LG Electronics 30, 10 User Manual
User Manual
& Installation Instructions
LG-10 thru LG-30
IMPORTANT – READ ALL INSTRUCTIONS BEFORE OPERATING
All steam boilers are built in accordance with ASME miniature boiler code.
NOTE: It is the responsibility of the installer to conform to any state or local codes. If further
inspection, following modification by installer, is required under state or local codes, that is
the responsibility of the local installer.
www.electrosteam.com
rev. 12282009
EXCEED 105° F
WARNING - The following labels have been placed on this boiler for YOUR SAFETY. Fai lure
to observe these instructions could lead to PROPERTY DAMAGE, SEVERE INJURY, or
even DEATH
CA
DANGER
PELIGRO
U
TION
OH T
HIGH VOLTAGE
AUTHORIZED
PERSONNEL
ONLY
CA OTI N
U
THROW OFF MAIN
POWER SWITCH
BEFORE WORKING ON
ELECTRICAL CABINET
A MANUAL WAS SHIPPED WITH THIS
BOILER. IT IS IMPORTANT THAT YOU
READ, UNDERSTAND, AND OPERATE
THIS STEAM GENERATOR IN ACCOR-
ALTO VOLTAJE
SOLAMENTE
PERSONAL
AUTORIZADO
REPLACE GLASS
EVERY SIX MONTHS
CAUTION USE ELECTRICAL
SUPPLY CONDUCTORS RATED
FOR A MINIMUM OF 90°C
DANCE WITH THE OPERATING
INSTRUCTIONS CONTAINED IN THE
MANUAL. IF FOR ANY REASON YOU
DO NOT HAVE A MANUAL, CALL
ELECRTO-STEAM AT 800-634-8177
RETIGHTEN SIGHT GLASS
TERMINALS ARE SUITABLE
FOR COPPER WIRE ONLY
U.L. 834 PAR. 4416
BEFORE USE
AMBIENT TEMPERATURE
AROUND UNIT NOT TO
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
TABLE OF CONTENTS
1.) INSTALLATION INSTRUCTIONS .................................................................... 4
2.) OPERATION & SEQUENCE OF EVENTS ..................................................... 5
3.) CLEANING & MAINTENANCE ................................................................... 6-14
3.1) M ANU AL “BLOW DOWN” ..................................................................................... 6
3.2) CLEANING WATER LEVEL PROBES .............................................................. 6-7
3.3) CLEANING OR REPLACING HEATERS .............................................................. 8
3.4) REPLACING GLASS GAUGE AND RUBBER WASHERS .............................. 8-9
3.4.1) BRASS SIGHT GLASS (STANDARD) .................................................................. 8
3.4.1) BRASS SIGHT GLASS (SEISMIC) ....................................................................... 9
3.5) CH AMBER CLEANING & CHEMICAL TREATMENT ............................... 10-11
3.6) PRESSURE CONTROL DATA SHEET ................................................................ 12
3.7) SETTING THE PRESSURE CONTROLS ....................................................... 13-14
4.) CALCULATIONS & DATA SHEETS ........................................................ 15-17
4.1) HEATER POWER & VOLTAGE RATINGS ........................................................ 15
4.2) TOTAL POWER RATING CALCULATIONS ..................................................... 15
4.3) AMPE RAGE C ALCULATIONS ............................................................................ 16
4.4) ACTU AL POWER RATING CALCUL ATIONS .................................................. 17
4.5) STEAM CAPACITY CALCULATIONS ............................................................... 17
5.) DRAWINGS & WIRING SCHEMATICS ................................................. 18-32
5.1) PARTS LEGE NDS ............................................................................................ 18-21
5.1.1) LG (LOW PRESSURE) (0-15PSI) ........................................................................ 18
5.1.2) LG (LOW PRESSURE) (MAFD) (0-15PSI) ........................................................... 19
5.1.3) LG (HIGH PRESSURE) (0-30, 0-100PSI) .............................................................. 20
5.1.4) LG (HIGH PRESSURE) (MAFD) (0-30, 0-100PSI) ................................................. 21
5.2) INSTALLATION DATA SHEETS .................................................................. 22-25
5.2.1) LG (LOW PRESSURE) (0-15PSI) ........................................................................ 22
5.2.2) LG (LOW PRESSURE) (MAFD) (0-15PSI) ........................................................... 23
5.2.3) LG (HIGH PRESSURE) (0-30, 0-100PSI) .............................................................. 24
5.2.4) LG (HIGH PRESSURE) (MAFD) (0-30, 0-100PSI) ................................................. 25
