Chromalox CES-6 User Manual
3 Phase Voltages*
Output
Quantity and Rating
No./kW
Elec at
of Contactors
of
Rating Cap. Vol. 212˚F Heating
Model (BHP) (kW) (Gals.)
(Lbs./Hr.)
208 240 480†
Elements
Type CES — 0-100 PSIG
CES-6 .6 6 6 18 30 30 30 1-6
CES-9 .9 9 6 27 30 30 30 1-9
CES-12 1.22 12 6 36.2 40 30 30 1-12
CES-18 1.73 17 6 51.2 50 50 30 1-17
CES-24 2.45 24 14.3 72.3 2-40 2-30 2-30 2-12
1-40 1-40 1-12
CES-30 2.95 29 14.3 87.4
1-50 1-30
40
1-17
CES-36 3.47 34 14.3 102.5 2-50 2-50 50 2-17
1-40 1-30 1-40 1-12
CES-48 4.69 46 14.3 138.7
2-50 2-50 1-30 2-17
2-50 2-30 2-12
CES-60 5.91 58 14.3 174.8
2-40 2-50
2-40
2-17
CES-72 6.93 68 14.3 205 4-50 4-50 2-50 4-17
CES-100 10.40 102 27.8 307 6-50 6-50 3-50 6-17
CES-135 13.9 136 30.5 410 — 8-50 4-50 8-17
1-30
CES-160 16.1 157.5 30.5 475 — 7-60
3-60
7-22.5
CES-180 18.4 180 30.5 543 — 8-60 4-60 8-22.5
Chromalox
®
DIVISION 4 SECTION
CES
SALES
REFERENCE
DATE
SERVICE REFERENCE
Installation, Operation
and
RENEWAL PARTS IDENTIFICATION
PQ444-1
MAY, 1999
(Supersedes PQ444)
161-562789-002
© 2010 Chromalox, Inc.
Type CES-6 through CES-180 Electric Steam Boiler
Standard Trim is 100 PSI — 0-90 Operating Pressure Range
Boiler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
National Board No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amps . . . . . . . . . . . . . . . Phase . . . . . . . . . . . Cy . . . . . . . . . .
Important — This data file contains the National Board Registration Certificate for your boiler. It must be kept near the boiler at all times.
* Single phase available up to and including 24 kW capacity.
† All boilers must have separate 120V Control Circuit or Transformer.
Boilers under 40 amps max are not fused.
MODEL CES-24 through CES-180
MODEL CES-6 through CES-18
DIMENSIONS
Drain
Blowdown
Valve
K
A
C
H
B
D
E
F
G
Check Valve
L
Optional
Transformer
Safety Valve
Outlet
J
Manual Reset
High Limit Control
Optional Vacuum
Breaker
McDonnell & Miller
Low Water Cutoff
Pump Control
Drain Blowdown
Valve
Operating
Pressure
Control
Control Circuit
On-Off Switch
with Pilot Light
1-1/4"
7/16" Bolt Hole (typical)
Pump/Solenoid
Connection
Conduit Box
Element
I
Steam Outlet
Sight Glass
Element
Access Door
5/8"
7/16" Bolt Hole (typical)
Drain
Blowdown
Valve
K
A
B
C
Check Valve
D
H
F
E
G
Operating
Pressure
Control
Safety Valve
Outlet
Manual Reset
High Limit Control
Optional Vacuum
Breaker
McDonnell & Miller
Low Water Cutoff
Pump Control
Drain Blowdown
Valve
1-1/4"
7/16" Bolt Hole (typical)
Control Circuit
On-Off Switch
with Pilot Light
Optional
Transformer
I
Steam Outlet
Sight Glass
Element
Access Door
Element
5/8"
7/16" Bolt Hole (typical)
Pump/Solenoid
Connection
Conduit Box
Control Panel
Standard when Three (3)
or more Contactors are used
L
2
Typical Plumbing Installation of a Steam Boiler with Condensate Return System
CES — Dimensions (In.)
DIMENSIONS
INSTALLATION
Model A B* C D E F G H I J K L
CES-6 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CES-9 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CES-12 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CES-18 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CES-24 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CES-30 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CES-36 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CES — Dimensions (In.)
