Page 1
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: [email protected]
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
Page 2
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
Page 3
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.
_________________________________________________________________________
Page 4
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
Page 5
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
Page 6
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
Page 7
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
Page 8
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.
Page 9
Sussman Boilers
Installation, Operation & Maintenance Manual
9
ALL ELECTRICAL WIRING MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN IN
ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES.
Assure that the power voltage and phase being supplied to the boiler matches the power
voltage and phase of the boiler. Connecting incorrect power supply can damage boiler components or
cause improper boiler operation. If the boiler power requirements do not match the power to be supplied to the boiler the
boiler must be returned to the factory for conversion. Boilers cannot be field converted.
ALL BOILERS ARE PRE-WIRED AND TESTED PRIOR TO SHIPMENT.
1.
Ground boiler according to National Electric Code requirements to avoid shock.
2.
Power wiring to boiler should be in accordance with National and Local Electrical Code requirements following wiring
diagram supplied. Use proper size wire. Wire size is specified adjacent to field wiring terminals. This label states the wire
size [AWG or MCM], minimum temperature rating (90 C) and conductor material (copper only). Deviation from these
requirements may result in improper or unsafe boiler operation.
3.
A disconnect switch employing circuit breakers or fuses should be installed between the main power source and the boiler. This disconnect switch should be located near the boiler and clearly marked for easy access and identification should
the boiler need to be turned off due to an emergency.
4.
Boiler control circuit is 120 Volt*. Unless boiler has an optional step down transformer, a separate 120 Volt power feed
wiring is required to be connected to the control circuit terminal block. A 15 Amp circuit is required for all boilers. If a
3/4 HP feed water motor and pump assembly is connected to the boiler, then a 20 Amp circuit is required.
5.
If a separate control circuit is used, it should be connected to the control circuit terminal block.
6.
Remote mounted water feed systems (i.e. condensate return, motor and pump) should be connected to the junction box
provided on the outside of the boiler jacket.
7.
With main power off, make sure all wiring terminations are tight to avoid arcing, carbonizing or overheating of contacts.
Boilers are susceptible to lightning damage due to water line connections. An industrial type
lightning/surge protector should be installed according to the manufacturer's recommendation at the
service entrance. Consult your contractor or electrical dealer.
Substitution of components or modification of wiring system voids the warranty and may
lead to dangerous operating conditions.
Wiring
!
CAUTION
!
CAUTION
!
WARNING
Page 10
Pressure Controls, Operation and Testing
Note:
All boilers are provided with one high limit
pressure control and at least one operating pressure
control.
1.
The high limit pressure control is equipped with a manual
reset feature. There is no subtractive differential scale
with this type of control
2.
All pressure controls are equipped with an adjusting
screw, allowing for setting of desired operational and
high limit pressures. To reduce pressure setting, turn
adjusting screw in direction that allows indicator to point
to a lower pressure setting on the scale. To increase pressure setting turn adjusting screw in direction that allows
indicator to point to a higher pressure on the scale
Note:
It is recommended that the high limit control be set
10psig above the desired normal operating pressure.
3.
Operating pressure controls, except low pressure (15psig)
types have a separate differential scale. Differential indicates pressure below the main operating maximum pressure, the pressure control will re-set. The differential set
point is adjusted in the same manner by turning the
adjusting screw in the desired direction to increase or
decrease the differential pressure value.
Sussman Boilers
Installation, Operation & Maintenance Manual
10
Pre-Operation Check (All Boilers)
LWCO/PUMP CONTROL OPERATION AND TESTING
1.
All valves for incoming water supply are to be fully opened.
Main disconnect switch is to be in the "on" position. Boiler main
switch is to be in the "on" position. Since boiler will be empty
the pump or solenoid will be energized allowing the boiler to
fill with water. Control will automatically fill boiler to proper
operating water level and the pump/solenoid will be de-energized. Contactors will then energize, applying voltage to the
heating elements.
2.
Pump switch operation – at this point water should be visible
approximately half way up the sight glass. Slowly open the
drain valve located at the bottom of the boiler. Water level in
the sight glass will begin to drop, allowing the low water cut
off/pump control to energize the feed water system. Close valve
for proper operation.
3.
Low water cutout switch performance – open the drain valve
completely. Maintain this condition until water level falls within
the gauge glass enough to cause the low water cutout switch to
de-energize the heating elements. All of the contactors will be
in a de-energized or open state at this time. Close the drain
valve, water feed system will automatically refill the boiler and
the contactors will re-energize.
Boilers equipped with an auxiliary low water cut-off
control with a manual re-set button (required as
mandatory equipment is some states): once the correct
operating water level has been reached, it will be necessary to depress the reset button in order for the contactors to re-energize.
Note:
For boilers equipped with an automatic blow-
down system:
• For test 1 - the blowdown time clock must be in the
“run” mode before the boiler will automatically
fill.
• For test 2 and 3 - in order for the drain valve to open
the blowdown clock must be in the “off” mode.
(See blowdown time clock insert) The automatic
blowdown indicator light will be on when the
valve is open. This light will remain on for the
duration of the blowdown cycle (a few seconds). It
may be necessary to cycle the time clock from the
“run” to “off” mode several times.
4.
Operating pressure control check: Close steam outlet
valve [supplied by customer] and adjust operating pressure control to 20psig and the differential to 10psig.
Set the high limit pressure control to 30psig. Switch
boiler on to allow steam pressure to build-up. Pressure
gauge reading will increase and the operating pressure
control will de-energize the contactor(s) when the pressure gauge indicates 20psig. Open steam outlet valve
to bleed off pressure. When the pressure gauge reading decreases below 10psig (differential) the operating
pressure control will re-energize the contactor(s).
5.
