlet 10 1 4 17 17 1 4 18 1 4 C Drain Valve 5 12 17 16 3 4 H D Drain Valve 6 1 2 6 6 1 4 6 1 4 E Check Valve 14 9 17 16 3 4 F PV Drain Valve 2 3 4 2 1 4 2 3 4 2 3 4 G PV Drain Valve 6 1 4 9 1 2 7 3 4 9 1 4 J Clearance 3 3 4 3 1 2 4 4 K Check Valve 2 1 2 2 3 4 3 3 M Door Width 8 3 4 14 12 3 4 14 3 4 Allow 24 inches all around for servicing WATER STEAM INLET OUTLET ES 12 18 HU 40 55 1 2 NPT 1 2 NPT ES 24 72 HU 75 205 1 2 1 NPT ES 100 HU 310 1 2 NPT 1 1 2 ES 135 180 HU 410 550 1 2 NPT 2 NPT SSB 12 18 1 2 NPT 1 2 NPT SSB 24 72 1 2 NPT 1 NPT SSB 80 100 1 2 NPT 1 1 2 SSB 135 180 1 2 NPT 2 NPT Allow minimum 21 inches clearance in front of door for servicing of heating elements Recommended clearance 24
37. ure 6 Heating element mounting bolts should be checked and tightened to a torque of 22 ft Ibs If there are indica tions of steam leaks from an element replace the element gasket A monthly check for leaks should be made any loose or damaged fittings should be tightened or replaced Every four months the boiler float control should be checked for proper operation The lower equalization col umn 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 ele ments 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 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 ON Ko Sussman Boilers installation Operation amp Maintenance Manual Optional Equipment AUXILIARY LOW WATER CUT OFF For model ES amp HU boilers P N ES81017 amp ES81017MR w manual reset this system will not work with distilled de ionized de mineralized or RO type water
38. ve the operating pressure setting Turn on water supply Turn main disconnect switch on 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 Boiler steam pressure will gradually increase to the operating pressure control set point at which time the contactor s will de energize o N 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 The boiler is equipped with float type liquid level controls employing micro switches They are extremely sensitive and reliable and will maintain the proper water level within the boiler pressure vessel automatically during boiler operation oo o The boiler should be blown down daily See blowdown instructions 11 Blowdown Sussman Boilers installation Operation amp Maintenance Manual A daily blowdown is an essential part of boiler operation It is the best and most important part of preventative main tenance 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 y
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