Chromalox PQ404-6 User Manual
(Supersedes PQ404-5)
PQ404-6
CHS
161-048642-001
OCTOBER, 1983
4
and
Installation, Operation
RENEWAL PARTS IDENTIFICATION
Horizontal Electric Steam Boiler
Model Number CHS 0 – 150 PSI
© 2010 Chromalox, Inc.
Power CC Size of Output
Nominal 90˚C Amps Standard Lbs. per
Model B.H.P. Fuse Delta Size Wire per Elements Control Hr. at
Number Rating kW Contactors Size kW (Amps) (M.C.M) Circuit (kW) System 212˚F
CHS-150* 15.3 150 5 50A 60A 30 1 300 4/0 181
260
452
130
CHS-180* 18.4 180 6 50A 60A 30 1 300 250 217 3 30 543
CHS-210* 21.4 210 7 50A 60A 30 1 600 600 253
360
633
130
CHS-240* 24.5 240 8 50A 60A 30 1 600 400 290 4 60 723
CHS-270* 27.6 270 9 50A 60A 30 1 600 600 326
460
814
130
CHS-300* 30.6 300 10 50A 60A 30 1 600 600 362 5 60 904
CHS-360 36.7 360 12 50A 60A 30 2 300 250 217
290
1085
360
CHS-420 42.9 420 14 50A 60A 30 2 600 350 254
490
1266
160
CHS-495 50.5 495 11 60A 100A 45 2 600 500 297
3 135
1492
190
CHS-540 55.1 540 12 60A 100A 45 2 600 600 324 4 135 1628
CHS-630 64.3 630 14 60A 100A 45 2 600 700 378
4 135
1889
190
CHS-720 73.5 720 16 60A 100A 45 3 600 400 324
5 135
2170
145
CHS-810 82.7 810 18 60A 100A 45 3 600 600 324 6 135 2441
CHS-945 96.4 945 21 60A 100A 45 3 600 700 378 7 135 2848
CHS-1080 110.0 1080 24 60A 100A 45 4 600 500 324 8 135 3255
CHS-1215 124.0 1215 27 60A 100A 45 4 600 700 378 9 135 3662
CHS-1350 138.0 1350 30 60A 100A 45 5 600 600 324 10 135 4069
CHS-1485 152.0 1485 3 60A 100A 45 5 600 700 378 11 135 4476
CHS-1620 165.0 1620 36 60A 100A 45 6 600 600 324 12 135 4883
Specifications — 480 Volt Boilers*
INSTALLATION
CAUTION: To avoid electrical shock hazard, boilers
must be suitably grounded to earth.
NOTE: Chromalox boilers are pre-tested before shipment; no internal
piping or wiring is necessary. WARNING: Substitution of compo-
nents or modification of wiring without prior consent of Chromalox,
Inc. voids warranty.
1. Locate unit on level floor or platform. NOTE: A minimum dis-
tance of 60 inches from wall, other equipment, etc. must be
allowed for removal of the elements.
2. 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.
3. 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.
4. All water feed systems are connected to supplied water inlet check
valve.
5. Connect steam line (with Globe valve) to boiler steam outlet. Valve
should be placed as close as possible to boiler outlet.
6. To insure maximum efficiency of supplied kw, all piping from out-
let should be insulated.
7. Drain and relief valve piping should be in accordance with state
and local codes.
CHS-360 Steam Boiler
*150 kW Thru 300 kW Boilers available in 280V and 240V. Check Factory
Boiler Serial No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No. of Power Circuits . . . . . . . . . . . . . . . Amps. . . . . . . . . . . . . . . . . . . .
Electrical Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
National Board No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total Amps . . . . . . . . . . . . . . . Phase . . . . . . . . . . . . Cy . . . . . . . . . . . . .
IMPORTANT – This data file contains the National Board Registration Certificate approving your generator. It must be kept near the generator at all times.
2 P’TROLS
3
P’TROLS
SEQUENCER
2
High Pressure
Control
Pressure
Gauge
Manual Reset
Pressure Conrol
Electric
Control
Box
Blow Down
Drain Valve
(L)
Return
Inlet (J)
Heating
Elements
Step Sequencer
(Optional)
Wall
30”
C
B
A
Wall
D
I
H
E
Blow Down
Drain Valve (L)
Check Valve
Water Inlet (K)
Water
Level
Control
G
60”
Safety
Valve (G)
Steam
Outlet (F)
INSTALLATION (cont’d.)
