3 Phase Voltages*
Output
Quantity/Rating
Elec at
of Contactors
No./kW
Rating Cap. Vol. 212˚F Heating
Model (BHP) (kW) (Gals.) (Lbs./Hr.)
208 240 480†
Elements
Type CHPES — 20-250 PSIG
CHPES-6A 0.6 6 6 18 30 30 30 1-6
CHPES-9A 0.9 9 6 27 30 30 30 1-9
CHPES-12A 1.22 12 6 36.2 40 30 30 1-12
CHPES-18A 1.73 17 6 51.2 50 50 30 1-17
CHPES-24A 2.45 24 14.3 72.3 2-40 2-30 2-30 2-12
1-40 1-40 1-12
CHPES-30A 2.95 29 14.3 87.4
1-50 1-30
40
1-17
CHPES-36A 3.47 34 14.3 102.5 2-50 2-50 50 2-17
1-40 1-30 1-40 1-12
CHPES-48A 4.69 46 14.3 138.7
2-50 2-50 1-30 2-17
2-50 2-30 2-12
CHPES-60A 5.91 58 14.3 174.8
2-40 2-50
2-40
2-17
CHPES-72A 6.93 68 14.3 205 4-50 4-50 2-50 4-17
CHPES-100A 10.40 102 27.8 307 6-50 6-50 3-50 6-17
CHPES-135A 13.9 136 30.5 410 — 8-50 4-50 8-17
1-30
CHPES-160A 16.1 157.5 30.5 475 — 7-60
3-60
7-22.5
CHPES-180A 18.4 180 30.5 543 — 8-60 4-60 8-22.5
Chromalox
®
DIVISION 4 SECTION
CHPES
SALES
REFERENCE
DATE
SERVICE REFERENCE
Installation, Operation
and
RENEWAL PARTS IDENTIFICATION
PQ436-1
MAY, 1999
(Supersedes PQ436)
161-562802-002
© 2010 Chromalox, Inc.
Type CHPES-6A through CHPES-180A
High Pressure Electric Steam Boiler
Standard Trim is 250 PSI — 0-225 PSI 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 CHPES-6A through CHPES-180A
DIMENSIONS
Pump Solenoid
Connection
Conduit Box
Control Panel
Standard When
Three (3) or
More Contactors
are Used
7/16" Bolt Hole Typical
Steam Outlet
Sight Glass
Element
Element
Access Door
Operating
Pressure
Controls
Control
Circuit Fuse
Control Circuit
On/Off Switch
with Pilot Light
5/8"
7/16" Bolt Hole Typical
1-1/4"
Drain
Blowdown
Valve
McDonnell & Miller
Low Water Cutoff
Pump Control
Manual Reset
High Limit Control
Safety Valve Outlet
Drain
Blowdown
Valve
Check
Valve
2
Typical Plumbing Installation of a Steam Boiler with Condensate Return System
Type CHPES — Dimensions (In.)
DIMENSIONS
INSTALLATION
Model A B* C D E F G H I J K L
CHPES-6A 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CHPES-9A 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CHPES-12A 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CHPES-18A 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2
CHPES-24A 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CHPES-30A 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CHPES-36A 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
Type CHPES — Dimensions (In.)
Model A B* C D E F G H I J K L
CHPES-48A 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CHPES-60A 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CHPES-72A 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4
CHPES-100A 63-1/2 30 55 21 27 36 16-3/4 37-1/2 1-1/2 1-1/4 1 3/4
CHPES-135A 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4
CHPES-160A 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4
CHPES-180A 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4
WARNING: To avoid electrical shock hazard, boilers
must be suitably grounded to earth.
1. The boiler should be mounted on a solid level foundation. Note:
When installing boiler, allow sufficient room (21” minimum) to
facilitate removal of elements if and when necessary.
2. WARNING: A minimum distance of 18” between boil-
er 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 existing 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 Shock. Disconnect all power
before working on boiler. Boilers must be effectively
grounded in accordance with the National Electrical
Code to eliminate shock hazard.
WARNING: Use 90˚copper conductors only.
1. Select proper wire gauge and type for supply conductors in accor-
dance with the National Electrical Code and local wiring codes following wiring diagram supplied (See recommendations for disconnect switches and fusing).
2. The unit is completely wired and pre-tested before shipment. No
internal wiring is required. Check all electrical connections for
tightness and retighten if necessary before energizing.
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.
CHPES-6A 1 1 1 CHPES-30A 2 2 3 CHPES-100A 8 8 9
CHPES-9A 1 1 1 CHPES-36A 2 2 3 CHPES-135A 10 11
CHPES-12A 1 1 1 CHPES-48A 4 4 5 CHPES-160A 12 12
CHPES-18A 1 1 1 CHPES-60A 6 6 7 CHPES-180A 10 10
CHPES-24A 2 2 3 CHPES-72A 6 6 7 Export 14
2PS
BR
Heater
Contactors
Feed Water
Boiler On
3
GND
B
FU9
B
1PB
Off
1
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
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
FU9
FU
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
CR
FU4
FU5
FU6
2L1
2L3
2L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
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
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
HTR
FU12
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
2
HTR
C1
FU
1 2 3
C2
FU
4 5 6
1TB
1 GND
3
GND
H4
H3
2 HTR
C2
FU4
FU5
FU6
2L1
2L3
2L2
CR
FU7
FU8
FU9
3L1
3L3
3L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
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
FU9
B
1PB
Off
