S02 - Attachment B - Steam Generator Inclusive Manual.pdf

Sussman Boilers: ES, SSB & HU Installation, Operation and Maintenance Manual

TABLE OF CONTENTS

Dimensional Information and

Component Identification Dimensional & Clearing Specifications Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Installation

Piping Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10

Pre-Operation Check Pressure Controls, Operation & Testing Operation Blowdown Maintenance Optional Equipment

Auxiliary Low Water Cut Off Line Pressure Water Feed System High Pressure Water Feed System Condensate Return System Vacuum Breaker Systems Automatic Blowdown System Blowdown Separators Control Voltage Stepdown Transformer Multistage Load Progressive Sequencers

Condensate Return Systems Blowdown Separator Tanks Specification Charts Sizing Gauge Glass Installation . . . . . . . . . . . . . . . . 20-21 Element Replacement Water Quality Information for Carbon Steel Boilers Warranty

Products covered by this manual:

Max Series KW Range Steam Rate* BHP Design Pres. Work 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

SSB Boilers have all wetted metal parts Stainless Steel and are required to be operated on distilled, de-ionized or RO type water having a minimum specific resistivity of 1 Megohm-cm.

ES & HU Boilers are of Carbon Steel construction and are not to be operated on distilled, deionized or RO type water.

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

Made in USA

PUR 101137 08/04

states a hazard which may cause serious injury or death if precautions are not followed.

signals a situation where minor injury or product dam-age may occur if you do not follow instructions.

IMPORTANT NOTE:

This highlights information that is especial-ly relevant to a problem-free installation.

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:

CAUTION!

WARNING

Model No. ______________________

Boiler Serial No. _________________

National Board No. ______________

Safety Valve Set Pressure________PSIG

Power Circuit Voltage ____________

Control Circuit Voltage ___________

Amps _____ Phase _____ HZ ______

IMPORTANT: This data file contains the National Board Registration Certificate approving your boiler.

It must be kept near the boiler at all times.

Sussman Boilers Installation, Operation & Maintenance Manual

Dimensional Information & Component Identification

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

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

EL

D

A

B

ER

FrontLeft

Drain Valve

On/Off Switch

Gauge Glass AssemblyHeight

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._________________________________________________________________________

Typical Wiring Diagrams:

Wiring Diagram Control Circuit

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.

RELAY

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

L

OPERATING

PRESSURE

CONTROL

HIGH LIMIT

PRESSURE

CONTROL

LIQUID

LEVEL

CONTROL

ON-OFF

SWITCH

CONTROL

TERMINAL

BLOCK

120V 1PH

INPUT

L

L1 L2

N

SOLENOID VALVE

CONTACTORS

PUMP MOTOR

P2P1

R

C1

C2

S

M

ES and SSB Electric Boilers (Basic Control Circuit)

Wiring Diagram Control Circuit

RELAY

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

L

OPERATING

PRESSURE

CONTROL

AUX LWCO

PC BOARD

MANUAL RESET

PILOT

LIGHT

L1 G

NC

COM

NO

L2 HIGH LIMIT

PRESSURE

CONTROL

LIQUID

LEVEL

CONTROL

ON-OFF

SWITCH

CONTROL

TERMINAL

BLOCK

120V 1PH

INPUT

L N

TO

PROBE

SOLENOID VALVE

CONTACTORS

PUMP MOTOR

P2P1

R

C1

C2

S

M

GN

D

LO

W

RE

SE

T

ES Electric Boilers with Manual Reset Auxiliary Low Water Cutoff

H1 H3 H5 H7

FB1 FB2 FB3 FB4

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

480V

120V

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. H2 H4 H6 H8

TO CONTROL

CIRCUIT

HEATING

ELEMENTS

TRANSFORMER

(optional)

TB 1

TB

FB

C

H

L1

L2

L3

G

POWER FUSES

(see Note 2)

CONTACTORS C1 C2 C3 C4

SINGLE PHASE

MAIN POWER SUPPLY

L1 L2 G

T1

TERMINAL POWER BLOCK

(see note 1)

THREE PHASE

MAIN POWER

SUPPLY

ES and SSB Electric Boilers (Power Circuit)

