Sussman ES, SSB, HU, ES-12, ES-18 Installation, Operation And Maintenance Manual
...
Sussman Boilers:
Made in USA
ES, SSB & HU
Installation, Operation and Maintenance Manual
Model No. ______________________
Boiler Serial No. _________________
National Board No. ______________
Safety Valve Set Pressure________
Power Circuit Voltage ____________
Control Circuit Voltage ___________
Amps _____ Phase _____ HZ ______
IMPORTANT:
Board Registration Certificate approving your boiler.
It must be kept near the boiler at all times.
Products covered by this manual:
Series KW Range Steam Rate* BHP Design Pres.
______________________________________________________________________
ES, HU 12-180 36-542 lbs/hr 1.2-18.4 0-100 psig 85 psig
SSB 12-180 36-542 lbs/hr 1.2-18.4 0-100 psig 85 psig
*Steam Rate- Steam @ 212 F with 50 F feed water
This data file contains the National
PSIG
Max
Work Pres.
SSB Boilers have Stainless Steel all wetted metal parts. SSB
boilers shall be operated using only deionized water, having
a maximum conductance of 1 microSiemen per cm
µS/cm) [minimum specific resistivity of 1 megohm per cm
(1
ΜΩ/cm)].
(1
ES and HU boilers are of Carbon Steel construction.
See page 23 for Water Quality Information.
TABLE OF CONTENTS
Dimensional Information and
Component Identification . . . . . . . . . . . . . . . . . 2
Dimensional & Clearing Specifications. . . . . . . . . 3
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Installation
Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pre-Operation Check. . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Controls, Operation & Testing . . . . . . . 10
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 14
Auxiliary Low Water Cut Off . . . . . . . . . . . . . . . . 14
Line Pressure Water Feed System . . . . . . . . . . . . . 14
High Pressure Water Feed System . . . . . . . . . . . . . 14
Condensate Return System . . . . . . . . . . . . . . . . . . 14
Vacuum Breaker Systems . . . . . . . . . . . . . . . . . . . 15
Automatic Blowdown System . . . . . . . . . . . . . . . . 15
Blowdown Separators . . . . . . . . . . . . . . . . . . . . . 15
Control Voltage Stepdown Transformer . . . . . . . . 15
Multistage Load Progressive Sequencers . . . . . . . . 15
Condensate Return Systems . . . . . . . . . . . . . . . . 16
Blowdown Separator Tanks . . . . . . . . . . . . . . . . . 17
Specification Charts . . . . . . . . . . . . . . . . . . . . . . . 18
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gauge Glass Installation . . . . . . . . . . . . . . . . . 20-21
Element Replacement . . . . . . . . . . . . . . . . . . . . . . 22
Water Quality Information
for Carbon Steel Boilers
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
. . . . . . . . . . . . . . . . . . 23
IMPORTANT NOTE:
As you follow these instructions, you will notice warning and caution symbols. This blocked information is important for the safe and efficient
installation and operation of electric boilers. These are two types of potential hazards that may occur during this installation and operation:
!
WARNING
death if precautions are not followed.
states a hazard which may
cause serious injury or
A Division of Sussman-Automatic Corporation
43-20 34th Street, Long Island City, NY 11101 • (718) 937-4500
1-800-238-3535 • Fax: (718) 937-4676 • email: seb@sussmancorp.com
www.sussmanboilers.com
!
CAUTION
age may occur if you do not follow instructions.
signals a situation where
minor injury or product dam-
IMPORTANT NOTE:
This highlights information that is especially relevant to a problem-free installation.