1
GND
1 HTR
C1
FU1
FU2
FU3
FU8FU7
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
FU9
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
CR
FU4
FU5
FU6
3L1
3L3
3L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
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
FU15
B
1PB
Off
2
GND
1
GND
1 HTR
C1
FU1
FU2
FU3
FU14
FU13
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
FU15
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
CR
FU10
FU11
FU12
4L1
4L3
4L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
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
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
HTR
FU12
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
CR
FU7
FU8
FU9
4L1
4L3
4L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
6
Diagram 6
TYPICAL WIRING DIAGRAMS
2PS
BR
Heater
Contactors
Feed Water
Boiler On
3
GND
B
FU18
B
1PB
Off
2
GND
1
GND
1 HTR
C1
FU1
FU2
FU3
FU17
FU16
H1
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
1 GND
2 GND
1
HTR
FU18
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
2
HTR
3
Htr
1TB
3
GND
H2
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
C4
FU
10
11 12
4
Htr
FU10
FU11
FU12
C4
4L1
4L3
4L2
4 HTR
C4
CR
FU13
FU14
FU15
5L1
5L3
5L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
Diagram 7
2PS
BR
Heater
Contactors
Feed Water
Boiler On
3
GND
B
FU12
B
1PB
Off
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
R
1LT
Y
On
IFS
O
1PS
O
O
W
Feed Water
Electrical
Connection
2
1
2TB
2 GND
1
HTR
FU12
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
2
HTR
FU
1 2 3
1 GND
3
GND
H4
H3
3 HTR
3L1
3L3
3L2
2
GND
3
HTR
4
HTR
C1
C2
FU
4 5 6
1TB
C2
FU4
FU5
FU6
1
GND
2 HTR
2L1
2L3
2L2
4 HTR
4L1
4L3
4L2
C2
CR
FU7
FU8
FU9
5L1
5L3
5L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
7
Diagram 8
TYPICAL WIRING DIAGRAMS
FU
1 2 3
FU
4 5 6
FU
7 8 9
C1 C3
C2
C4
FU
10
11 12
C5
FU
13
14 15
C6
FU
16
17 18
5
HTR
4
HTR
3
HTR
6
HTR
2
HTR
1
HTR
1
2
2TB
1TB
3 GND
2
GND
1
GND
FU24
1PB
3
GND
C2
C6
C5
C4
C3
2PS
3PS
1PS
On
Off
FU24
IFS
O
O
O
Y
BR
B
B
1PB
1
1
2
2
W
R
Boiler
On
Feed Water
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
1LT
Optional Transformer
X1 X4
X2
X3
FU22
FU23
2 HTR
3 HTR
1 HTR
1L1
1L3
1L2
2L1
2L3
2L2
3L1
3L3
3L2
4 HTR
4L1
4L3
4L2
C1
C4
C3
C2
FU1
FU18
FU17
FU16
FU15
FU14
FU13
FU12
FU11
FU10
FU9
FU8
FU7
FU6
FU5
FU4
FU3
FU2
C6
C5
5 HTR
6 HTR
5L1
6L3
6L2
6L1
5L3
5L2
L1
L3
L2
1
GND
2
GND
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Feed Water
Electrical
Connection
CR
FU19
FU20
FU21
7L1
7L3
7L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
C1
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
Diagram 9
FU
1 2 3
FU
4 5 6
FU
7 8 9
C1 C3
C2
5
HTR
4
HTR
3
HTR
6
HTR
2
HTR
1
HTR
1
2
2TB
1TB
3 GND
2
GND
1 GND
FU15
1PB
3
GND
C1
C2
C3
3PS
1PS
On
Off
FU15
IFS
O
O
O
Y
BR
B
B
1PB
1
1
2
2
W
R
Boiler
On
Feed Water
Heater Contactor
Heater Contactor
Heater Contactor
1LT
Optional Transformer
X1
X4X2
X3
C1
C2
FU1
FU9
FU8
FU7
FU6
FU5
FU4
FU3
FU2
C3
5 HTR
6 HTR
5L1
6L3
6L2
6L1
5L3
5L2
1
GND
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Feed Water
Electrical
Connection
2PS
H1
H4
H2
H3
FU13
FU14
2 HTR
3 HTR
1 HTR
1L1
1L3
1L2
2L1
2L3
2L2
3L1
3L3
3L2
4 HTR
4L1
4L3
4L2
2
GND
L1
L2
L3
CR
FU10
FU11
FU12
7L1
7L3
7L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
8
Diagram 10
TYPICAL WIRING DIAGRAMS
13
14 15
16
17 18
19
20 21
C5 C7
C6
C1
1 2 3C24 5 6C37 8 9
5
HTR
4
HTR
3
HTR
6
HTR
2
HTR
1
HTR
1
2
2TB
1TB
3 GND
2
GND
1
GND
FU30
1PB
3
GND
C1
C2
C6
C3
2PS
3PS
1PS
On
Off
FU30
IFS
O
O
O
Y
BR
B
B
1PB
1
1
2
2
W
R
Boiler
On
Feed Water
Heater Contactor
1LT
Optional Transformer
X1
X4X2
X3
FU28 FU29
2 HTR
3 HTR
1 HTR
1L1
1L3
1L2
2L1
2L3
2L2
3L1
3L3
3L2
4 HTR
4L1
4L3
4L2
C1
C4
C3
C2
FU1
FU18
FU17
FU16
FU15
FU14
FU13
FU12
FU11
FU10
FU9
FU8
FU7
FU6
FU5
FU4
FU3
FU2
C6
C5
5 HTR
6 HTR
5L1
6L3
6L2
6L1
5L3
5L2
L1
L3
L2
1
GND
2
GND
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Feed Water
Electrical
Connection
22
23 24
C4
7
HTR
8
HTR
10
11 12
C8
C8
C4
Heater Contactor
H1 H4
H2
H3
FU24
FU23
FU22
FU21
FU20
FU13
C8
C7
7 HTR
6 HTR
7L1
8L3
8L2
8L1
5L3
7L2
C5
C7
CR
FU25
FU26
FU27
9L1
9L3
9L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
Diagram 11
FU
1 2 3
FU
4 5 6
FU
7 8 9
C1 C3
C2
5
HTR
4
HTR
3
HTR
6
HTR
2
HTR
1
HTR
1
2
2TB
1TB
3 GND
2
GND
1 GND
FU18
1PB
3
GND
C1
C2
C3
3PS
1PS
On
Off
FU18
IFS
O
O
O
Y
BR
B
B
1PB
1
1
2
2
W
R
Boiler
On
Feed Water
Heater Contactor
Heater Contactor
1LT
Optional Transformer
X1
X4X2
X3
C1
C2
FU1
FU9
FU8
FU7
FU6
FU5
FU4
FU3
FU2
C3
5 HTR
6 HTR
5L1
6L3
6L2
6L1
5L3
5L2
1
GND
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Feed Water
Electrical
Connection
2PS
H1
H4
H2H3
FU16
FU17
2 HTR
3 HTR
1 HTR
1L1
1L3
1L2
2L1
2L3
2L2
3L1
3L3
3L2
4 HTR
4L1
4L3
4L2
2
GND
L1
L2
L3
FU
10
11 12
C4
7HTR 8
HTR
C4
FU12
FU11
FU10
C4
7 HTR
8 HTR
5L1
8L3
8L2
8L1
5L3
7L2
CR
FU13
FU14
FU15
9L1
9L3
9L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
9
Diagram 12