RELAY

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

L

OPERATING

PRESSURE

CONTROL

PROPORTIONING

PRESSURE CONTROL

135 OHM

COM

SEQUENCER

HIGH LIMIT

PRESSURE

CONTROL

LIQUID

LEVEL

CONTROL

ON-OFF

SWITCH

CONTROL

TERMINAL

BLOCK

120V 1PH

INPUT

L N

L1 L2

SOLENOID VALVE

C1

C2

C3

C4

CONTACTORS

PUMP MOTOR

P2

P3

P1

R

120V COM

M

S

M

ES and SSB Electric Boilers with Sequencer

RELAY

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

L L2 L1

G

NC

COM

NO

OPERATING

PRESSURE

CONTROL

HIGH LIMIT

PRESSURE

CONTROL

LIQUID

LEVEL

CONTROL

AUX LWCO

PC BOARD

TO

PROBE

ON-OFF

SWITCH

CONTROL

TERMINAL

BLOCK

120V 1PH

INPUT

L N

SOLENOID VALVE

CONTACTORS

PUMP MOTOR

P2P1

R

C1

C2

S

M

GN

D

LO

W

RE

SE

T

ES Electric Boiler with Auxiliary Low Water Cutoff

RELAY

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

L

AUTOMATIC

PRESSURE

CONTROL

AUX LWCO BOARD

BOILER SHELL

PROBE

GUARD

GROUND

LWCO

LWCO

HIGH LIMIT

PRESSURE

CONTROL

LIQUID

LEVEL

CONTROL

ON-OFF

SWITCH

CONTROL

TERMINAL

BLOCK

120V 1PH

INPUT

Ho t L eg

Ne utr al

SOLENOID VALVE

C1

C2

CONTACTORS

P2

L1 L2

LO

P1

R

S

Sussman Boilers Installation, Operation & Maintenance Manual

Wiring Diagram Control Circuit

ES and SSB Electric Boilers with Automatic Blowdown System

SSB Electric Boilers with Auxiliary Low Water Cutoff

RELAY

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

PILOT LIGHT

L

OPERATING

PRESSURE

CONTROL

PROPORTIONING

PRESSURE CONTROL

HIGH LIMIT

PRESSURE

CONTROL

LIQUID

LEVEL

CONTROL

ON-OFF

SWITCH

CONTROL

TERMINAL

BLOCK

120V 1PH

INPUT

L N

7-DAY 24-HR

TIMER

TIME DELAY RELAY

ES81600

AUTOMATIC

BLOWDOWN SYSTEM

C1

C2

CONTACTORS

S

M

SOLENOID VALVE

PUMP MOTOR

P2P1

R

OPEN

CLOSE

D

T

MOTORIZED

BLOWDOWN

VALVE

RELAY

FIELD WIRING

FACTORY WIRING

PILOT

LIGHT

L

AUTOMATIC

PRESSURE

CONTROL

AUX LWCO BOARD

MANUAL RESET

BOILER SHELL

PROBE GUARD

GROUND

LWCO

LWCO

HIGH LIMIT

PRESSURE

CONTROL

LIQUID

LEVEL

CONTROL

ON-OFF

SWITCH

CONTROL

TERMINAL

BLOCK

120V 1PH

INPUT

SOLENOID VALVE

C1

C4

CONTACTORS

P2

L1 L2

LO

L1 L2

LLCO

RESET

G

NC

COM

NO

P1

R

S

L N

SSB Electric Boilers with Manual Reset, Auxiliary Low Water Cutoff

Installation

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.

ALL PIPING SHOULD BE INSTALLED BY A QUALIFIED LICENSED PLUMBER IN ACCOR-

DANCE WITH NATIONAL AND LOCAL CODES.

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.

3. 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.

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 compo-nents or cause improper boiler operation. If the boiler power requirements do not match the power to be sup-plied 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 follow-ing 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.

Piping

Wiring

CAUTION

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 recommenda-tion 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.

CAUTION

WARNING

Installation- Wiring (cont.)

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" posi-tion. 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 heat-ing 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, allow-ing 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 ele-ments. 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 blowdown 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.

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 differen-tial 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.

4. Operating pressure control check: Close steam outlet valve [supplied by customer] and adjust operating pres-sure control to 20psig and the differential to 10psig. Set the high limit pressure control to 30psig. Switch boil-er 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 pop-up 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.

Operation

With main disconnect “OFF” tighten all electrical connections before ener-gizing 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.

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 controls 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 blowdown instructions.)

Blowdown

A daily blowdown is an essential part of boiler operation. It is the best and most important part of preventative main-tenance 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 accu-mulation 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 ELE-

MENTS.

AUTOMATIC BLOWDOWN INSTRUCTIONS (PN ES81600)

1” NPT, Starts, stops and blows down the boiler automatically, 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 activated. 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.