High limit pressure control check: FOR TEST PURPOSES
ONLY! Set the high limit pressure control 10psig lower
than the operating pressure control. Close the steam
outlet valve and switch the boiler on to allow boiler to
build pressure. When the pressure gauge indicates the
pressure at which the high limit pressure control is set,
the high limit pressure control re-set button will popup and the control will de-energize the contactor(s).
Open the steam outlet valve to bleed off pressure. The
contactor(s) should not re-energize on pressure drop.
The contactor(s) should only re-energize when the pressure has dropped and the high limit pressure control
reset button is depressed.
Page 11
Sussman Boilers
Installation, Operation & Maintenance Manual
11
Operation
With main disconnect “OFF”
tighten all electrical connections
before energizing boiler to prevent arcing, carbonizing of contact and/or overheating
1.
Set the desired operating pressure and differential pressure
on the operating pressure control.
2.
Set the high limit pressure control. (Recommended to be 10
psig above the operating pressure setting.)
3.
Turn on water supply.
4.
Turn main disconnect switch on.
5.
Turn boiler control switch on. The water feed will begin and
continue until the water level reaches half way up the gauge
glass. The water feed will automatically shut off and the contactor(s) will energize.
Blowdown
A daily blowdown is an essential part of boiler operation. It is the best and most important part of 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 may be necessary more than once a day. If there is a particular problem that
applies to your local water condition (i.e. high concentrations of minerals etc.) we recommend a consultation with a reputable local water treatment-engineering firm. Pre-treating the boiler feed water may reduce mineral accumulation enough
to allow a daily blowdown to be sufficient.
MANUAL BLOWDOWN INSTRUCTIONS
1. At the end of the working day, while boiler is still
operating, turn boiler main switch to the “OFF” position, close water supply valve and open disconnect
switch.
2. If blow down valve is plumbed into a blowdown tank,
the boiler can be discharged at operating pressure.
3. If the blowdown valve is not plumbed into a blowdown tank, consult with local plumbing codes regarding boiler discharge.
4. When discharge is complete and boiler is drained,
close the blowdown valve, open the water supply
valve, turn boiler main switch to “ON” position and
close disconnect switch.
5. When refilling is complete, turn off the boiler unless
further operation is needed.
6. If boiler is equipped with a “Manual Re-set Auxiliary
Low Water Cut-off” (as required in some states) the
re-set button must be pushed before the boiler will
begin developing steam. Do not push re-set button
until the boiler has refilled with water.
NOTE:
THE USE OF CHEMICAL BOILER CLEANING
COMPOUNDS IN THESE BOILERS VOIDS ALL WARRANTIES. SOME COMPOUNDS CAN/WILL DAMAGE
INCOLOY SHEATHED HEATING ELEMENTS AND
SHORTEN THE LIFE OF THE ELEMENTS.
AUTOMATIC BLOWDOWN INSTRUCTIONS
(PN ES81600) 1” NPT, Starts, stops and blows down the boiler auto-
matically, utilizing a programmable time clock a time-delay relay
and motorized ball valve.
If the blowdown valve is plumbed into a blowdown tank, the boiler can be discharged at operating pressure. If
the blowdown valve is not plumbed into a blowdown tank, consult
with local plumbing codes regarding boiler discharge.
NOTE:
The manual valves from the boiler drain and the lower
float control equalization tube must be fully open for the automatic blowdown to be effective.
1. Program time clock by setting the time boiler is to turn on and
off daily. (Refer to instructions in time clock insert.)
2. When the time clock turns the boiler “off” the blowdown is acti-
vated. A red pilot light over the time clock will come on and
remain on while the motorized ball valve is open. The time duration the valve is open is set by an adjustable potentiometer built
into the time delay board. The water level in the boiler after
blowdown is complete, will be approximately at the lower gauge
glass valve. (Elements are not exposed to air between operations.)
3. Boiler will automatically refill at next programmed on cycle.
Blowdown program can be overridden to allow for unscheduled
blowdown or operational cycles. Refer to the time clock instruction
insert.
!
CAUTION
6.
Boiler steam pressure will gradually increase to the
operating pressure control set point, at which time
the contactor(s) will de-energize.
7.
With steam demand, the boiler steam pressure will
decrease. When the boiler pressure has dropped
below the operating pressure control differential set
amount, the contactor(s) will re-energize.
8.
The boiler is equipped with float type liquid level con-
trols employing micro switches. They are extremely
sensitive and reliable and will maintain the proper
water level within the boiler pressure vessel automatically during boiler operation.
9.
The boiler should be blown down daily. (See blow-
down instructions.)
!
CAUTION
Page 12
Sussman Boilers
Installation, Operation & Maintenance Manual
24-Hour and 7-Day Time Switches
PROGRAMMING
F
or electric steam boilers equipped with Automatic Blowdown Systems
ES 81600, refer to the following instructions for time clock operation and
settings. T
the owner/operator.
The weekly program dial shows the seven days of the week and AM/PM
imprints for each day.
The time switch is set by pushing the captive trippers to the outer ring
position for the entire period that the load is to be turned ON, i.e.,
2 hours to each tripper on the 7-day dial. When the tripper is pushed to
the inside, the switch is in the OFF position.
SETTING TIME
To set the current time and day of week, turn the minute hand clockwise. Do not set the time by rotating
“Outer” Dial.
Turn the minute hand clockwise until the day of the week and the time of day on the outer dial is aligned
with the triangle marker on the inner dial (two o'clock).
imer settings for blowdown operation are at the discretion of
Example for 7-day program dial Monday 10:30 AM.Turn the minute hand clockwise until Monday 10:30 AM
is aligned with the triangle on the inner dial.The hour and minute hand will show exactly 10:30.
FOR MANUAL OVERRIDE
Manual override can be accomplished at the discretion of the owner/operator
3-WAY MANUAL OVERRIDE SWITCH
I = permanent ON
= automatic
O = permanent OFF
IMPORTANT:
It is recommended that for periodic and effective blowdown,
the override switch be set in the automatic setting.
I
O
as follows.