TYPICAL WIRING DIAGRAMS
FU
13
14 15
FU
16
17 18
FU
19
20 21
C5 C7
C6
C1
1 2 3C24 5 6C37 8 9
5
HTR
4
HTR
3
HTR
6
HTR
2
HTR
1
HTR
1
2
2TB
1TB
3 GND
2
GND
1
GND
FU27
1PB
3
GND
C1
C2
C5
C3
2PS
3PS
1PS
On
Off
FU27
IFS
O
O
O
Y
BR
B
B
1PB
1
1
2
2
W
R
Boiler
On
Feed Water
Heater Contactor
1LT
Optional Transformer
X1 X4
X2
X3
FU25 FU26
2 HTR
3 HTR
1 HTR
1L1
1L3
1L2
2L1
2L3
2L2
3L1
3L3
3L2
4 HTR
4L1
4L3
4L2
C1
C4
C3
C2
FU1
FU18
FU17
FU16
FU15
FU14
FU13
FU12
FU11
FU10
FU9
FU8
FU7
FU6
FU5
FU4
FU3
FU2
C6
C5
5 HTR
6 HTR
5L1
6L3
6L2
6L1
5L3
5L2
L1
L3
L2
1
GND
2
GND
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Feed Water
Electrical
Connection
C4
7
HTR
FU
10
11 12
C4
Heater Contactor
H1 H4
H2
H3
FU21
FU20
FU19
C7
7 HTR
7L1
5L3
7L2
FU
FU
FU
C7
C6
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
CR
FU22
FU23
FU24
8L1
8L3
8L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
Diagram 13
FU
1 2 3
FU
4 5 6
FU
7 8 9
C1
C4
C2
5
HTR
4
HTR
3
HTR
6
HTR
2
HTR
1
HTR
1
2
2TB
1TB
3 GND
2
GND
1
GND
FU18
1PB
3
GND
C1
C2
C3
2PS
3PS
1PS
On
Off
FU18
IFS
O
O
O
Y
BR
B
B
1PB
1
1
2
2
W
R
Boiler
On
Feed Water
Heater Contactor
1LT
Optional Transformer
X1 X4
X2
X3
FU16 FU17
2 HTR
3 HTR
1 HTR
1L1
1L3
1L2
2L1
2L3
2L2
3L1
3L3
3L2
4 HTR
4L1
4L3
4L2
C1
C2
FU1
FU9
FU8
FU7
FU6
FU5
FU4
FU3
FU2
C3
5 HTR
6 HTR
5L1
6L3
6L2
6L1
5L3
5L2
L1
L3
L2
1
GND
2
GND
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Feed Water
Electrical
Connection
7
HTR
FU
10
11 12
C4
Heater Contactor
H1
H4
H3
H2
FU12
FU11
FU10
C4
7 HTR
7L1
5L3
7L2
Heater Contactor
Heater Contactor
C3
CR
FU13
FU14
FU15
8L1
8L3
8L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
10
After proper wiring and piping of boiler system is complete, testing of
controls can start. Before testing controls, it is recommended that
all contactor fusing be removed. This is to prevent possible element
failure under test conditions.
A. OPERATING AND TESTING THE McDONNELL &
MILLER LOW WATER CUTOFF CONTROL.
1. Be sure all valves from incoming water supply are fully open.
Turn boiler switch to “ON” position, pump or solenoid
valve will energize, allowing boiler to fill with water. Proper
water level is automatically reached with level control supplied. Pump or solenoid feed will shut off at proper water level.
Contactor(s) will energize, supplying power voltage to elements.
2. Checking operation of pump switch. (Figure 1) With water
level visible in sight glass, partially open drain valve at bottom
of boiler. If automatic blowdown supplied, push manual blowdown switch until valve open light is on, hold for few seconds.
Water level will fall, allowing float to trip pump switch to
“ON” position. Close drain valve or release manual blowdown
switch.
Pump motor or solenoid valve will energize and water level
will resume to normal level in sight glass.
3. Checking low water cutout switch operation, open drain
valve completely. If automatic blowdown supplied, push in
and hold manual blowdown switch until water level falls
enough to trip cutout switch. Close drain valve or release manual blowdown switch. If low water cutout is automatic reset,
pump or solenoid will return water level to normal. If low
water cutout is manual reset, then manual reset button on
McDonnell & Miller low water cutoff control must be pushed
to complete circuit. Turn off boiler. Reinstall contactor
fuses.
WARNING: Be sure all electrical connections are tight
before energizing boiler. Reset all manual reset controls by pushing reset buttons on: (1) high limit control
located on top of boiler and (2) McDonnell & Miller
located on the side of boiler.
Diagram 14
TYPICAL WIRING DIAGRAMS
3
GND
C1
CR
C2
C3
2PS
1PS
On
Off
FU16
IFS
O
O
Y
BR
B
B
1PB
1
2
W
R
Boiler
On
9.9
Heater Contactor
1LT
2 HTR
1 HTR
1L1
1L3
1L2
2L1
2L3
2L2
C1
C2
FU1
FU9
FU8
FU7
FU6
FU5
FU4
FU3
FU2
C3
3 HTR
3L1
3L3
3L2
L1
L3
L2
1
GND
2
GND
Heater Contactor
FU12
FU11
FU10
C4
4 HTR
4L1
4L3
4L2
Heater Contactor
Heater Contactor
346V 3Ø 50 HZ
220 VAC Single Phase Control Circuit
1
C4
1CR-1
BW
1CR-2
Customer Pump
Connection
FU
1 2 3
FU
4 5 6
FU
7 8 9
C1
C4
C2
3
HTR
2
HTR
1
HTR
4
HTR
1
2
2TB
1TB
3
GND
2
GND
1
GND
FU16
1PB
Cabinet Exterior Left Side Cabinet Exterior Right Side
Panel Layout
Feed Water
Electrical
Connection
FU
10
11 12
C3
1CR
FU13
FU14
FU15
5L1
5L3
5L2
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
11
A
C
D
B
Line
Pump
Low-Water
Cut-Off
Terminals
Alarm
Circuit
Terminals
Pump
Circuit
Terminals
Pump
Switch
Cut-off
and
Alarm
Switch
Adjusting
Screws
Figure 1 — Automatic Reset Low-Water Cutoff Junction Box
PRE-OPERATION CHECK
B. ADJUSTING OPERATING PRESSURE CONTROLS
1. Chromalox boilers are supplied with operating and high limit pres-
sure controls. One is used for controlling the operating pressure of
the boiler while the other is used as a high limit control. To determine the difference in the controls, the high limit has a manual reset
lever on top of the case. Also, there is no differential scale present.
