Heat Transfer Sussman SVW Series Instruction manual

Series SVW
Hot Water Boiler
Installation, Operation, Maintenance Manual & Spare Parts List
PUR 100434 Rev 1.17
stat s a hazard which
maycaus s rious injury or d ath if pr cau-
tions ar not follow d.
signals a situation wh r
minor injury or product damag may occur if
you do not follow instructions.
IMPORTANT NOTE:
This highlights information that is sp cially
r l vant to a probl m-fr installation.
IMPORTANT NOTE:
As you follow th s instructions, you will notic warning and caution symbols. This block d information is important for th saf and ffici nt
installation and op ration of l ctric boil rs. Th s ar two typ s of pot ntial hazards that may occur during this installation and op ration:
TABLE OF CONTENTS
Scop . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0
Op rating Principl s. . . . . . . . . . . . . . . 2.0
Sp cifications . . . . . . . . . . . . . . . . . . . . 3.0
Installation . . . . . . . . . . . . . . . . . . . . . . 4.0
Start-Up and Op ration . . . . . . . . . . . . 5.0
Maint nanc . . . . . . . . . . . . . . . . . . . . . 6.0
Gaug Glass Installation, Us & Car . . . 7.0
Drawings & Lit ratur . . . . . . . . . . . . . 8.0
Troubl Shooting . . . . . . . . . . . . . . . . . 9.0
Warranty . . . . . . . . . . . . . . . . . . . . . . . 10.0
Model No. _____________________
Boiler Serial No._________________
National Board No. _____________
Safety Valve Set Pressure ________
PSIG
Power Circuit Voltage ___________
Control Circuit Voltage __________
Amps ____ Phase ____ HZ ______
!CAUTION
!
WARNING
439 Main Road, Towaco, New Jersey 07082
[phone] • 1-800-221-1522
sussmanboilers.com • Email: [email protected]

Installation, Operation & Maintenance Manual
1. Scope
2
Sussman l ctric hot wat r boil rs provid saf , v rsatil , asy to us h at sourc s for low or high pr ssur hot wat r in
industrial, comm rcial, or spac h ating applications.
2.1 Principles of Operation
2.1.1 Sussman SVW l ctric hot wat r boil rs utiliz
stat of th art t chnology, control compon nts,
valv s and acc ssori s. Th S ri s SVW f atur s v rti-
cally position d h ating l m nts which hav many
advantag s ov r horizontally position d l m nts:
a.Sinc th l m nts ar r mov d from th top, th
boil r r quir s l ss spac .
b.V rtical hot wat r boil r l m nts ar l ss pron to
scal build-up, a major caus of l m nt failur .
c. Boil rs with v rtical l m nts, b ing mor compact,
hav fast r r spons tim than boil rs r quiring larg-
r v ss ls.
2.1.2 El ctric boil r op ration:
a. A st l v ss l is fitt d with tubular r sistanc typ
h ating l m nts, inl t and outl t conn ctions, a
drain/blowdown valv (s), an air v nt, a wat r control
m chanism, a pr ssur r li f valv , and a t mp ra-
tur control. Th s d vic s ar configur d with a
s ri s of l ctrical controls for automatic op ration.
b. Wh n th boil r is switch d on, an l ctronic l v l
s nsor first d t cts if a low wat r l v l condition
xists.
If th s nsor d t cts a low wat r l v l condition, th
h at rs will not n rgiz until wat r is introduc d
through th piping syst m at th boil r inl t.
If a low wat r l v l condition do s not xist, th s n-
sor will activat th l m nts and imm diat ly b gin
to h at th wat r.
c. Th air v nt at th top of th boil r allows air to xit
th boil r as it fills.
If air and oth r gas s ar not liminat d from th
flow circuit, th y may caus failur of th h ating
l m nts and nois in th piping circuit.
This manual d tails th installation, op ration and maint -
nanc instructions, and spar parts list for Sussman S ri s SVW
Hot Wat r Boil rs.
R f r to s ction 6.0 for sp cific drawings and bills of mat rial
for r lat d quipm nt suppli d und r this ord r.
Sussman hot wat r boil rs ar d sign d and manufactur d
to m t A.S.M.E. and cod r gulations. Wh n prop rly
op rat d and maintain d, you can xp ct y ars of troubl
fr s rvic .
Car fully follow th instructions outlin d in this manual to
nsur prop r installation and p rformanc of your boil r.
d. In forc d r circulating syst ms, th n c ssary flow through
th boil r is maintain d by a circulation pump (by oth rs).
For most calculation purpos s, pr ssur drop through th
boil r can b assum d to b th quival nt of 10 ft. of
standard inl t piping siz
Flow through th boil r nt rs at th inl t (bottom of th
boil r) and xits through th outl t (top of th boil r).
. Th boil r is controll d by s nsing wat r t mp ratur .
An adjustabl t mp ratur controll r will switch off th
h at rs wh n th s t t mp ratur is r ach d. Th t mp ra-
tur controll r is back d up by a high limit t mp ratur
controll r.
In th v nt that th boil r t mp ratur ov rshoots th
high limit s t point, th controll r will trip and d - n rgiz
all th h ating circuits.
Th high limit t mp ratur controll r must th n b manu-
ally r s t b for th h at rs will com back on.
N te: Cycling n the high limit is unacceptable. The cause
f a high limit trip must be determined and rectified bef re
resetting the limit.
f. All boil rs ar fitt d with a pr ssur r li f valv which will
op n if th pr ssur approach s a s t point chos n to b
w ll b low th withstand pr ssur of th boil r and syst m
compon nts.
g. Drain and/or blowdown valv (s) locat d at th bottom of
th boil r ar provid d for maint nanc purpos s. Boil rs
should pr f rably b install d with flang d conn ctions or
unions with stop valv s on th inl t and outl t to allow th
boil r to b drain d without draining th ntir syst m and
to simplify s rvicing.
h. P riodic insp ctions of th v ss l int rior will giv
advanc d notic of an imp nding probl m. Th local boil r
insp ction authority is availabl for guidanc in th s
instanc s.
2. Operating Principles