Model A B* C D E F G H I J K L
CES-48 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CES-60 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CES-72 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CES-100 63-1/2 30 55 21 27 36 16-3/4 37-1/2 1-1/2 1-1/4 1 3/4
CES-135 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4
CES-160 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4
CES-180 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4
Note: When installing boiler, allow sufficient room (21” minimum) to
facilitate removal of elements if and when necessary.
1. The boiler should be mounted on a solid level foundation.
2. WARNING: A minimum distance of 18” between
boiler and any combustible material must be maintained.
3. Complete all piping to boiler. Connect water line to tagged fitting
on the motor and pump assembly, if used, or to tagged fitting on
water control feeder.
4. When any type of feed other than a pump feed is used — the exist-
ing water supply must be 10 pounds greater than the boiler operating pressure to assure water supply maintains proper water level in
boiler. Otherwise, lack of water can cause heater failure. Keep feed
water line valves open at all times except during blowdown.
5. All water feed systems are connected to water inlet check valve.
6. Connect steam line (with Globe valve) to boiler steam outlet.
Valve should be placed as close as possible to boiler outlet and
sized per label on boiler.
7. To insure maximum efficiency of supplied kW, all piping from
outlet should be insulated.
8. Drain and relief valve piping should be in accordance with state
and local codes. Floor drain to be provided directly below unit.
9. All electrical wiring should be done by licensed electrician in
accordance with national and local electrical codes.
10. If pump is located less than 30 feet from boiler, a second
check valve is required.
Vacuum
Breaker
Safety
Valve
Drain
Boiler
Check
Valve
Check
Valve
Check
Valve
Globe
Valve
Gate
Valve
Heat
Exchanger
Water/Steam
Separator
Insulated Steam Lines
(Pitch Down 5˚)
Pitch Down 5˚
Vent
Condensate
Return
Drain
Gate
Valve
Strainer
Return
Cold Water
Make-Up
Centrifugal
Turbine Pump
Steam
Water
Condensate
Vapor
(Typical
Load)
Trap
Trap
3
*Add two inches for transformer.
Diagram 1
3 Phase Voltage 3 Phase Voltage 3 Phase Voltage
Boiler 208 240 480 Boiler 208 240 480 Boiler 208 240 480
WIRING
TYPICAL WIRING DIAGRAMS
WARNING: Hazard of Electric Shock. Boiler must be
suitably grounded according to N.E.C. standard.
1. Be sure to use the proper wire. Electric wiring to boiler should be
in accordance with National Electrical Code or local wiring code
following wiring diagram supplied. (See recommendations on
safety switches and fusing.)
2. The unit is completely wired and pre-tested before shipment. No
internal wiring is required.
If a separate control circuit is used, the control circuit should be
connected to the control terminal block, inside access door (not
required with transformer).
3. Safety Switches — WARNING: Purchaser should use a
safety switch employing circuit breakers or fuses
between his main power source and the boiler.
4. Because of their water lines, boilers are susceptible to lightning
damage. Industrial type lightning protectors should be installed per
manufacturer’s recommendations at your service entrance. Check
your contractor or electrical dealer for recommended type for your
system.
5. Be sure all electrical connections are sufficiently tightened.
6. WARNING: Substitution of components or modifica-
tion of wiring system voids the warranty and may
lead to dangerous operating conditions.
7. SPECIAL INSTRUCTIONS FOR CUSTOMERS SUPPLYING THEIR OWN CONDENSATE OR PUMP SYSTEMS.
A. Check the voltage of the motor before making the wiring con-
nection. Some Chromalox boilers are supplied with dual voltage systems. The motor should always match the voltage of the
control circuit.
B. The motor circuit should be wired into the pump control as
shown in wiring diagram (float type pump control). If boiler is
equipped with solid state pump control, refer to wiring diagram
and use terminals 5 and 2.
Use Applicable wiring diagrams based on model number and power voltage.