2. On all controls, the pressure adjusting screw on the top of the case
sets the desired pressure. Turning the screw counterclockwise
reduces the pressure setting (CUT OUT) (See Figure 2). High limit
control should be set at 10 psig above the operating pressure of the
boiler.
3. The differential adjusting screw on the operating control is set in the
same manner as the pressure adjusting screw. The CUT OUT setting minus the differential setting, equals CUT IN pressure of the
operating control.
To check operation of the controls, close steam outlet valve and adjust
operating pressure control to a low pressure setting. Also, set high limit
control at 10 psig above operating pressure control. Turn on boiler, and
allow pressure to build up. When pressure gauge reading approaches
set point of pressure control, the switch will trip and shut off boiler.
Turn off boiler.
To reset pressure control, bleed off enough pressure in the boiler by
opening steam outlet drain, or blowdown valve to allow the operating
control to reset.
4. HIGH LIMIT PRESSURE CONTROL OPERATION
The high limit is tested in the same manner but with the operating
control set above the pressure setting of the high limit. (Figure 3)
CAUTION: THIS IS FOR TEST PURPOSES ONLY!
When the high limit trips, turn off boiler and reset high limit to
proper setting. The manual reset level must be pushed to resume
operation upon startup.
Scaleplates
Pressure
Adjusting
Screw
Mercury
Switch
Index
Mark
Pointer
Leveling
Indicator
Diaphragm
Assembly
Operating
Lever
Pressure
Setting
Indicator
Differential
Setting
Indicator
Differential
Adjusting Screw
Figure 2 — Pressure Control
Scaleplates
Pressure
Adjusting
Screw
Manual
Reset
Lever
Mercury
Switch
Index
Mark
Pointer
Leveling
Indicator
Diaphragm
Assembly
Operating
Lever
Pressure
Setting
Indicator
Figure 3 — Hi Limit Control
12
OPERATION
OPERATION
RECOMMENDED START-UP PROCEDURES
1. Close globe valve on steam outlet side of boiler. (Customer Supplied)
2. Turn on boiler and allow pressure to build up to operating pressure.
3. Only open globe valve at quarter turns at first, introducing smaller
amounts of steam into process. Avoid opening globe valve all at
once. This will eliminate the possibility of evacuating the boiler of
water caused by the suddenly increased boiling of the water in the
vessel as the pressure is reduced. On boilers where constant pressure is not maintained, globe valve should be kept partially closed.
This will maintain a constant head on the boiler and stabilize any
fluctuation in boiler water level.
Note: For best boiler performance, a 1/4” less steam valve
than size of safety valve should be plumbed as close as practicable to steam outlet. Where 1/2” safety valve is used on boiler, a 1/4” steam valve is recommended.
MANUAL BLOWDOWN INSTRUCTIONS
Blowdown is an essential part of boiler operation. It is the best
preventative maintenance 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 is necessary once a
day. In soft water areas, once each 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. At 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.
2. If blowing-down into a receptacle, allow pressure to decrease to
15-20 psi before opening blowdown valve.
3. It is preferable to connect the blowdown valve directly into a
drainage system. If this is done, the boiler can be discharged at
operating pressure.
4. When discharge is complete and boiler is drained — (a) close the
blowdown valve; (b) open water supply valve; (c) put boiler switch
in the ON position; and, (d) close wall mounted safety switch.
5. When refilling is complete, turn off the boiler switch unless further
operation is desirable.
6. 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.)
The use of chemical boiler cleaning compounds in these boilers
voids all warranties unless approved by manufacturer. Some compounds will damage copper sheathed heating elements to shorten
useful life.
OPERATION
AUTOMATIC BLOWDOWN INSTRUCTIONS
(IF FURNISHED)
The Automatic Blowdown is a device which automatically starts
up your boiler in the morning; shuts it down at night and blows down
(partially drains) the main boiler drain and the low water cut-off column for a predetermined time interval each working day.
The heart of the unit is an electrically operated straight through
type ball valve. It is specially designed to handle dirty, corrosive fluids and particles without requiring cleaning or the use of a strainer.
Both the valve and the boiler are controlled by an electric control
unit which indicates with pilot lights when the drain valve is in the
opened or closed position and when the boiler is ON or OFF. In addition to the automatic control function, the unit has a push button which
momentarily de-energizes the boiler and opens the drain valve regardless of the time of day.
The unit may also be used to blow down boilers which run continuously, day and night.
INITIAL TESTING — Set the switch marked “Programmed
duty/24 Hour duty” located on the panel box to the “ON” position.
On the large timer set the “ON” tab at about 8 AM and the “OFF”
tab at about 8 PM. Set the blowdown cycle dial at “O”.
Turn the large timer by hand until the “ON” tab passes the “TIME
NOW” indicator so the “TIME NOW” arrow indicates 10 AM.
Energize the main feed to the “LINE TERMINALS” of the unit.
The “BOILER ON” pilot light as well as the “VALVE CLOSED”
light should glow.
Hold down the “DRAIN” button for about six seconds. The
“BOILER ON” light should go out immediately as well as the
“VALVE CLOSED” light. It takes about 4 seconds for the drain valve
to open fully at which time the “DRAIN VALVE OPEN” light should
light. As soon as the “DRAIN” button is released the valve begins to
close. When it reaches the closed position, the “VALVE CLOSED”
and the “BOILER ON” should light up again.
Now turn the wheel on the large timer until the “OFF” tab passes
the “TIME NOW” arrow. The “BOILER ON” light should go out and
the valve should begin to open. Once the “VALVE OPEN” light goes
on, the valve should remain open for a few seconds and then automatically close. The “VALVE CLOSED” light should light and the
“BOILER ON” light should remain off.