12
Page 13
Sussman Boilers
Installation, Operation & Maintenance Manual
Maintenance
13
HAZARD OF ELECTRIC SHOCK.
DISCONNECT ALL ELECTRICAL
POWER BEFORE WORKING ON BOILER.
S
ussman Electric Steam Boilers are designed for years of
trouble-free performance. To establish a good preventative
maintenance program, we suggest that the facility maintenance person or engineer familiarize themselves with these
simple rules.
1.
The use of chemical boiler cleaning compounds voids all
warranties and should not be used. Some compounds
can/will damage the incoloy sheathing of the heating
elements. A reputable water treatment-engineering
firm should be consulted regarding pre-treating or conditioning the boiler feed water.
2.
Daily blowdown at pressure is essential for ideal boiler
performance. Extended periods of operation may
require more frequent blowdown. If the boiler is not
equipped with an automatic blowdown, in order to
safeguard the heating elements, it is recommended to
turn both the main disconnect switch and the boiler
switch to the off position before manually blowing
down the boiler.
3.
The sight glass should be checked frequently to assure
the boiler has adequate water.
4.
The sight glass should be checked daily for damage (i.e.
scratches, erosion, leaks etc.) The sight glass should be
replaced if damaged. (See insert.)
!
CAUTION
5.
A monthly inspection should be made of the internal
wiring. Open the access door and check all electrical
connections for tightness. Replace any wires that
show signs of damage.
NOTE:
The electrical power MUST be shut off during
this maintenance procedure.
6.
Heating element mounting bolts should be checked
and tightened to a torque of 22 ft.-lbs. If there are
indications of steam leaks from an element, replace
the element gasket.
7.
A monthly check for leaks should be made; any loose
or damaged fittings should be tightened or replaced.
8.
Every four months the boiler float control should be
checked for proper operation. The lower equalization
column can be examined visually and manually to see
if is clear and clean. If there are signs of scale or mineral deposit buildup the float control must be disassembled and cleaned.
One of the lower heating elements should be
removed. If scale or mineral deposits have begun to
form all elements should be removed cleaned and
reinstalled using new element gaskets.
Operating and high limit pressure control operation
should be checked. Pressure controls should be
removed and cleaned if necessary. Water feed supply
check valves should be inspected and replaced if necessary.
9.
If the boiler is equipped with an electronic auxiliary
low water cut-off every four months the probe should
be removed and checked for deposits. The probe
should be cleaned and reinstalled.
Page 14
Sussman Boilers
Installation, Operation & Maintenance Manual
Optional Equipment
14
AUXILIARY LOW WATER CUT OFF
• For model ES & HU boilers P/N ES81017 & ES81017MR (w/ manual reset).
• For model SSB boilers p/n SSB81017 & SSB81017MR (w/ manual reset).
Senses water level electronically using a resistance probe. When a low water condition is detected, the contactor
control voltage circuit is interrupted and the heating elements are de-energized. When water level returns to
proper levels voltage is restored to the contactor coils and the elements are re-energized. For controls with a
manual reset button voltage to the contactor coils is not restored until the water level has returned to proper
operating levels and the reset button is pushed. Do not depress the reset button before the correct water level is
achieved.
LINE PRESSURE WATER FEED SYSTEM
• For model ES & HU boilers P/N ES99117
• For model SSB boilers
P/N
P/N SSB99117
Water feed system used to supply makeup water to the boiler when incoming water line pressure is 10 psig
greater than the operating pressure of the boiler. Completely factory plumbed and wired; 0-100psig range; 1/2”
NPT size. Consists of strainer, solenoid valve (120/1/50-60Hz), and check valve for automatic feed. For SSB boilers
P/N SSB99117 components are of stainless steel construction.
HIGH PRESSURE WATER FEED SYSTEM
• For model ES12-72 P/N ES38002A
• For model ES100-180 P/N ES38020A
• For model SSB12-72 P/N SSB38002A
• For model SSB100-180 P/N SSB38020A
Used to supply makeup water and to maintain constant water level when the boiler operating pressure is equal
to or greater than incoming water line pressure and condensate is not returned to the boiler.
• ES38002A & SSB38002A – Range is 0 – 100 psig, 1/2” NPT size consisting of strainer, solenoid valve and 1/3 HP
120/1/60 motor and pump.
• ES38020A & SSB38020A – Range is 0 – 125 psig, 3/4” NPT size consisting of strainer solenoid valve and 1/2 HP
120/1/60 motor and pump.
These assemblies are mounted on rubber shocks and secured to a steel base mounting plate. These units require
field plumbing and wiring to the boiler. SSB38002A and SSB38020A pump components are of stainless steel construction.
CONDENSATE RETURN SYSTEM
(see page 17)
• For model ES12-72 p/n ES38083V; for model ES85-180 p/n ES38084V.
These systems are used whenever condensed steam can be collected for reuse in the boiler. Returning the condensate to the boiler can save a significant amount of energy. The water returned is relatively free of corrosive
minerals and carries a substantial amount of heat that does not have to be replenished. A vacuum breaker is
required whenever a condensate return system is used.
Each system consists of a vertical condensate return tank, a motor and pump and support plumbing. A 1/2”
inlet is located on the tank to accept make-up water. A vent fitting is located on the condensate tank top for
atmospheric air venting. The return fitting is to be plumbed to the trapped condensate return line coming
from the process.
A gauge glass and valve set are mounted on the side of the condensate tank. The tank has a ball check valve
internally mounted, and a float arm and float ball assembly that serve mechanically allowing make-up water to
enter the tank as the original supply is used. The pump discharge outlet is to be plumbed to the boiler check
valve. The tank drain valve should be plumbed to a proper drain line. The motor is required to be wired to the
boiler.