PUR 101137 2/07
Sussman Boilers
Installation, Operation & Maintenance Manual
Dimensional Information & Component Identification
2
_______________________________________
WATER STEAM
MODEL H W L INLET OUTLET
_______________________________________
ES 12, 18; HU 40–55 36" 20" 28" 1/2” NPT 1/2”NPT
_________________________________________________
ES 24–72; HU 75–205 44" 23" 33" 1/2”NPT 1” NPT
_________________________________________________
ES 100; HU 310 59" 28" 34" 1/2”NPT 1-1/2”NPT
_________________________________________________
ES 135–180; HU 410–550 61" 30" 36" 1/2”NPT 2” NPT
_________________________________________________
SSB 12–18 36" 20" 28" 1/2”NPT 1/2”NPT
_________________________________________________
SSB 24–72 45" 27" 33" 1/2”NPT 1” NPT
_________________________________________________
SSB 80–100 59" 28" 34" 1/2”NPT 1-1/2”NPT
_________________________________________________
SSB 135–180 61" 30" 36" 1/2”NPT 2” NPT
_______________________________________
Allow minimum 21 inches clearance in front of door for servicing of heating
elements. Recommended clearance: 24 inches all around boiler for servicing.
Models: ES, HU, SSB
_________________________________
SYMBOL ITEM ES12-18 ES24-72 ES100 ES135-180
___________________________________
Height Overall Height 36" 44" 59" 61"
__________________________________________________________________
Length Overall Length 28" 33" 34" 38"
__________________________________________________________________
Width Overall Width 20" 22" 26" 30"
__________________________________________________________________
A Steam Outlet 6-1/4" 10" 8-1/4" 9"
__________________________________________________________________
B Steam Outlet 10-1/4" 17" 17-1/4" 18-1/4"
__________________________________________________________________
C M/M Drain Valve 5" 12" 17" 16-3/4"
__________________________________________________________________
D M/M Drain Valve 6-1/2" 6" 6-1/4" 6-1/4"
__________________________________________________________________
E Check Valve 14" 9" 17" 16-3/4"
__________________________________________________________________
F PV Drain Valve 2-3/4" 2-1/4" 2-3/4" 2-3/4"
__________________________________________________________________
G PV Drain Valve 6-1/4" 9-1/2" 7-3/4" 9-1/4"
__________________________________________________________________
J Clearance 3-3/4" 3-1/2" 4" 4"
__________________________________________________________________
K Check Valve 2-1/2" 2-3/4" 3" 3"
__________________________________________________________________
M Door Width 8-3/4" 14" 12-3/4" 14-3/4"
__________________________________________________________________
Allow 24 inches all around for servicing.
Height
Width
Length
Sussman Boilers
Installation, Operation & Maintenance Manual
3
Dimensional & Clearance Specifications
Steam Outlet
High Limit
Pressure
Control
Operating
Pressure
Control
Pressure
Gauge
Safety Valve
MM 150
Liquid Level
Control
(see note 3)
Water Feed Inlet
F
E
L
D
A
B
E
R
FrontLeft
Drain Valve
On/Off
Switch
Gauge Glass
Assembly
Height
Width Length
Side Elevation Front Elevation
Allow 24" all around for servicing.
__________________________________________________
Clearance from combustible surfaces
__________________________________________________
A
1" Clearance above top of boiler
_________________________________________________________________________
B
A Clearance from Front of boiler. Prefix "C" to numeral indicates acceptability for
closet or alcove installations; prefix acceptability for alcove installations but not
for closet installations.
_________________________________________________________________________
D
1" Clearance from back of boiler.
_________________________________________________________________________
EL
1" Clearance from left side of boiler.
_________________________________________________________________________
ER
16" Clearance from right side of boiler.
_________________________________________________________________________
F
C Indicates type of flooring: "NC" for non-combustible; "C" for combustible.
Numeral indicates minimum clearance below suspended units to combustible floor.
_________________________________________________________________________
G-
Total minimum free area in square inches of close ventilating openings.
_________________________________________________________________________
Sussman Boilers
Installation, Operation & Maintenance Manual
Typical Wiring Diagrams:
Wiring Diagram Control Circuit
4
a.
Three phase power circuit with separate 120Volt control circuit. (With singe phase power circuit insert.)
b.
Three phase power circuit with step down transformer.
c.