OPERATION— Set the “BOILER PROGRAMMED DUTY”
switch to “BOILER ON” if the boiler is to be shut down each night.
Set it to “24-HOUR DUTY” if the boiler is to remain on continuously 24-hours per day (except during blowdown).
Set the tabs on the large timer for the ON and OFF times desired
for the boiler, screw in the small black day-skip tabs if is to remain off
during the weekend, etc.
If the boiler is on 24-hour duty, set the OFF tab for the time that is
desired for blowdown. Tzhe ON tab can be ignored, but must remain
on timer.
The small time delay relay controls the time that the drain valve
remains open. The time is controlled by adjusting knob marked
Blowdown cycle. Counterclockwise decreases, clockwise increases
blowdown time. Time must be adjusted by trial.
13
Boiler On
Valve Open
Valve Closed
Programmed Duty
24 Hour Duty
Manual Drain
Valve Actuator
Timer
Automatic Blowdown Control Cabinet
Display View of Automatic Blowdown Control Cabinet
Terminal Block
Support
7 Day Clock
Control
Relay
Time Delay Relay
311
7
2102628
Terminal Block
Component Layout
Support
Replace with
Amp Fuse Only
Manual Drain
24 Hour Duty
Prorammed Duty
Valve Open
Valve Closed
Boiler On
Blowdown Cycle
30's
0's
80's
Cycle
Adjustment
On/Off Switch
Indicator Light
Indicator Light
Switch
PB Switch
Fuse
Valve Closed
Boiler Control
(3)
Boiler On
Ball Valve
Control
(5)
7-Day Timer
(2.3)
Exterior Side
2
w
Clock
3A
1
8
1LT
2LT
3LT
0
Valve Open
Blowdown Valve
Motorized
6
Y
B
2A
1A2B1B
BL
2
3
4
2
34
1
2
1
P
2PB
1PB
1CL
1CL
1TR
PR
1CR
G
3
B
1FU
15A
7
R
B
10
1CR
1TR
1
R
R8
2W
O
R
/
M
O
BL
/
R11
Wiring Diagram for Automatic Blowdown
OPTIONAL EQUIPMENT FOR STEAM BOILERS
AUXILIARY LOW WATER CUTOFF
Operation
Operation of this control is accomplished by sensing a minute AC
current flowing between submerged contact probe in the boiler shell.
When this minute AC current is conducted through an external circuit resistance up to 40,000 ohms or less, a signal of sufficient magnitude is present to trigger the SCR and, in turn energize the control
relay.
As the water level in the boiler drops below the level of the probe,
the AC current is broken and the control relay is de-energized. The
control will not energize until sufficient water is present in the boiler.
Specifications
Input Supply — 120 vac/50-60 hz
Detectable Range — 100,000 ohms
Probe Voltage — 24 Vac
Probe Current — 10 milliamps
Control Relay — Single pole double throw
WARNING: Control will not work with de-ionized or
demineralized water.
PROPORTIONING PRESSURE CONTROL FOR
SEQUENCER AND SCR CONTROLS
Typical Operation
Pressure variations cause the bellows to expand or contract.
Linkage between the bellows and the potentiometer wiper causes the
wiper to move across the windings on the potentiometer. This varies
the resistance between R and B, and between R and W, causing an
unbalance in the circuit connected to the controller.
A proportioning pressure control is used to regulate a motor driven
or solid state sequencer. The controller potentiometer, the feedback
potentiometer in the motor and a balancing relay in the motor form an
electric bridge circuit. As long as the pressure of the controlled medium remains at the set point of the controller, the circuit is balanced;
i.e., equal currents flow through both sides of the balancing relay and
the relay contacts are open. When the circuit is balanced, the motor
does not run.
If the pressure of the controlled medium rises, the wiper in the controller moves toward W. This unbalances the circuit so a larger current
flows through one side of the balancing relay. The “close” contacts in
the relay make, causing the motor to drive toward its closed position. As
the motor runs, the wiper on the feedback potentiometer moves in a
direction to balance the circuit. When the circuit is again in balance, the
balancing relay contacts open and the motor stops.
Similarly if the pressure of the controlled medium falls, the wiper on
the controller potentiometer moves toward B, and the “open” contacts
in the balancing relay make. The motor drives towards its open position
until circuit balance is achieved.
The slightest change in the pressure of the controlled medium will
cause a change in the number of elements energized to compensate for
it, thus keeping the pressure constant. This process is called modulation.
PROPORTIONAL PRESSURE CONTROL ONLY SUPPLIED
WITH SEQUENCER
Main Setting — Turn the adjustment screw until the indicator is
opposite the low point of the desired throttling range. That is, if the pressure is to be held at a minimum of 50 psi, set the indicator at 50 psi. The
pressure will them be maintained between 50 psi and a higher pressure
equal to the 50 psi plus the throttling range.
THROTTLING RANGE SETTING L91B
After setting the indicator for the minimum pressure, turn the throttling range adjustment screw until the throttling range indicator points to
the desired throttling range on the scale. This scale is graduated from
“min” to “F”. The value of each division varies with the scale range of
the instrument.
PRESSURE VALUE EACH
SCALE RATING DIVISION ON SCALE
0-15 psi 2.2 psi
20-300 psi 16.4 psi
Pressure scale rating will vary depending on pressure control supplied.
CHECKOUT
After the controller has been installed, wired, and set, it should be
tested with the system in operation. First allow the system to stabilize.
Then observe the operation of the controller while raising and lowering
its set point. Pressure should increase when the set point is raised and
decrease when the set point is lowered. Use accurate pressure testing
equipment when checking out the controller. Do not rely on inexpensive
gauges. The controllers are carefully calibrated at the factory.
If the motor or actuator runs the proper direction when the set point
is adjusted, it can be assumed that the controller is operating properly. If
it runs in the wrong direction, reverse the B and W wires. Observe the
action of the motor to see if it stabilizes. If the motor is moving constantly, widen the proportioning range a little at a time, until the system
is stable.
14
Adjusting Screw
Differential Adjusting Screw
R
W
B
3
3
2
2
2
2
6
6
2
2
1
1
LWCO Probe
Aux. Low
Water Cutoff
O
O
O
R
H
C
1PS
C1
NO
L1 L2
1PS
BL
W
Y
2PS
BL
Auto
Blow
Down
System
BR
C1
W
W
Heater
Contactor
Feed Water
(Solenoid Pump)
R
1LT
W
Boiler On
2
GND
3
GND
1
GND
B
FU3
B
1PB On
Off
X1
X3
X2 X4
1 HTR
C1
Fuses Supplied
on Boilers Rated
Over 40 Amps.