CES-6 1 1 1 CES-30 2 2 3 CES-100 8 8 9
CES-9 1 1 1 CES-36 2 2 3 CES-135 10 11
CES-12 1 1 1 CES-48 4 4 5 CES-160 12 13
CES-18 1 1 1 CES-60 6 6 7 CES-180 10 11
CES-24 2 2 3 CES-72 6 6 7 Export 14
2PS
BR
Heater
Contactors
Feed Water
Boiler On
3
GND
B
FU6
B
1PB
Off
1
GND
1
GND
1 HTR
C1
FU1
FU2
FU3
FU5
FU4
H1
H2
X1
X3
L3
1L1
1L3
1L2
L2L1
X2
X4
Optional Transformer
1
1
C1
2
2
C4
C3
C2
R
1LT
Y
On
IFS
O
1PS
O
O
W
Feed Water
Electrical
Connection
21
1TB
123
3
GND
1
GND
2
GND
1
HTR
FU6
FU
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
* Boilers under 40 Amps total (not fused)
4
Diagram 2
TYPICAL WIRING DIAGRAMS
2PS
BR
Heater
Contactors
Feed Water
Boiler On
3
GND
B
FU9
B
1PB
Off
2
GND
1
GND
1 HTR
C1
FU1
FU2
FU3
FU8
FU7
H1
H2
X1
X3
L3
1L1
1L3
1L2
L2L1
X2 X4
Optional Transformer
1
1
C1
2
2
C2
R
1LT
Y
On
IFS
O
1PS
O
O
W
Feed Water
Electrical
Connection
2
1
2TB
2 GND
1
HTR
FU9
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
2
HTR
C1
FU
1 2 3
C2
FU
4 2 6
1TB
1 GND
3
GND
H4
H3
2 HTR
C2
FU4
FU5
FU6
2L1
2L3
2L2
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
Diagram 3
2PS
BR
Heater
Contactor
Feed Water
Boiler On
3
GND
B
FU6
B
1PB
Off
1
GND
1 HTR
C1
FU1
FU2
FU3
FU5FU4
H1
H2
X1
X3
L3
1L1
1L3
1L2
L2L1
X2 X4
Optional Transformer
1
1
C1
2
2
R
1LT
Y
On
IFS
O
1PS
O
O
W
Feed Water
Electrical
Connection
2
1
2TB
2 GND
1
HTR
FU6
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
2
HTR
C1
FU
1 2 3
1 GND
3 GND
H4
H3
2 HTR
2L1
2L3
2L2
2
GND
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
* Boilers under 40 Amps total (not fused)
5
Diagram 4
TYPICAL WIRING DIAGRAMS
2PS
BR
Heater
Contactor
Feed Water
Boiler On
3
GND
B
FU12
B
1PB
Off
2
GND
1
GND
1 HTR
C1
FU1
FU2
FU3
FU11
FU10
H1
H2
X1
X3
L3
1L1
1L3
1L2
L2L1
X2
X4
Optional Transformer
1
1
C1
2
2
C2
R
1LT
Y
On
IFS
O
1PS
O
O
W
Feed Water
Electrical
Connection
2
1
2TB
2 GND
1 GND
2 GND
1
HTR
FU12
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
2
HTR
3
Htr
1TB
3
GND
H4
H3
2 HTR
C2
FU4
FU5
FU6
2L1
2L3
2L2
FU
1 2 3
FU
4 5 6
FU
7 8 9
C1
C3
C2
FU7
FU8
FU9
C3
3L1
1L3
3L2
3 HTR
C3
Heater
Contactor
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
Diagram 5
2PS
BR
Heater
Contactors
Feed Water
Boiler On
3
GND
B
FU9
B
1PB
Off
2
GND
1
GND
1 HTR
C1
FU1
FU2
FU3
FU8
FU7
H1
H2
X1
X3
L3
1L1
1L3
1L2
L2L1
X2
X4
Optional Transformer
1
1
C1
2
2
C2
R
1LT
Y
On
IFS
O
1PS
O
O
W
Feed Water
Electrical
Connection
2
1
2TB
2 GND
1
HTR
FU9
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
2
HTR
C2
FU
4 5 6
1TB
1 GND
3
GND
H4
H3
2 HTR
C2
FU4
FU5
FU6
2L1
2L3
2L2
C1
FU
1 2 3
3
HTR
3 HTR
3L1
3L3
3L2
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
6
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