Figure 1 Figure 2 Figure 3
Model Number A B C D E F* G H I J K L
CHS-150 thru CHS-300 57” 45” 32” 40” 68” 3” NPT 1” 25” 31” 2” NPT 1” NPT 1” NPT
CHS-360 thru CHS-420 57” 45” 32” 40” 68” 4” 1” 25” 31” 2” NPT 1” NPT 1” NPT
CHS-495 thru CHS-630 57” 45” 32” 47” 86” 4” 1” 34” 40” 2” NPT 1” NPT 1” NPT
CHS-720 thru CHS-810 76” 58” 45” 47” 94” 6” 1-1/2” 38” 44” 2” NPT 1” NPT 1” NPT
CHS-945 thru CHS-1080 76” 68” 45” 47” 94” 6” 1-1/2” 38” 44” 2” NPT 1” NPT 1” NPT
CHS-1215 thru CHS-1620 86” 76” 56” 50” 98” 6” 1-1/2” 40” 46” 2” NPT 1-1/2” NPT 1” NPT
*CHS- thru 1620 have 2 control boxes (See Figure 2). Add 13” to “B” dimension.
*4” and 6” are flanged.
Safety
Valve
Globe
Valve
Insulated Steam Lines
(Pitch Down 5˚)
Water/Steam
Separator
Gate
Valve
Heat
Exchanger
Gate
Valve
Trap
Trap
(Typical Load)
Check Valve
Check Valve
Check
Valve
Vacuum
Breaker
Drain
Boiler
Auxiliary
Inlet
Cold Water
(for Initial Fill)
Pitch Down 5˚
Vent
Condensate
Return
Return
Cold Water
Make-Up
Strainer
Drain
Centrifugal
Turbine Pump
Typical Plumbing Installation of a Steam Boiler with Condensate Return System
3
INSTALLATION (cont’d.)
SPECIAL INSTRUCTIONS FOR CUSTOMERS SUPPLYING
THEIR OWN CONDENSATE OR PUMP SYSTEMS.
1. Check the voltage of the motor before making the wiring connec-
tion. Some Chromalox boilers are supplied with dual voltage systems. The motor should always match the voltage of the control
circuit.
2. The motor circuit should be wired into the pump control as shown
in wiring diagram.
3. Aheavy-duty vacuum breaker is required when condensate system
is used. (part number ES-89369)
WIRING
1. Wiring to boiler should be as per appropriate wiring diagram sup-
plied with boiler and in accordance with Local and National
Electrical Codes.
2. SAFETY SWITCHES - Purchaser should use a safety switch
between his main power source and the boiler. The safety switch
should use circuit breakers or fuses and be in accordance with
NEC and local codes.
Serious thought should be given to the advisability of using a shunt
trip safety switch of the circuit breaker type as an additional safety precaution. It is possible to utilize the spare contacts in the low
water cutoff to energize the shunt mechanism on the safety switch.
This is an additional safety feature that prevents a dangerous situation should a contactor or relay stick. Activation of the shunt trip
device will completely disconnect the boiler from the power supply. (See Figure 7).
3. Since boiler heating elements are susceptible to lightning damage,
plants not having lightning arresters that have above-ground electrical cable supply sources should install lightning arresters in the
proper size to meet the boiler kw load.
1/2” Water Line
1/2” Solenoid
6-5/8”
1/2” Strainer
3”
7-1/4”
15-1/4” for CHS-150
16-3/8” for CHS-180 to 300
1” Discharge
to Boiler
4-1/4”
5-7/8”
Width – 6-1/2
Figure 4 – Motor and Pump Assembly
To Aux.
L.W. C.O.
Hi-Limit
Pressuretrol
Operating
Pressuretrols
To L2 on
Terminal Strip
Common
*Standard on CHS-150 to CHS-300 units in lieu of step
sequencer and operating pressuretrol shown in Figure 8
Figure 6 – Pressuretrol Control System*
Shunt Trip Device
(Supplied by Others)
Supply
Voltage
To Field
Wiring
Input
Terminal
To
L2
To Main
Switch
To Motor Starter
L.W.C.O. &
Pump Control
To Aux.
L.W.C.O.
Figure 7 – Safety Switch (Field Installed)
“W” Dimension – Overall Width
Strainers
H
1/2”
Water
Line
L
1” Outlet
to Boiler
Motor and
Pump
1” Drain
1” Vent
1” Condensate
Return
Figure 5 – Condensate Return System
Model Max. Tank Cap.
Number PSI (Gal.) L H W
CHS-150
thru 125 33 33-1/4 41-1/2 21
CHS-300
CHS-360
thru 150 40 40 41-1/2 21
CHS-420
4
WIRING (cont’d.)
Figure 8 – Typical Wiring Diagram
Power Circuit
Terminal Block
To Other
Heater
Groups
To
Other
Heater
Groups
Typical 3 Phase Heater Group
To
Power
Curcuit
Relay
Step
Sequencer
Figure 9 – Power Circuit Detail
Low Water
Probe
120 Volt
Control Voltage
Hi Limit
Control
Electronic Resistance
Sensing Amplifier for
Auxiliary Low Water Cutoff
Figure 10 – Auxiliary Low Water Cutoff
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