Detailed ES81017/81017MR auxiliary low water cut off wiring.
d.
Detailed SSB auxiliary low water cut off wiring.
e.
ES81600 Auto blowdown wiring diagram.
f.
Detailed sequencer package wiring diagram.
ES and SSB Electric Boilers (Basic Control Circuit)
120V 1PH
INPUT
ON-OFF
SWITCH
PILOT
LIGHT
L
LIQUID
LEVEL
CONTROL
L
L1 L2
N
CONTROL
TERMINAL
BLOCK
P1
HIGH LIMIT
PRESSURE
CONTROL
R
RELAY
P2
OPERATING
PRESSURE
CONTROL
FIELD WIRING
FACTORY WIRING
SOLENOID VALVE
S
PUMP MOTOR
M
CONTACTORS
C1
C2
Sussman Boilers
Installation, Operation & Maintenance Manual
Wiring Diagram Control Circuit
ES Electric Boilers with Manual Reset Auxiliary Low Water Cutoff
ES and SSB Electric Boilers (Power Circuit)
5
THREE PHASE
MAIN POWER
SUPPLY
L1
L2
L3
G
TRANSFORMER
NOTES:
1. Power Terminal Block only on boilers with two or more contactors
2. Power Fuses only on boilers rated 20 amperes and larger.
3. See Parts List for contactor and heating element information.
TB 1
(optional)
TO CONTROL
TERMINAL POWER BLOCK
(see note 1)
PILOT
LIGHT
480V
T1
120V
CIRCUIT
POWER FUSES
(see Note 2)
CONTACTORS C1 C2 C3 C4
HEATING
ELEMENTS
FIELD WIRING
FACTORY WIRING
FB1 FB2 FB3 FB4
H1 H3 H5 H7
H2 H4 H6 H8
SINGLE PHASE
MAIN POWER SUPPLY
L1 L2 G
TB
FB
C
H
120V 1PH
INPUT
N
ON-OFF
SWITCH
PILOT
LIGHT
L
LIQUID
LEVEL
CONTROL
AUX LWCO
PC BOARD
L
L2
GND
CONTROL
TERMINAL
BLOCK
LOW
RESET
COM
FIELD WIRING
FACTORY WIRING
SOLENOID VALVE
S
PUMP MOTOR
M
R
RELAY
C1
PILOT
LIGHT
P2
OPERATING
PRESSURE
CONTROL
C2
CONTACTORS
P1
L1
G
NC
NO
HIGH LIMIT
PRESSURE
CONTROL
MANUAL RESET
TO
PROBE
Sussman Boilers
Installation, Operation & Maintenance Manual
Wiring Diagram Control Circuit
ES and SSB Electric Boilers with Sequencer
ES Electric Boiler with Auxiliary Low Water Cutoff
6
ON-OFF
SWITCH
PILOT
LIGHT
L
LIQUID
LEVEL
CONTROL
120V 1PH
INPUT
L N
L1 L2
CONTROL
TERMINAL
BLOCK
FIELD WIRING
FACTORY WIRING
SOLENOID VALVE
S
PUMP MOTOR
M
R
RELAY
P1
HIGH LIMIT
PRESSURE
CONTROL
P2
OPERATING
PRESSURE
CONTROL
PROPORTIONING
PRESSURE CONTROL
P3
120V COM
M
135 OHM
COM
SEQUENCER
1
2
3
4
C1
C2
C3
C4
CONTACTORS
ON-OFF
SWITCH
PILOT
LIGHT
L
LIQUID
LEVEL
CONTROL
AUX LWCO
PC BOARD
120V 1PH
INPUT
LN
L2 L1
LOW
GND
CONTROL
TERMINAL
BLOCK
COM
RESET
FIELD WIRING
FACTORY WIRING
SOLENOID VALVE
S
PUMP MOTOR
M
R
RELAY
C1
P1
HIGH LIMIT
G
NC
NO
PRESSURE
CONTROL
P2
OPERATING
PRESSURE
CONTROL
C2
CONTACTORS
TO
PROBE
Sussman Boilers
Installation, Operation & Maintenance Manual
Wiring Diagram Control Circuit
7
ES and SSB Electric Boilers with Automatic Blowdown System
SSB Electric Boilers with Auxiliary Low Water Cutoff