Page 15
Sussman Boilers
Installation, Operation & Maintenance Manual
Optional Equipment (cont)
15
VACUUM BREAKER SYSTEMS
• For model ES boilers P/N ES89369
• For model SSB boilers P/N SSB89369
A vacuum breaker will prevent a boiler from flooding as a result of the steam condensing internally and creating a
vacuum after boiler shutdown. The breaker allows air to enter the boiler shell breaking the vacuum. This system is
a must for boilers connected to a condensate return tank. The vacuum breaker consists of a spring-loaded disc and
associated piping and is factory plumbed to the boiler. The SSB89369 is of stainless steel construction.
AUTOMATIC BLOWDOWN SYSTEM
• Extends life of boiler
• Saves labor costs
• Starts the boiler automatically every day
• Shuts down the boiler every day
• Automatically blows down the boiler every day
• Completely programmable, can skip days, different start and shutdown times, different operational durations.
• ES81600 for all model boilers.
A stainless steel, motor driven straight-through, self-cleaning ball valve with Teflon seats handles particles and dirty
fluid without the use of an up-stream strainer or other cleaning device. A timer (Standard analog time clock is set
for two hour time intervals, optional digital time clock can be programmed to one minute intervals.) and electronic
time delay relay control the boiler and the blowdown valve. A pilot light indicates when the blowdown valve is
open. The valve shall be plumbed to a proper drain or receptacle. An automatic blowdown system can be installed
on any boiler, regardless of size operating pressure or operating duty cycle.
BLOWDOWN SEPARATORS
(see page 18)
• For models ES12-48 and SSB12-48 p/n BDT-ASME36
• For models ES60-180 and SSB60-180 p/n BDT-ASME42
A separator accepts the flash steam and effluent from the boiler blowdown and reduces the temperature and pressure to insure a safe discharge of water and sludge. Steam flash and pressure are absorbed and pass harmlessly to
the outside via a vent. The separator design utilizes a water seal at the outlet, which permits the operator to introduce cold water from the bottom to mix with the hot water and boiler steam in the blowdown separator. This
reduces outlet temperature to a safe discharge level.
These separators require specific plumbing from the boiler blowdown valve and require connection to a cold water
supply. (If the separator is less than half full of water after the boiler is blown down cold water must be added to
bring the water level to the halfway mark before the next blowdown).
• 0-30 psig pressure gauge; 0-200F temperature gauge; water sight gauge glass and valve set assembly are included.
CONTROL VOLTAGE STEPDOWN TRANSFORMER
• Provides 120 Volt (220 Volt export) from main power supply. Factory wired and fused.
MULTISTAGE LOAD PROGRESSIVE SEQUENCERS
Accurate control is provided by automatic progressive sequencing in the use of energy and minimizing wear on
electrical components. The sequencers are designed to apply power progressively to larger KW boilers. A factory
installed pressure sensitive sequential control reacting to steam boiler pressure progressive energizes or de-energizes heating elements through power contactors. A delay between sequencer steps before start-up and between
each subsequent step eliminates power surges. Each sequencer is matched and factory pre- set to boiler system
requirements. Electronic progressive sequencers give accurate control of multi-stage loads of the type used in steam
boilers. Features include progressive sequencing (first on- first off) that equalizes the operating time of each load.
Integral solid-state light emitting diodes show active stages. Should a power interruption occur, all elements are
instantly de-energized for safety. Upon resumption of power the control will re-stage the loads one at a time.
Page 16
Sussman Boilers
Installation, Operation & Maintenance Manual
Condensate Return Systems
16
Notes:
1.
Motor/Pump is closed - Coupled design
2.
Pump capacity as follows:
3.
Normal cold water level approximately 1/2 to 5/8 up to visible part of gauge glass.
Models 38083V & 38084V
MODEL 38083V
___________________
PSIG HEAD GPM
___________________
54 125 ft. 3.2
___________________
75 175 ft. 2.9
___________________
97 225 ft. 2.7
___________________
_____________________________________________________________________________
PUMP MOTOR
MODEL Used on "A" "B" "C" "D" "E"` H.P. VOLT/PH/HZ
_____________________________________________________________________________
38083V ES12 - ES72 38-1/4" 18 14-1/4" 14 18 1/3 120 / 1 / 60
_____________________________________________________________________________
38084V ES100 - ES180 51-1/2" 18 14-1/4" 14 30 1/2 120 / 1/ 60
_____________________________________________________________________________
MODEL 38084V
___________________
PSIG HEAD GPM
___________________
54 125 ft. 4.6
___________________
75 175 ft. 4.3
___________________
97 225 ft. 4.0
___________________
B
9-1/2" DIA COVER PLATE
EASY ACCESS FOR MAINTENANCE
E
A
PUMP EASY ACCESS
VENT SAFETY BAR
FLOAT VALVE
39010-F
1
/4"
1-
SIGHT GLASS
99074-1
SITE GLASS ASSY
PN 99173C
1
1-
/4"
SIGHT GLASS
99074-1
CONDENSATE RETURN FLASH TUBE
OVERFLOW OUTLET 1" NPT (farside)
OVERFLOW (label)
SIMPLE RUGGED LINKAGE
5" DIA UPPER FLOAT BALL
39011FB
SHUTOFF GATE VALVE
STRAINER CLEANOUT
D
C
1-1/4" VENT WITH SAFETY BAR
1/2" COLD WATER INLET COUPLING
WITH #100 MESH STRAINER
CONDENSATE RETURN (label)
VENT (label)
TOP VIEW
COLD WATER INLET
(label)
LIMIT MAKEUP WATER PRESSURE
TO TO 30 PSI MAXIMUM” (label)
1
1-
/4" CONDENSATE
RETURN COUPLING
Page 17
Sussman Boilers
Installation, Operation & Maintenance Manual
Blowdown Separator Tanks-
Models BDT-ASME 36, 42, 48, 54
Dimensions and Features Suggested Hook-Up to Boiler
D
"C" Drain
A
Temperature
Gauge
H
3/4" Coupling
for Temperature
Probe (opt.)