Maintenance

HAZARD OF ELECTRIC SHOCK.

DISCONNECT ALL ELECTRICAL POWER BEFORE WORKING ON BOILER.

Sussman Electric Steam Boilers are designed for years of trouble-free performance. To establish a good preven-tative maintenance program, we suggest that the facility maintenance person or engineer familiarize them-selves with these simple rules.

1. The use of chemical boiler cleaning compounds voids all warranties and should not be used. Some com-pounds can/will damage the incoloy sheathing of the heating elements. A reputable water treatment-engi-neering 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.)

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 indi-cations 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 min-eral 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 nec-essary.

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.

Optional Equipment

AUXILIARY LOW WATER CUT OFF

• For model ES & HU boilers P/N ES81017 & ES81017MR (w/ manual reset), this system will not work with distilled, de-ionized, de-mineralized or RO type water.

• 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/NP/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 con-struction.

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 con-densate 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.

Optional Equipment (cont)

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 pres-sure 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 intro-duce 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-ener-gizes 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.

Condensate Return Systems

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

E

A

D C

9-1/2" DIA COVER PLATE

EASY ACCESS FOR MAINTENANCE

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

VENT SAFETY BAR

FLOAT VALVE

39010-F

1-1/4"

SIGHT GLASS

99074-1

SITE GLASS ASSY

PN 99173C

1-1/4"

SIGHT GLASS

99074-1

PUMP EASY ACCESS

1-1/4" VENT WITH SAFETY BAR

VENT (label)

1/2" COLD WATER INLET COUPLING

WITH #100 MESH STRAINER

CONDENSATE RETURN (label)

TOP VIEW

COLD WATER INLET

(label)

LIMIT MAKEUP WATER PRESSURE

TO TO 30 PSI MAXIMUM” (label)

1-1/4" CONDENSATE

RETURN COUPLING

Blowdown Separator Tanks- Specifications and Data

Models BDT-ASME 36, 42, 48, 54

D

A

H

G

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 the hot water and boiler steam blowdown in the separator. This reduces the outlet temperature to a level that makes it safe for discharge.

Note: 1BHP is approximately 10KW.

Dimensions and Features Suggested Hook-Up to Boiler

"C" Drain Temperature

Gauge

Pressure Gauge

"E" Vent

"B" Inlet

Water Gauge

Handhole Assembly 3" x 4" (except BDT-ASME 36)

"F" Cold Water Inlet & Washout Drain

Maximum Boiler Working Pressure: 250 psi

Maximum Blowdown Separator Pressure: 65 psi Blowdown Separators are sized in accordance with National Board Standards______________________ Standard Equipment

• 0-100 lb. Pressure Gauge

• 0-200˚ Temperature Gauge

• Water Level Gauge______________________ Constructed in accordance with Section VII Division I ASME Boiler & Pressure Vessel Code

BOILER DIMENSIONS SHIPPING________________________________________________

HP A B C D E F G H WEIGHT_______________________________________________________________________

BDT-ASME 36 0-5 18" 3⁄4" 2" 12" 2" 2" 14" 32" 125_______________________________________________________________________ BDT-ASME 42 6-25 24" 1" 2" 18" 2-1⁄2" 2" 18" 42" 230_______________________________________________________________________ BDT-ASME 48 26-59 30" 1-1⁄4" 2" 16" 3" 2" 18" 48" 280_______________________________________________________________________

BDT-ASME 54 60-100 38" 1-1⁄2" 3" 18" 4" 2" 18" 54" 290

Blowdown Separator

Blowdown Inlet

From Boiler Blowdown Outlets

Cold Water Supply

3/4" Coupling for Temperature Probe (opt.)

Drain Valve (closed during normal operator)

Vent to atmosphere must be full size

Tempered Blowdown to Drain

Specifications Steam Gauge Pressure/ Temperature Chart

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________________________

Sizing

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

IMPORTANT NOTE: Read all warnings and instruc-tions 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 mainte-nance of gauge glass and connections can cause imme-diate 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 fit-tings are threaded into the tappings the same num-ber of turns (distance A= distance B).

3. Remove glass packing nut, friction washer (or pack-ing 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 fit-ting, 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 pre-vent 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

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

Gauge Glass Installation - Use and Care

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.

Element Replacement

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 immedi-ate 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

Water Quality Information for Carbon Steel Boilers

FOR OPTIMUM RESULTS, THE FEEDWATER SUPPLY SHOULD BE TESTED PRIOR…