5.3) CONT ROL WIRING SCHEMATICS .............................................................. 26-29
5.3.1) LG (LOW PRESSURE) (0-15PSI) ........................................................................ 26
5.3.2) LG (LOW PRESSURE) (MAFD) (0-15PSI) ........................................................... 27
5.3.3) LG (HIGH PRESSURE) (0-30, 0-100PSI) .............................................................. 28
5.3.4) LG (HIGH PRESSURE) (MAFD) (0-30, 0-100PSI) ................................................. 29
5.4) HE ATE R WIRING SCHEMATICS ................................................................. 30-32
5.4.1) LG (10-30KW) (THREE PHASE) ........................................................................ 30
5.4.2) LG (10-30KW) (SINGLE PHASE) ....................................................................... 31
5.4.3) LG (10-30KW) (THREE AND SINGLE PHASE) (550-600V) ................................... 32
6.) TERMS & CONDITIONS ..................................................................................... 33
3 of 33
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
1.) INSTALLATION INSTRUCTIONS
LITTLE GIANT “LG-SERIES”
The Electro-Steam Generator design consists essentially of a high pressure chamber filled with water
that is heated by one or more submerged resistance type electric heating elements. Automatic controls
are provided to maintain the pre-set operating pressure and water level. Safety features include:
automatic low-water cutoff (manual low-water reset optional), dual pressure controls, safety valve, and
visible water level gauge. All of our generators are built in accordance with A.S.M.E . Miniature Boiler
Code and are individually inspected and stamped by an Authorized National Board Insurance Inspector.
IMPORTANT – READ ALL INSTRUCTIONS BEFORE OPERATING
Important – Set unit perfectly level, and as close as possible to the steam vessel or appliance it
will operate. For generator measurements, refer to Installation Data Drawing attached. For
interpretation of numbered items, refer to Parts Legend Drawing attached. NOTE: Ambient
temperature around this unit must not exceed 105°F.
CONNECTIONS:
Periodically check all plumbing and electrical connections for tightness; this should also be done
before initial start-up.
ELECTRICAL:
This generator must be connected to a disconnect switch protected by fuses or
circuit breakers with the proper size wire by a licensed electrician in
accordance with N.E.C. and your local codes – Voltage, KW, and Phase
requirement are marked on the nameplate.
WATER SUPPLY:
Connect city water line to Y-Strainer (#6).
Purity: NOT to exceed 26,000 OHMS per CM
Temperature Range: 32°F – 140°F or 0°C – 60°C.
Pressure Range: 20PSI – 150PSI.
*CAUTION: The Pump (#8) requires clean tap water. If the water is not free of foreign matter, a 5
micron cartridge filter shou ld be installed in the water supply line.
STEAM OUTLET:
Connect Steam Outlet Valve (#16) to piece of equipment, vessel, room, or ar ea to be operated by
the Electro Steam Generator.
SAFETY VALVE & DRAIN:
Separately route the Safety Valve (#18) & Drain (#23) to a high temperature drain *NO PVC.
Discharging pipe of the Safety Valve (#18) should never be smaller than the valve outlet and
should be rigidly supported, placing no weight on the safety valve itself. If equipped with
Motorized Auto-Flush & Drain “MAFD” (#20), it should be routed with the Drain (#23).
4 of 33
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
2.) OPERATION & SEQUENCE OF EVENTS
IMPORTANT – READ INSTALLATION INSTRUCTIONS BEFORE OPERATING
1. Turn on water supply from the source to the Generator.
2. OPEN all valves on the Generator except for the Manual Drain (#19).
3. Place main disconnect switch in ON position.
4. Place ON/OFF Switch (#2) in ON position.
• The Water Solenoid (#7) [and Pump (#8), if high pressure] will engage and the
chamber will begin to fill with water. As the water level rises, it will make contact
with the (G OR D) and (A) probes, indicating the heater s are safely submerged. At
this time the contactor(s) will engage, supplying power to the heaters, causing
steam pressure to accumulate.
• The chamber will continue to fill with water unt il 1 second after the water makes
contact with the (C) probe, causing the Water Solenoid (#7) [and Pump (#8), if
high pressure] to turn off.