Pressure Gauge
"E" Vent
"B" Inlet
Water Gauge
Handhole Assembly
3" x 4"
(except BDT-ASME 36)
"F" Cold Water Inlet
& Washout Drain
G
Tempered
Blowdown
to Drain
Specifications and Data
Vent to atmosphere must be full size
Blowdown Separator
Blowdown Inlet
From Boiler
Blowdown Outlets
Cold Water Supply
Drain Valve (closed during normal operator)
BOILER DIMENSIONS SHIPPING
_______________________________________________________________________
BDT-ASME 36 0-5 18" 1" 2" 12" 2" 2" 14" 32" 125
_______________________________________________________________________
BDT-ASME 42 6-25 24" 1" 2" 18" 2-1⁄
_______________________________________________________________________
BDT-ASME 48 26-59 30" 1-
_______________________________________________________________________
BDT-ASME 54 60-100 38" 1-1⁄2" 3" 18" 4" 2" 18" 54" 290
The Sussman Separator design incorporates a water
seal at the outlet which permits the operator to
introduce cold water from the bottom to mix with
________________________________________________
HP
A B C D E F G H WEIGHT
2" 2" 18" 42" 230
1
⁄4" 2" 16" 3" 2" 18" 48" 280
Maximum Boiler Working Pressure: 250 psi
Maximum Blowdown Separator Pressure: 65 psi
Blowdown Separators are sized in accordance with National Board Standards
the hot water and boiler steam blowdown in the
separator. This reduces the outlet temperature to
Standard Equipment
• 0-100 lb. Pressure Gauge
a level that makes it safe for discharge.
• 0-200˚ Temperature Gauge
Note: 1BHP is approximately 10KW.
• Water Level Gauge
Constructed in accordance with Section VII Division I ASME Boiler & Pressure Vessel Code
17
Page 18
Sussman Boilers
Installation, Operation & Maintenance Manual
Specifications
Steam Gauge
Pressure/
Temperature
Chart
18
__________________________________________
Boiler Bhp Lbs/Hr 3-Ph
Model No. KW Rating Steam** Volts*** Amps
__________________________________________
208 34
ES-12* 12 1.22 36.2 240 29
480 15
__________________________________________
208 50
ES-18* 18 1.84 54.2 240 44
480 22
__________________________________________
208 67
ES-24* 24 2.45 72.3 240 58
480 29
__________________________________________
208 84
ES-30 30 3.06 90.4 240 73
480 37
__________________________________________
208 100
ES-36 36 3.67 108 240 87
480 44
__________________________________________
208 134
ES-48 48 4.90 145 240 116
480 58
__________________________________________
208 167
ES-60 60 6.12 181 240 145
480 73
__________________________________________
208 200
ES-72 72 7.35 217 240 174
480 87
__________________________________________
208 300
ES-100 108 11.2 325 240 260
480 130
__________________________________________
208 400
ES-135 144 14.7 434 240 347
480 173
__________________________________________
ES-160 158 16.2 475
240 379
480 190
__________________________________________
ES-180 180 18.4 542
240 434
480 217
__________________________________________
* Single phase available
** @ 212˚ F
*** Other voltage available
________________
Gauge Temperature
Pressure
PSIG
F˚ C˚
________________
15 179 82
________________________
10 192 89
________________________
5 203 95
________________________
0 212 100
________________________
1 215 102
________________________
3 221 105
________________________
5 227 111
________________________
9 237 114
________________________
11 241 119
________________________
15 250 121
________________________
17 253 123
________________________
19 257 125
________________________
21 260 127
________________________
23 264 129
________________________
25 267 131
________________________
27 270 132
________________________
29 273 134
________________________
31 275 135
________________________
33 278 137
________________________
35 281 138
________________________
37 283 139
________________________
39 286 141
________________________
41 288 142
________________________
43 290 143
________________________
45 292 144
________________________
47 295 146
________________________
49 297 147
________________________
51 299 148
________________________
53 300 149
________________________
55 303 151
________________________
60 308 153
________________________
65 312 156
________________________
70 316 158
________________________
75 320 160
________________________
80 324 162
________________________
85 327 164
________________________
90 331 166
________________________
95 335 168
________________________
100 338 170
________________________
Page 19
Sussman Boilers
Installation, Operation & Maintenance Manual
Sizing
19
Use the following Table to determine KW Boiler rating when steam load and feedwater temperatures are known.
___________________________________________________________________
Feed Water
0 2 10 15 25 40 50 75 100 125 150
( F˚)
___________________________________________________________________
40 .3347 .3355 .3375 .3388 .3406 .3422 .3431 .3447 .3458 .3464 .3470
___________________________________________________________________
50 .3318 .3326 .3345 .3359 .3376 .3392 .3401 .3317 .3429 .3435 .3441
___________________________________________________________________
60 .3288 .3296 .3316 .3329 .3347 .3363 .3372 .3388 .3400 .3407 .3411
___________________________________________________________________
70 .3259 .3267 .3287 .3300 .3318 .3334 .3343 .3359 .3370 .3376 .3382
___________________________________________________________________
80 .3229 .3238 .3278 .3271 .3288 .3305 .3313 .3329 .3341 .3347 .3353
___________________________________________________________________
90 .3200 .3208 .3238 .3242 .3259 .3275 .3284 .3300 .3312 .3318 .3324
___________________________________________________________________
100 .3171 .3179 .3199 .3212 .3229 .3246 .3255 .3271 .3283 .3288 .3294
___________________________________________________________________
110 .3142 .3150 .3170 .3183 .3200 .3217 .3225 .3242 .3253 .3259 .3265
___________________________________________________________________
120 .3112 .3210 .3140 .3154 .3171 .3287 .3196 .3212 .3224 .3230 .3236
___________________________________________________________________
130 .3083 .3091 .3111 .3124 .3142 .3160 .3167 .3183 .3195 .3200 .3206
___________________________________________________________________
140 .3054 .3062 .3082 .3095 .3113 .3129 .3137 .3154 .3165 .3171 .3177
___________________________________________________________________
150 .3025 .3032 .3052 .3066 .3083 .3099 .3108 .3124 .3136 .3142 .3148
___________________________________________________________________
160 .2995 .3003 .3029 .3036 .3054 .3070 .3079 .3095 .3107 .3113 .3118
___________________________________________________________________
170 .2966 .2974 .2994 .3001 .3025 .3041 .3050 .3066 .3077 .3083 .3089
___________________________________________________________________
180 .2937 .2945 .2964 .2978 2995 .3011 .3020 .3036 .3048 .3054 .3060
___________________________________________________________________
190 .2907 .2915 .2935 .2948 .2966 .2982 .2981 .3007 .3019 .3025 .3030
___________________________________________________________________
200 .2878 .2886 .2906 .2919 .2937 .2953 .2962 .2978 .2989 .2995 .3001
___________________________________________________________________
Example:
Need a boiler to produce 450 lbs. steam/hr. at 75 psig with the available feedwater temperature 50˚ F.