FU
FU
FU
FU2
FU1
H1 H2H3 H4
480V/120V
1.5 KVA
480V
3
60 HZ
L1 L3
L2
Typical Wiring for
Auxiliary Low Water Cutoff
Electronic Resistance Sensing
Amplifier for Auxiliary
Low Water Cutoff
(L91B) Proportioning Pressure Control used with Sequencer Control
OPTIONAL EQUIPMENT FOR STEAM BOILERS
IF A CONTROLLER SEEMS TO OPERATE IMPROPERLY
If the controller is suspected of operating improperly, it may be
further checked as follows:
1. Leave the controller installed where it is, but disconnect all power
to the boiler.
2. Loosen the cover screw below the main scaleplate and remove the
cover.
3. Disconnect the wires from the controller.
4. Connect an ohmmeter between controller terminals B and W to
measure the resistance of the potentiometer in the controller. The
ohmmeter should read about 135 ohms on an L91B.
5. Connect the ohmmeter between controller terminals W and R and
raise the set point of the controller above the actual pressure being
measured. The ohmmeter should read the full value of the potentiometer measured in step 4 (135 ohms for an L91B).
6. Slowly lower the set point of the controller while observing the
ohmmeter reading. The resistance should drop to zero at some set
point below the actual pressure.
7. An approximation of the proportioning range can be made by
observing the change in set point required for a resistance change
from zero to full value.
8. When the controller is operating properly, reconnect the wires,
replace the cover, tighten the cover screw, and reset the controller
to the desired value.
9. Reconnect power to the controlled motor.
BOILER SEQUENCER (5 STEP) MOTOR DRIVEN
RECYCLE FEATURE
The step control is designed to drop out all contactors when control circuit is interrupted. On resumption of power, the camshaft
rotates to the counterclockwise (ccw) limit, opening all the load
switches. The recycle relay then energizes, pulling in the load contact, and finally the camshaft rotates clockwise (cw) to the position
called for by the pressure controller energizing, in sequence, the
required load stages.
TESTING OPERATION OF SEQUENCER
1. With boiler off, remove wiring from pressure control on
sequencer low voltage terminal board.
2. Turn on boiler to supply the voltage to the sequencer. Short ter-
minal R and B for counterclockwise rotation and terminal R and
W for clockwise rotation.
3. If sequencer operates under this test procedure, but when rewired
to pressure controller and does not function, check pressure control. Note that wiring is W-B and B-W-R-R between sequencer
and pressure controller
BOILER SEQUENCE — SOLID STATE
Solid State Progressive Sequencer
The solid state progressive sequencer provides accurate electronic control of multi-stage loads of the type used in Chromalox
steam boilers. It features progressive sequencing (first on-first off)
which equalizes the operating time of each load. This control gives
visual indication of each energized stage by means of integral solid
state light emitting diodes. In the event of power interruption, all
heating elements are immediately de-energized for safety. When
power resumes, the control will restage the loads one at a time.
The solid state sequencer operates on 120V AC/60 Hz and each
output is relay switched with a load rating of 125 VA at 120V AC.
The input to the sequencer is a 0-135 OHM potentiometer supplied on the operating pressure control. The sequencer has a sensitivity control which is adjustable from min. to max. This sensitivity
control defines the amount of resistance (pressure) deviation
allowed before adding or subtracting a load. Potentiometer resistance should decrease with increasing pressure. Connections are
made to red and white terminals of proportional pressure control.
See Wiring Diagram 337-300164-452 for Boiler With Solid State
Sequencer.
Main Scale
Adjusting
Screw
Proportioning Range
Adjusting Screw
R
W
B
Main Scale
Setting
Indicator
Set Point
Increase
R
W
B
Ohmmeter
Increases to
135 Ohms
Terminals are not Labeled, but Screw-Heads are
Color Coded Red (R), White (W) and Blue (B).
15
Solid State Sequencer
Sequencer (5-Step)
HIGH PRESSURE FEED
High pressure makeup water pumps are used when water pressure
does not exceed boiler pressure by more than 10 psi and when condensate water is not returned to the boiler. Note: Consult factory or
sales office for motor/pump sizing for appropriate water feed system.
Installation
WARNING: Hazard of Electric Shock. Water feed system
must be effectively grounded in accordance with the
National Electrical Codes to eliminate shock hazard.
1. Locate feed on level floor or platform.
2. Connect water line to tagged fitting on feed.
3. Connect piping from discharge to water inlet check valve on boil-
er with minimum of 90˚ bends or other restrictions.
4. All electrical wiring should be done by licensed electricians in
accordance with local and national electrical codes. Refer to boiler instruction for manual wiring diagram.
5. If pump is located less than 30 feet from boiler, a second check
valve is required.
WATER FEED SYSTEMS
Automatic High Pressure Water Feed Pump/Motor Assembly
OPTIONAL EQUIPMENT FOR STEAM BOILERS
16
Pipe
Dimensions (In.)
Assembly Pressure Size
Model HP Range (NPT) A B C D E F
ES-38020 3/4 0-200 1/2 16-1/4 3 7-3/16 4-7/8 6-1/2 6-1/8
Pressure
Control
5 Step
Control
Sequencer
Auto
Blowdown
System
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Feed Water
Solenoid Valve
Boiler
On
Optional Transformer
480/120V
480V 3Ø 60 HZ
CR
W
1
Mtr
Customer
Connect
Feed Water
Motor
10L
30L
20L
IT1
IT3
IT2
CR
L1 L3
L2
Pump Motor Dimensions
Typical wiring for boilers equipped with Auto Blowdown System and/or Solid State Sequencer
Wire Color Code
B = Black
BR = Brown
R = Red
O = Orange
Y = Yellow
G = Green
BL = Blue
W = White
30 Gal.
Condensate
Return System
WATER FEED SYSTEMS
CONDENSATE RETURN SYSTEMS
Chromalox condensate return systems are used wherever condensed
steam can be collected for reuse in the boiler. Significant energy can be
saved by returning condensate to the boiler. The condensed water is free
from corroding minerals and carries a substantial amount of heat which
does not have to be replenished.