• If the contactor(s) still have not engaged at this time, you may need to press the
Safety Reset (#13) on the “Safety” Pressure Control (#12). If your generator is
equipped with a Manual Low-Water Reset (MLWR) (#3), it must be pressed at
this time to engage the contactor(s). If your generator is equipped with a Motorized
Auto-Flush & Drain (MAFD) (#20), you must wait until it closes before the
contactor( s) will engage. (approximately 3 minutes)
• Steam pressure will continue to rise until is reaches its set operating pressure. This
may take up to 25 minutes. At this time, the “Contr ol” Pressure Control (#12)
will cause the contactor(s) to disengage. The pressure will drop approximately 2-8
PSI until the “Control” Pressure Control (#12) causes the contactor(s) to
reengage, causing the pressure to rise again. The contactor(s) will continue to c ycle
on and off during operation.
5. The Generator is now fully operational and will produce steam until it is turned off.
• As steam is exhausted, the water level will drop until 3 seconds after it breaks
contact with the (C) probe. At this time, the Water Solenoid (#7) [and Pump (#8),
if high pressure] will engage and the chamber will again fill with water. The
chamber will continue filling unt il 1 second after the water makes contact with the
(C) probe. The Water Solenoid (#7) [and Pump (#8), if high pressure] will
continue to cycle on and off during operation.
6. To shut off the Generator, place ON/OFF Switch (#2) in OFF position. Pressure will
drop naturally as the chamber cools, or the Generator may be drained manually through
Manual Drain (#19). (See Manual Blow Down 3.1)
WARNING – HOT WATER and STEAM under HIGH PRESSURE can lift dra in pipes
right off the ground and cause SERIOUS INJURY. Make sure drain pipe is SECURE
and CANNOT move. The drain must be directed into a HIGH TEMPERATURE drain
(NO PVC) or outside.
5 of 33
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
3.) CLEANING & MAINTENANCE
The following cleaning procedures are HIGHLY RECOMMENDED in order to keep your
Steam Generator in the best operating condition at all times.
3.1) MANUAL “BL OW DOWN”
A Manual “Blow Down” is an easy way to GREATLY extend the life of your Steam
Generator. Using a Motorized Auto-Flush & Drain (MAFD) of course helps, but is not a “Cure
all”. The following is the LEAST amount of times recommended to blow down your generator:
NORMAL WATER AREAS – Should be done ONCE A WEEK.
BAD WATER AREAS – Should be done ONCE A DAY.
NORMAL WATER AREAS WITH MAFD – Should be done TWICE A MONTH.
BAD WATER AREAS WITH MAFD – Should be done ONCE A WEEK.
NOTE: The best time to Blow Down your generator is after it has been running for so me time,
while it is still hot.
1. Place Toggle Switch (#2) and Main Disconnect Box in OFF position.
2. Allow pressure to drop between 10 and 20 PSI.
3. Open Manual Drain (#19) s low ly, allowing HOT WATER and STEAM to blow out
into the drain, cleaning out the generator.
NOTE: Blow Down your generator at any pressure you feel comfort able with. 10 to 20 PSI is
only a recommendation. You may go higher or lower, but higher is always better.
WARNING – HOT WATER and STEAM under HIGH PRESSURE can lift drain pipes right
off the ground and cause SERIOUS INJURY. Make sure drain pipe is SECURE and
CANNOT move. The drain must be directed into a HIGH TEMPERATURE drain (NO
PVC).
3.2) CLE ANING WATER LEVEL PROBES
Water Level Probes are the heart of your generator. Almost a ll steam generator malfunctions
are caused by dirty water level probes. CLEANING your PROBES is by far the MOST
IMPORTANT maintenance step to keep your generator running properly. The following is the
LEAST amount of times recommended to clean yo ur probes:
NORMAL WATER AREAS – Should be done TWICE A YEAR.
BAD WATER AREAS – Should be done 3-4 TIMES A YEAR.
NOTE: The best time to clean your pro bes is before you t urn your generator on, while it is still
cool.
1. Place Toggle Switch (#2) and Main Disconnect Box in OFF position.
2. Make sure generator is cool and the Pressure Gauge (#15) reads 0 PSI.
3. Remove cover plate, exposing the Water Level Probes (#5).
4. Use 5/16” Socket to remove wires from probes.
5. Use 13/16” Spark Plug Socket to r emove probes from chamber.
6 of 33
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
3.2) CLE ANING WATER LEVEL PROBES (Continued)
6. Clean probes to remove rust and scaling.
NOTE: To clean probes you may use wire wheel, wire brush, steal woo l, or Scotch-Brite.