From the chart above, find .3417 KW/Lb. of steam
450 lbs. steam/hr. x .3417= 153.8 KW boiler required
Page 20
IMPORTANT NOTE:
Read all warnings and instructions before performing installation or maintenance.
Safety glasses and gloves should be worn at all times
when working with or examining water gauge glass
and connections. Pressure in generator to be at zero
before proceeding. Improper installation or maintenance of gauge glass and connections can cause immediate or delayed breakage resulting in bodily injury
and/or property damage.
1.
Apply Teflon tape or pipe dope to pipe threads.
Install top gauge fitting (fitting without a drain
valve) into the uppermost tapping. Wrench tighten
the fitting until it is snug and the glass outlet is
pointing at five o'clock (about 1/8 turn from its final
downward vertical position).
2.
Install the bottom gauge fitting (the fitting with a
drain valve) until it is snug and the glass outlet is
pointing directly upward. Verify top and bottom fittings are threaded into the tappings the same number of turns (distance A= distance B).
3.
Remove glass packing nut, friction washer (or packing gland, depending upon the model), and glass
packing from the fittings, and place them, in the
same order, on to both ends of the gauge glass.
Push both packings about an inch up the gauge
glass.
4.
Gently insert one end of the glass into the top
gauge fitting. Keeping the glass inside the top fitting, gently rotate the top gauge fitting clockwise
until vertically aligned with the bottom gauge, then
insert glass into bottom fitting until glass bottoms
out on the shoulder inside the bottom fitting.
5.
Carefully raise glass about 1/16" and slide lower
glass packing down until the glass packing contacts
the lower gauge fitting. DO NOT allow the glass to
remain in contact with any metal!
6.
Carefully slide upper glass packing 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 lightly, a quarter turn at a time, checking for leakage after each turn.
IMPORTANT NOTE:
Read all warnings and instructions before performing installation or maintenance.
Safety glasses and gloves should be worn at all times when working with
or examining water gauge glass and connections.
Pressure in generator to be at zero before proceeding.
Improper installation or maintenance of gauge glass and connections can cause
immediate or delayed breakage resulting in bodily injury and/or property damage.
Sussman Boilers
Installation, Operation & Maintenance Manual
Gauge Glass Installation
20
!
WARNING
Vessel Wall
Gauge Glass
Glass Packing
Nut
Glass Packing
Top Gauge
Fitting
Guard Rod
Friction Washer
(or Packing Gland)
Bottom
Gauge
Fitting
Drain Valve
A
B
Page 21
Sussman Boilers
Installation, Operation & Maintenance Manual
Gauge Glass Installation - Use and Care
21
DO NOTs
DO NOT use glass if it contains any scratches, chips, or any other visible signs of damage.
DO NOT reuse any tubular glass or glass packings.
DO NOT subject gauge glass to bending or torsional stresses.
DO NOT over tighten glass packing nuts.
DO NOT allow glass to touch any metal parts.
DO NOT exceed the recommended pressure of the gauge or gauge glass.
DO NOT clean the gauge or gauge glass while pressurized or in operation.
DO's
DO verify proper gauge has been supplied.
DO examine gauge glass and packings carefully for damage before installation.
DO install protective guards and utilize automatic ball checks where necessary to help prevent injury
in case of glass breakage.
DO inspect the gauge glass daily, keep maintenance records, and conduct routine replacements.
DO protect glass from sudden changes in temperatures such as drafts, water spray, etc.
MAINTENANCE
Examine the gauge glass regularly for any signs of clouding, scratching, erosion, or corrosion. The glass should be
inspected daily until the need for replacement becomes apparent. This will help establish the routine inspection
and routine replacement schedules.
CLEANING
Use commercial non-abrasive glass cleaners to keep glass clean. Use diluted acids such as Hydrochloric (muriatic)
acid when regular cleaners do not seem to work. Do not use wire brushes or any other abrasive materials which
could
scratch the glass.
INSPECTION
Examine the surface of the glass for scratches, corrosion, chips, cracks, surface flaws, or nicks. To do this, shine a
very bright concentrated light at an angle of about 45 degrees.A defective glass will glisten as the light strikes
imperfections. Glass which appears cloudy or roughened, and will not respond to cleaning, should be replaced.
STORING
Keep gauge glass in original packaging until ready to install.
Page 22
Sussman Boilers
Installation, Operation & Maintenance Manual
Element Replacement
22
READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK
Before Installing your new elements be sure the
McDonnell Miller low water cut-off and aux. low
water cutoff (if supplied) is operating properly. The float chamber and
lower equalizer column of the MM control must be completely clear of
sludge or other foreign matter. Failure to do this may cause the immediate burn-out of the new elements. If the unit is probe equipped, check
condition of the probes and isolator.