IMPORTANT: Vacuum breaker is required whenever using a condensate return system.
Installation — Wiring
A. Check the voltage of the motor before making the wiring connection.
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 located on
the boiler. See boiler instruction sheet for wiring diagram.
C. All electrical wiring should be done by licensed electrician.
D. Be sure to use the proper wire. Electrical wiring to boiler
should be in accordance with National Electrical Code or local
wiring code following wiring diagram supplied.
Plumbing
A. Connect water line to tagged fitting on the motor and pump assem-
bly control feeder.
B. Interconnecting piping between boiler and condensate return system
should be installed with a minimum of 90˚ bends or other restrictions.
17
MAINTENANCE
WARNING: Hazard of Shock. Disconnect all power
before working on boiler.
Chromalox Electric Steam Boilers are designed for years of trouble-free
performance. To establish a good preventative maintenance program,
we suggest the building maintenance man or engineer familiarize himself with these simple rules:
1. The use of specific boiler cleaning compounds cannot be rec-
ommended. We do recommend that a reputable firm of water treat-
ment engineers be consulted regarding conditioning boiler water.
Proper selection must be made of a compound to prevent damage to
copper sheath heating elements.
2. The sight glass should be checked daily to ensure the boiler has ade-
quate water.
3. A monthly inspection should be made of internal wiring. All elec-
trical connections should be checked for tightness.
A check for water or steam leaks should also be made and any loose
fittings immediately tightened.
4. If boiler is equipped with Solid State Auxiliary Low Water Cutoff,
every four months the probe should be checked for deposits and
cleaned, if necessary. This is accomplished by removing inspection
plate, removing the probe (with a standard sparkplug wrench) clean-
ing and replacing.
Note: The system will not operate if the boiler is using distilled,
demineralized or deionized water. At the same time, one of the bot-
tom heating elements should be removed. If scale has begun to form,
all elements should be cleaned and boiler drained and flushed.
5. IMPORTANT: The Manufacturers’ Data Report enclosed
within the instruction sheet is very important and must be put in a
safe place. You may be called upon to produce it by a state agency.
INSTRUCTIONS FOR ELEMENT REPLACEMENT
WARNING: Before installing your new elements, be sure
the McDonnell-Miller low-water cut-off is operating
perfectly and the float chamber and lower equalizer
column are completely clear of sludge or other foreign
matter.
Failure to do this may cause the immediate burnout of the new ele-
ments.
All elements are thoroughly checked before shipment. The manufacturer cannot be responsible for burnouts 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 fingers or probes to see if it is clear and clean.
Boiler
1" Steam Equalizing Pipe
Pump and Low
Water Control
Normal Boiler
Water Level
Cutoff Level
is Arrow Mark
Blowdown
Valve
1" Water Equalizing Pipe
1-1/2"
Condensate Storage Tank Pump Discharge Condensate
Model For Boiler Model Max. Pressure (psig) Capacity (Gals.) Pump (Hp) Motor (Volts/Phase) Conn. (NPT) Ref. Conn. (NPT) L H W
HPCS-
3003 All CHPES 250 30 3 240 / 480 1 1-1/4 2 36 42-3/16 24
1-1/4” NPT Vent
Return Inlet
Make-Up Valve
Inlet
1-1/4” NPT
3” NPT Discharge
1” NPT
Drain
L
H
W
Dimensions (In.)
18
MAINTENANCE
RENEWAL PARTS IDENTIFICATION
Drain Blowdown Valve
Drain Blowdown Valve
Water Level Sight Glass
On/Off Switch and
Pilot Light
Steam Outlet
Operating Pressure Control
Range 10-300 Psi
Safety Valve
Manual Reset High
Limit Control
Pressure Gauge, 0-600 Psi
McDonnell & Miller #194
Low Water Cutoff/Pump
Check Valve/Water Inlet
(not shown)
READ COMPLETELY BEFORE STARTING WORK
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 expose heating element.
4. Disconnect wire (electric) leads connecting element to main power
system of boiler. Again note wire connections to facilitate
reassembly. Proceed to remove (6) 5/16-18 bolts from flange.
5. Thoroughly clean boiler flange of all foreign material. Be certain
no part of old gasket remains on boiler flange.
6. Apply “Slic-Tite” Gasket Compound or equal to both surfaces of
new gasket with supplied 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
wire connection terminals on element assembly are in line with
previously disconnected wire leads to facilitate easy connections.
7. When all (6) flange bolts are tight, connect all wires to terminals.
Make certain wires are clean and bright to assure good electrical
contact and nuts on screws are firmly secured.
WARNING: Avoid use of chemical cleaning compounds. Follow maintenance instructions.
8. Open water valve so water supply can reach boiler feed mecha-
nism.
9. Put main safety switch to “on” position.
10. Turn boiler to “on” position.
11. As boiler automatically refills, observe the new flange assemble
for possible leaks. If water is noticed, to bolts must be retightened.
Before doing this, turn the boiler off at the main fuse safety switch.
12. As boiler is heated to working pressure, check flange assembly
again for leaks.