(Wire wheel works the best) You may also want to try so me sort of chemical like CLR
remover or LIME-A-WAY.
7. Reinstall probes assuring each probe’s length is assigned to its pro per letter.
8. Reconnect wires to probes assuring each color is also assigned to its proper letter.
NOTE: DO NOT make wires too tight. Just tighten enough to make contact. Over
tightening can cause probe plugs to pull apart o ver time.
9. Reinstall cover plate.
Water Level Probe Specifications:
Letter Assignment on Chamber A B C D/G
Water Level Probe Length 4 ½” 4 ¾” 3 ¾” 4 ¾”
Wire Color Assignment RED Not Used BLACK GREEN
Assignment on Dual Function Board LLCO Not Used
NOTE: The (B) Probe is not used. It is a spare probe that can be cut and used to r eplace any one
of the other probes.
WARNING – There MUST be NO PRESSURE in the chamber when removing probes. If you
must change probes while chamber is HOT, make sure the steam out and drain valves are open
to assure chamber will remain depressurized. DO NOT touch probes with your bare hands
while HOT, and be cautious of escaping steam from probe holes while probes are removed.
H G
3.3) CLE ANING OR REPLACING HEATERS
Heaters are located inside the control panel (#1) below the insulation barrier, bo lted into the
chamber. If (3.5) Chamber Chemical/Acid Treatments are not regularly done, heaters must be
taken out at least ONCE A YEAR, cleaned with wire brush and reinstalled using a new gasket.
If you are replacing or cleaning your heater elements:
1. Place Toggle Switch (#2) and Main Disconnect Box in OFF position.
2. Make sure generator is cool and the Pressure Gauge (#15) reads 0 PSI.
3. Remove heater wires from heater(s), using an 11/32” or 3/8” Socket.
4. Unbolt and remove heater(s) using a 1/2” Socket.
NOTE: Heater( s) may be difficult to get o ut ; you may need to use some sort of pry bar to
get them loose.
5. Clean heater(s) with wire brush. If replacing, dispose of old heater(s).
6. Reinstall heater(s) with new gasket(s).
7. Attach heater wires assuring proper wiring. *Refer to Heat er Wiring Schemat ics
attached*
NOTE: If you are replacing a heater because of a heater failure, you must also clean the probes
and clean out the chamber, or you may have another heater failure within 48 hours.
7 of 33
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
3.4) REPLACING GLASS GAUGE & RUBBER WASHERS OR
GLASS PACKINGS
The Sight Glass (#10) gives the operator the ability to easily monitor t he act ual water level
inside the chamber. If the Sight Glass (#10) gets clogged or is no longer functional, it can be very
difficult to troubleshoot a pro blem.
3.4.1) BRASS SIGHT GLASS (STANDARD)
GLASS GAUGE and RUBBER WASHERS
MUST be replaced EVERY SIX MONTHS
INSTALLATION:
Only properly trained personnel should insta ll and
maintain water gauge glass and connections.
Remember to wear safety gloves and glasses
during installation. Before installing, make sure
all parts are free of chips and debris.
1. U ninstall GUARD RODS, GLASS GAUGE, and
RUBBER WASHERS. (You may need to rotate one of the
GAUGE FITTINGS to remove GLASS GAUGE)
2. Slip a new RUBBER WASHER on the new GLASS
GAUGE about an inch from the bottom.
3. Now slip the following items through the top of GLASS
GAUGE in the following order:
• FRICTION WASHER
• GLASS PACKING NUT (facing down)
• GLASS PACKING NUT (facing up)
• FRICTION WASHER
• RUBBER WASHER (inch down from top)
4. Gently insert GLASS GAUGE into GAUGE FITTINGS.
You may need to rotate GAUGE FITTINGS until
vertically aligned, after GLASS GAUGE is in.
5. Carefully raise GLASS GAUGE about 1/16” from bottom
and slide lower RUBBER WASHER down until it makes
contact with the BOTTOM GAUGE FITTING. (DO NOT
allow GLASS GAUGE to remain in contact with any metal)
6. Carefully slide upper RUBBER WASHER 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 slightly, a quarter turn at a time,
checking for leakage after each turn.
8. Reinstall GUARD RODS.
8 of 33
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
3.4) REPLACING GLASS GAUGE & RUBBER WASHERS OR
GLASS PACKINGS (Continued)
The Sight Glass (#10) gives the operator the ability to easily monitor t he actual water level inside t he
chamber. If the Sight Glass (#10) gets clogged or is no longer functional, it can be very difficult to
troubleshoot a problem.