All elements are thoroughly checked before shipment The manufacturer
cannot be responsible for burn-outs 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 finger or probes to see if it is clear and clean.
1.
Disconnect boiler from electric power supply at main safety switch or fuse panel.
Then turn boiler switch to “OFF" position.
2.
Close water supply valve on incoming water supply line. Drain boiler completely of water.
3.
Open boiler door to access heating element.
4.
Disconnect wire (electric) leads connecting element to main power system of boiler.
Again, note wire connections to facilitate re-assembly. Proceed to remove and discard
(6) bolts from flange.
IMPORTANT:
Note the wire connections to facilitate re-assembly (see wiring schematic).
Remove and discard six (5/16"-18) bolts from flange. Do not reuse these bolts.
5.
Thoroughly clean boiler flange of all foreign material. Be certain no part of old gasket
remains on flange.
6.
Apply "Slic-Tite" Gasket Compound (or equal) to both surfaces of new gasket supplied
with 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 element wire connection terminals on element assembly are in line with previously
disconnected wire leads to facilitate easy connections.
NOTE:
Observe markings on element flange. Install element marking “TOP” on top.
7.
Use only new element flange bolts. Tighten all (6) element flange bolts to a torque value
of 22 lb-ft each (see illustration).
8.
Connect all wires to the terminals. Tighten all element terminals to a torque value of
20 lb-in each (see illustration). Make sure all wires are clean and bright to assure good
electrical contact.
9.
Check that the wires are correctly connected to the contactor terminals and are tightened
to a torque value of 45 lb-in. (see illustration). Make sure all wires are clean and bright to
assure good electrical contact.
10.
Open water valve to allow water supply to reach boiler feed mechanism.
11.
As boiler automatically refills, observe the new flange assembly for possible leaks. If water
is noticed, the bolts must be re-tightened. Before doing this, turn the boiler off at the
main fuse safety switch.
12.
When boiler reaches working pressure, check flange assembly again for leaks.
Avoid use of chemical cleaning compounds.
Follow maintenance instructions provided with the boiler.
!
CAUTION
!
CAUTION
Torque Values:
Element Flange Bolts: 22 lb-ft
Element Terminals: 20 lb-in
Contactor Terminals: 45 lb-in
For Illustrative Purposes Only.
Power wiring shown in approximate
factory-installed location
TORQUE VALUES
________________________________________
Element Flange Bolts 22 lb-ft
________________________________________
Element Terminals 20 lb-in
________________________________________
Contactor Terminals 45 lb-in
Torque
Wrench
Torque
Wrench
Torque
Wrench
Boiler with
McDonnell Miller
11⁄2”
1” Steam Equalizing Pipe
Pump and Low Water Control
Normal Boiler Water Line
Cut-Off Level is Arrow Mark
Blowdown Valve
1” Water Equalizing Pipe
Page 23
Sussman Boilers
Installation, Operation & Maintenance Manual
Water Quality Information for Carbon Steel Boilers
23
FOR OPTIMUM RESULTS, THE FEEDWATER SUPPLY SHOULD BE TESTED PRIOR TO INITIAL STARTUP, IF THE MINERAL
CONTENT EXCEEDS THE FOLLOWING RECOMMENDED LIMITS, VARIOUS EXTERNAL TREATMENT PROCESSES
(WATER SOFTENER, REVERSE OSMOSIS, ETC,) MAY BE USED TO CORRECT THE PROBLEM.
NOTE:
WATER TREATMENT COMPANY TO ASCERTAIN THE EXISTING CONDITION AND TREATMENT REQUIRED.
RECOMMENDED FEEDWATER QUALITY
HARDNESS, ppm 8 – 85 (~0.5 – 5 gpg)
P-ALKALINITY, ppm 85 – 410 (~5 – 24 gpg)
T-ALKALINITY, ppm 200 – 500 (~7 – 0 gpg)
pH (strength of alkalinity) 8.0 – 11.4
SPECIFIC RESISTIVITY ~50k Ω cm (50,000 ohm-centimeter)
BLOW DOWN BOILER ON AT LEAST A ONCE A DAY BASIS. IF BOILER WATER OR FEEDWATER ARE OUTSIDE THE
ABOVE LIMITS, A MORE FREQUENT BLOWDOWN IS REQUIRED.
RECOMMENDED LIMITS WITHIN A BOILER
TOTAL DISSOLVED SOLIDS, ppm 3500
TOTAL ALKALINITY, ppm 850
SUSPENDED SOLIDS, ppm 300
SILICA (Si02), ppm 125
SULFITE (SO3), ppm 25–50
PHOSPHATE, ppm 30–60
P-ALKALINITY AS CaCO3, ppm 900
IRON, ppm 2
AN ANALYSIS OF THE ON-SITE BOILER FEEDWATER MUST BE MADE BY A RECOGNIZED AND RELIABLE
WATER QUALITY CAN AFFECT EFFICIENCY OR RESULT IN BOILER DAMAGE IF NEGLECTED. BOILER FEEDWATER
CONTAINS IMPURITIES IN SOLUTION AND SUSPENSION. THESE IMPURITIES CONCENTRATE IN THE BOILER SINCE THE
STEAM GENERATED IS ESSENTIALLY PURE. THE CONCENTRATION OF THESE IMPURITIES INCREASES AS MORE FEEDWATER IS INTRODUCED INTO THE BOILER AND STEAM IS PRODUCED. IF THE SUSPENDED SOLIDS ARE ALLOWED TO
CONCENTRATE BEYOND CERTAIN LIMITS, A DEPOSIT OR "SCALE" WILL FORM ON THE BOILER INTERNAL SURFACES. THIS DEPOSIT CAN INTERFERE WITH PROPER BOILER OPERATION AND CAUSE BOILER FAILURE.