ON-OFF
SWITCH
PILOT
LIGHT
L
LIQUID
LEVEL
CONTROL
120V 1PH
INPUT
L N
CONTROL
TERMINAL
BLOCK
T
7-DAY 24-HR
TIMER
ES81600
AUTOMATIC
BLOWDOWN SYSTEM
P1
HIGH LIMIT
PRESSURE
CONTROL
PROPORTIONING
PRESSURE CONTROL
R
RELAY
OPERATING
PRESSURE
CONTROL
TIME DELAY RELAY
P2
FIELD WIRING
FACTORY WIRING
D
PILOT LIGHT
2
OPEN
CLOSE
3
MOTORIZED
BLOWDOWN
VALVE
1
SOLENOID VALVE
S
PUMP MOTOR
M
CONTACTORS
C1
C2
ON-OFF
SWITCH
PROBE
120V 1PH
INPUT
Hot Leg
Neutral
PILOT
LIGHT
CONTROL
TERMINAL
BLOCK
LIQUID
LEVEL
CONTROL
L
L1 L2
LO
GUARD
GROUND
AUX LWCO BOARD
LWCO
LWCO
RELAY
R
P1
HIGH LIMIT
PRESSURE
CONTROL
FIELD WIRING
FACTORY WIRING
SOLENOID VALVE
P2
AUTOMATIC
PRESSURE
CONTROL
S
C1
C2
CONTACTORS
BOILER SHELL
Installation
Sussman Boilers
Installation, Operation & Maintenance Manual
Wiring Diagram Control Circuit
8
SSB Electric Boilers with Manual Reset, Auxiliary Low Water Cutoff
120V 1PH
INPUT
ON-OFF
SWITCH
PROBE
L N
PILOT
LIGHT
CONTROL
TERMINAL
BLOCK
CONTROL
L
LIQUID
LEVEL
LO
GUARD
GROUND
AUX LWCO BOARD
L1 L2
LWCO
LWCO
L1 L2
LLCO
COM
RESET
NO
G
NC
MANUAL RESET
RELAY
HIGH LIMIT
PRESSURE
CONTROL
R
P1
FIELD WIRING
FACTORY WIRING
P2
AUTOMATIC
PRESSURE
CONTROL
S
SOLENOID VALVE
C1
C4
CONTACTORS
BOILER SHELL
REFER TO NATIONAL AND ALL APPLICABLE LOCAL CODES FOR SPECIFIC INSTALLATION REQUIREMENTS.
1.
The boiler should be mounted on a solid, level foundation.
2.
The boiler should be located with suitable clearances, refer to page 3 and Code requirements.
NOTE:
Allow minimum of 21 inches clearance in front of door for servicing of heating elements.
Piping
ALL PIPING SHOULD BE INSTALLED BY A QUALIFIED LICENSED PLUMBER IN ACCORDANCE WITH
NATIONAL AND LOCAL CODES.
3.
1.
When water feed is other than pump type the water
supply pressure must be 10 psig greater than boiler operating pressure to assure water supply maintains proper
water level in the boiler. Insufficient water levels can result
in improper boiler operation. (Keep feed water valves
open at all times during normal operation.)
2.
If pump and boiler are plumbed within 30 feet (pipe
length) a minimum of 2 check valves are required to
avoid damage to pump.
Connect steam line with customer supplied outlet valve
to boiler steam outlet.
4.
Provide for boiler drain connection, a daily blowdown is
required. A "Blowdown Separator Tank" may be necessary, check with local code.
5.
Safety valve shall be plumbed according to local code.
NOTE:
The safety valve shall not be plumbed with a line
sized less than the outlet size of the safety valve.
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