3.4.2) BRASS SIGHT GLASS (SEISMIC)
GLASS GAUGE and GLASS PACKINGS MUST be
replaced EVERY SIX MONTHS
The Seismic Sight Glass is equipped with BALL
CHECKS in each GAUGE FITTING.
Only properly trained personnel should insta ll and
maintain water gauge glass and connections. Remember
to wear safety gloves and glasses during installation.
Before installing, make sure all parts are free o f chips
and debris.
1. U ninstall GUARD RODS, GLASS GAUGE, and GLASS
PACKINGS. (You may need to rotate one of the GAUGE
FITTINGS to remove GLASS GAUGE)
2. Slip a new GLASS PACKINGS on the new GLASS
GAUGE about an inch from the bottom.
3. Now slip the following items through the top of GLASS
GAUGE in the following order:
• PACKING GLAND (facing down)
• GLASS PACKING NUT (facing down)
• GLASS PACKING NUT (facing up)
• PACKING GLAND (facing up)
• GLASS PACKINGS (inch down from top)
4. Gently insert GLASS GAUGE into GAUGE FITTINGS.
5. Carefully raise GLASS GAUGE about 1/16” from bottom
6. Carefully slide upper GLASS PACKINGS up as far as
7. Hand tighten both GLASS PACKING NUTS, then tighten
8. Reinstall GUARD RODS.
• PACKING WASHER
You may need to rotate GAUGE FITTINGS until
vertically aligned, after GLASS GAUGE is in.
and slide lower GLASS PACKINGS down until it makes
contact with the BOTTOM GAUGE FITTING. (DO NOT
allow GLASS GAUGE to remain in contact with any
metal)
possible.
1/2 turn more by wrench. Tighten only enough to prevent
leakage. DO NOT OVER TIGHTEN! If any leakage
should occur, tighten slightly, a quarter turn at a time,
checking for leakage after each turn.
INSTALLATION:
9 of 33
LG-10 thru LG-30 - User Manual Electro-Steam Generator Corp.
3.5) CHAMBER CHEMICAL/ACID TREATMENT
All Electric Steam Generator should be cleaned regularly. The following is the least amount of
times recommended to clean out your chamber:
NORMAL WATER AREAS – Should be done ONCE A YEAR.
BAD WATER AREAS – Should be done TWICE A YEAR.
If equipped with Motorized Auto-Flush & Drain “MAFD” (#20), locate the MAFD
TIMER/RELAY in the Control Panel (#1) and do steps 1-3 before the chamber treatment and
steps 4-5 after chamber treatment is done:
WARNING – Before opening Control Panel (#1), TO AVOID ELECTRICAL SHOCK, place
Main Disconnect Box and the Toggle Switch (#2) in the OFF position.
BEFORE:
1. Dial TIME ADJUSTMENT on MAFD
TIMER/RELAY all the way down to 15 seconds.
2. Make sure MAFD (#20) in the closed position.
3. Disconnect the orange wire from the nor mally open
(NO) terminal on the MAFD TIMER/RELAY.
AFTER:
4. Reconnect the orange wire to the normally open
(NO) terminal on the MAFD TIMER/RELAY.
5. Dial TIME ADJUSTMENT on MAFD
TIMER/RELAY up to the desired flush time (Most
commonly 3 minutes)
Chamber Treatment Instructions:
1. Turn on generator, allowing pressure to climb to 10 to 20 PSI o n Pressure Gauge (#15),
and then shut off.
2. “Blow Down” Open Manual Drain (#19) slowly, allow ing HOT WATER and STEAM
to blow out into the drain.
NOTE: You may Blow Down your generator at any pressure you feel comfort able with. 10
to 20 PSI is only a recommendation. You may go higher or lower, but higher is always
better.
WARNING – HOT WATER and STEAM under HIGH PRESSURE can lift dr ain pipes
right off the ground and cause SERIOUS INJURY. Make sure drain pipe is SECURE and
CANNOT move. The drain must be directed into a HIGH TEMPERATURE drain (NO
PVC).
3. Remove Safety Valve (#18).
WARNING – There MUST be NO PRESSURE in the chamber when removing the Safety
Valve (#18), make sure the steam out and drain are open to assure chamber will remain
depressurized. Be cautious o f escaping steam fro m chamber while Safety Valve (#18) is
removed.
10 of 33
Loading...