THE CONCENTRATION OF THESE IMPURITIES IS GENERALLY CONTROLLED BY THE FEEDWATER QUALITY AND BY
BLOWDOWN. BLOWDOWN REFERS TO REMOVING A PORTION OF THE BOILER WATER WITH HIGH SOLIDS CONCENTRATION AND REPLACING IT WITH MAKEUP WATER OF A LOWER CONCENTRATION.
Page 24
Sussman Boilers
Installation, Operation & Maintenance Manual
24
Limited Warranty
THIS WARRANTY SUPERCEDES ALL PRIOR WARRANTY COVERAGE.
Sussman-Automatic Corporation hereby extends to the original purchaser of its Industrial Steam and Hot Water Boilers,
Steam Superheaters and Heat Exchanger products (“Boiler Products”) a warranty against defects in materials and workmanship for the period indicated below.
NO OTHER EXPRESS OR IMPLIED WARRANTY, WRITTEN OR ORAL APPLIES (INCLUDING, WITHOUT LIMITATION, WARRANTIES
OR MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE). NO PERSON IS AUTHORIZED TO GIVE ANY OTHER WARRANTY OR ASSUME ANY OTHER LIABILITY EXCEPT BY WRITTEN STATEMENT SIGNED BY AN OFFICER OF SUSSMAN-AUTOMATIC
CORPORATION, LONG ISLAND CITY, NY.
The warranty is only valid on ”Boiler Products’ purchased and used in the United States of America and Canada.
WARRANTY:
______________________________________
WARRANTY PERIOD: The warranty on Boilers Products
extends for one (1) year from the date of first purchase by
the original purchaser. The ASME pressure vessel used on
Boiler Products extends for five (5) years from the date of
first purchase by the original purchaser.
Sussman-Automatic Corporation will repair or replace (at its
sole option) a Boiler Product if it fails to conform to this warranty. In the event a Boiler Product is to be repaired pursuant
to this warranty, such repair work will be performed by
Sussman-Automatic Corporation or at its direction. Under no
circumstances will Sussman-Automatic Corporation make
reimbursement for repair costs without written authorization
by Sussman-Automatic Corporation. See Merchandise Return
Authorization under Terms and Conditions for returns.
LIMITATIONS:
______________________________________
B
OILER PRODUCTS MUST BE INSTALLED, OPERATED AND
MAINTAINED IN ACCORDANCE WITH ALL INSTRUCTIONS PROVIDED BY SUSSMAN-AUTOMATIC CORPORATION. FAILURE TO
FOLLOW OUR INSTALLATION, OPERATING OR MAINTENANCE
PROCEDURES AND/OR USE OF UNAUTHORIZED PARTS AUTOMATICALLY VOIDS THIS WARRANTY.
Purchasers and/or Users are responsible for the suitability of
the products for their application.
This warranty does not apply to (i) repairs or replacements
necessitated by any cause beyond the control of SussmanAutomatic Corporation including, but not limited to, any malfunction, defect or failure caused by or resulting from unauthorized service or parts; installation, operating or maintenance contrary to furnished instructions; local water conditions, handling, shipping or transit accidents; modification or
repair by the user; abuse; misuse; neglect; accident; incorrect
power line voltage; power line surge; lightening damage; or
fire, flood, or other Acts of God; (ii) repair or replacement in
the ordinary course of expendable Boiler Products part, and
(iii) heating elements and boiler controls whose damage or
failure is attributable to corrosion, scale, or dirt accumulations or to low water conditions.
The foregoing is in lieu of all other express warranties.
Sussman-Automatic Corporation does not assume or authorize any party to assume for it any other obligation or liability.
TERMS AND CONDITIONS FOR RETURNS:
_____________________________________
Merchandise Return Authorization: To ensure processing of
warranty claim, a Merchandise Return Authorization (MRA)
must be obtained by the original purchaser and prominently shown on correspondence and packages. Returns made
without an MRA will not be processed. To obtain MRA, call
1-800-238-3535. Authorized returns which, after examination by Sussman, are not covered by this warranty will be
subject to a labor charge.
Freight Charges and Handling Fees: The purchaser is responsible for all shipping charges. All Boiler Product returned
pursuant to this warranty must be shipped freight prepaid.
Proof of Purchase: Proof of purchase (original sales receipt)
identifying the model number and serial number of Boiler
Product must accompany warranty claim.
SUSSMAN-AUTOMATIC CORP. IS NOT LIABLE FOR LABOR
AND OTHER COSTS INCURRED IN REMOVAL, REINSTALLATION, OR UNAUTHORIZED REPAIR OF THE BOILER PRODUCT
OR FOR DAMAGES OF ANY TYPE WHATSOEVER INCLUDING
INCIDENTAL OR CONSEQUENTIAL DAMAGES.
THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE
DESCRIPTION CONTAINED HEREIN AND SPECIFICALLY LIABILITY FOR ANY BREACH OF ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PURPOSE IS EXCLUDED. THE DURATION OF ANY WARRANTIES WHICH MAY BE
IMPLIED BY LAW NOTWITHSTANDING THE PREVIOUS SENTENCE (INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS) IS LIMITED TO THE TERM OF THIS WARRANTY. IN NO EVENT SHALL SUSSMAN-AUTOMATIC CORPORATION BE LIABLE FOR SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING FROM OWNERSHIP OR USE
OF ANY BOILER PRODUCT, OR FOR ANY DELAY IN THE PERFORMANCE OF ITS OBLIGATIONS UNDER THIS WARRANTY
DUE TO CAUSES BEYOND ITS CONTROL. SOME STATES DO
NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED
WARRANTY LASTS AND/OR DO NOT ALLOW
THE EXCLUSION OR LIMITATION OF CONSEQUENTIAL DAMAGES, SO
THE ABOVE LIMITATIONS AND EXCLUSIONS MAY NOT
APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC
LEGAL RIGHTS. YOU MAY HAVE OTHER RIGHTS, WHICH
VARY FROM STATE TO STATE.
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