WARNING: Avoid the use of chemical cleaning compounds. Follow maintenance instructions
Part Description Part Number
1/4” Ball Valve (Pressure Gauge) . . . . . . . . . . . . . . . . . . . . . . . . 344-121194-007
Blowdown Valve 1” CHPES-24A
through 180A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344-121194-042
Pressure Gauge 3-1/2” 0-600 psi CHPES-100A
through 180A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130-118661-012
Fusible Contactors
30 amp with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . . . 072-122686-003
40 amp with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . . . 072-122686-006
50 amp with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . . . 072-122686-009
Non Fusible Contactors
60 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 072-047913-016
50 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 072-047913-019
40 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 072-047913-012
30 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 072-047913-020
35 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-123459-012
40 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-123459-013
45 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-123459-014
50 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-123459-015
60 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-123459-016
Fuse Block 35-60 amp 60 amp 600V . . . . . . . . . . . . . . . . . . . . 129-047445-002
Power Terminal Blocks
3 Pole 115 amp 1 line circuit 1 load circuits . . . . . . . . . . . . . . . 303-071809-032
3 Pole 175 amp 1 line circuit 4 load circuits . . . . . . . . . . . . . . . 303-071809-012
3 Pole 335 amp 1 line circuit 4 load circuits . . . . . . . . . . . . . . . 303-071809-014
3 Pole 335 amp 1 line circuit 8 load circuits . . . . . . . . . . . . . . . 303-071809-016
SINGLE PHASE
12kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-004
12kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-009
17kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-006
17kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-011
THREE PHASE
12kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-003
12kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-001
12kW 346V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-012
12kW 380V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-017
12kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-008
17kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-005
17kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-002
17kW 346V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-013
17kW 380V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-018
17kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-010
22.5kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-021
22.5kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-022
22.5kW 550V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155-554735-019
Check Valve 1/2” CHPES-6A through 18A . . . . . . . . . . . . . . . . . 344-114590-013
Check Valve 3/4” CHPES-24A through 180A . . . . . . . . . . . . . . . 344-114590-014
Gauge Glass Assemble Valves
(O-ring gaskets included) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344-120970-004
Protector Rods (2 Required) CHPES-6A
through 18A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242-121047-008
Protector Rods (2 required) CHPES-24A
through 180A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242-121047-001
O-ring gaskets (2 required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132-073284-003
Sight Glass Tubing, 7” CHPES-6A
through 18A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374-121046-006
Sight Glass Tubing, 9” CHPES-24A through 72A . . . . . . . . . . . 374-121046-038
Sight Glass Tubing, 11” CHPES-100A through 180A . . . . . . . . 374-121046-015
250 psig 1/2” CHPES-6A through 180A . . . . . . . . . . . . . . . . . . . 344-300032-006
19
RENEWAL PARTS IDENTIFICATION
VALVES & GAUGES
HEATING ELEMENTS — SPECIFY VOLTAGE
Part Description Part Number
Operating Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429-300038-009
Hi-Limit Control (Manual Reset) 15 psi . . . . . . . . . . . . . . . . . . . 429-300038-008
Proportional Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 429-300039-004
5-Step Motor-Driven Sequencer . . . . . . . . . . . . . . . . . . . . . . . . 323-121505-001
10-Step Motor-Driven Sequencer . . . . . . . . . . . . . . . . . . . . . . . 323-121505-002
6-Step Solid State Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . 323-300107-015
10-Step Solid State Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . 323-300107-015
Siphon Tube for Pressure Controls . . . . . . . . . . . . . . . . . . . . . . 215-300026-002
MM-94 Control Complete (Auto Reset) . . . . . . . . . . . . . . . . . . . 292-300065-007
MM-94M Control Complete (Manual Reset) . . . . . . . . . . . . . . . 292-300065-008
1KVA 208V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315-300088-020
1KVA 240/480V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315-300088-021
1-1/2 KVA 208V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315-300088-025
1-1/2 KVA 240/480V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . 315-300088-026
Motor and Pump used in ES-38020 HP . . . . . . . . . . . . . . . . . . . 226-300177-009
Pump only used in ES-38020 HP . . . . . . . . . . . . . . . . . . . . . . . . 226-300173-011
Motor and Pump used in ES-38020 HP . . . . . . . . . . . . . . . . . . . 193-121843-020
Strainer used in ES-38020 HP . . . . . . . . . . . . . . . . . . . . . . . . . . 351-118664-001
V-Band Mount used in ES-38020 HP . . . . . . . . . . . . . . . . . . . . . 355-300174-001
Solenoid Valve used in ES-38020 HP . . . . . . . . . . . . . . . . . . . . 344-121780-002
Hose Assembly 18” Long used in EES-38020 HP . . . . . . . . . . . . . 349-300181-002
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-121133-053
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359-122688-031
Condensate Return System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296-300222-026
Pump/Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contact Factory
Probe Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346-300035-001
Aux Low Water Cut-off Board with Relay . . . . . . . . . . . . . . . . . . 323-300033-016
Aux Low Water Cut-off Board Without Relay . . . . . . . . . . . . . . . 323-300033-017
Relay for Aux Low Cut-off Board . . . . . . . . . . . . . . . . . . . . . . . . 072-300047-003
Probe 7-15/16” CHPES 6A through 18A . . . . . . . . . . . . . . . . . . 242-300036-019
Probe 9-1/2” CHPES 24A through 72A . . . . . . . . . . . . . . . . . . . 242-300036-002
Probe 10-15/16” CHPES-100A through CHPES-180A . . . . . . . . 242-300036-017
ON-OFF Switch with Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . . 292-053223-002
Control Circuit Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-072576-027
Control Circuit Terminal Block 4 Pole 250V 20AMP . . . . . . . . . 303-075443-003
Control Circuit Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129-300029-001
Blank Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121-300199-001
Element Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132-146012-001
Stainless Steel Bolts (6 required) for Element . . . . . . . . . . . . . . 345-072565-428
Vacuum Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344-300149-003
Motorized Valve 1/2” CHPES-6A through CHPES-18A . . . . . . . . 344-300089-009
Motorized Valve 1” CHPES-24A through CHPES-180A . . . . . . . 344-300089-010
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292-300101-002
Relay SPST No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 072-300072-002
Relay Interval Delay .6-60 Sec. 3 . . . . . . . . . . . . . . . . . . . . . . . . 072-300148-001
Switch Momentary Contact DPDT 4 . . . . . . . . . . . . . . . . . . . . . . 292-300146-001
Switch Rocker SPDT 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272-300147-001
Pilot Light Red 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213-300145-001
Terminal Block 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-075444-003
Terminal Block 5 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-075444-004
Fuse Block 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129-024494-001
Fuse 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128-121133-072
CONTACTORS
POWER FUSES AND TERMINAL BLOCKS
GAUGE GLASS ASSEMBLIES, CHECK VALVES & SIGHT GLASSES
SAFETY VALVE
PRESSURE CONTROLS & SEQUENCES
COLD WATER INJECTION PUMPS (0-100 PSIG)
CONDENSATE RETURN SYSTEMS
CONTROL VOLTAGE TRANSFORMERS (120V SECONDARY)
LOW WATER CUTOFF & PUMP CONTROLS
AUX LOW WATER CUT-OFF (OPTIONAL EQUIPMENT)
MISCELLANEOUS PARTS
AUTO BLOWDOWN PARTS
2150 N. RULON WHITE BLVD., OGDEN, UT 84404
Phone: 1-800-368-2493 www.chromalox.com
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
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