4
18 20 7
8
3
1, 9, 11,
12,13, 15,
17, 19
2
10
14
16
6
5
Installation, Operation & Maintenance Manual
3. Specifications
3
3.1 Standard Boiler Accessories
Th following shows th standard boil r acc ssori s
for SVW hot wat r boil rs.
No. D scription
1 Insulat d ASME d sign d pr ssur v ss l
2 V nt d control cabin t
3 Pr ssur r li f valv
4 Insp ction and cl anout hol s
5 Pr ssur gaug c/w isolating stopcock
(not shown)
6 Air v nt
7 T mp ratur gaug
8 Drain blowdown valv
9 Flang d h at rs c/w low watt d nsity l m nts
10 Control circuit on/off switch
11 Control circuit transform r (fus d)
12 HRC pow r fusing
13 Magn tic contactors
14 Indicating pilot lights
15 El ctronic low wat r control
16 Push to r s t button for low wat r simulation
17 On/off staging up to 95 amps
18 Proportional t mp ratur controll r for units
ov r 95 amps
19 Staging controll r with d tail no. 18
20 High t mp ratur controll r
3.2 General Specifications
List d b low is a summary of th approximat piping
siz s and volum s for th various standard boil r typ s
and within this s ri s. Minimum cl aranc r quir m nts
ar shown in s ction 3.0.
STANDARD DESIGN PRESSURES ARE 100 PSIG (690 KPA)
OR 160 PSIG (1104 KPA)
Front View Side View
Up to V ss l Op nings
(NPT)
Normal Wat r
Max. KW
Inl t/Outl t Drain Valv
Volum
Gal. (Lit rs)
144 2 3/4 5.3 (24)
202 2 3/4 11.3 (51.4)
585 4 1-1/4 46.5 (212)
1080 4 1-1/2 105 (478)
1890 8 1-1/2 206 (936)
3.3 Other Optional Equipment Sussman off rs th following as options for packag d hot wat r boil r
syst ms. Ch ck to s that optional quipm nt has b n suppli d as ord r d.
 Inl t and outl t valv s (gat )
 Auxiliary low wat r cutoff
 High t mp ratur alarm
 Low t mp ratur alarm
 Audibl alarm c/w r s t
 Pilot light p r h ating stag
 Manual OFF/AUTO switch for h at-
ing stag
 Voltm t r c/w thr position s l c-
tor switch
TABLE 1: HOT WATER BOILER GENERAL SPECIFICATIONS
 Amm t r c/w thr position
s l ctor switch
 kW hour m t r
 Main pow r disconn ct switch
 Main pow r automatic br ak r
 Saf ty door int rlock switch
 El ctronic progr ssiv s qu nc r
 Motor start r
 Ground fault indicator
 Spar compon nts
 High r kW capaciti s
 Sp cial voltag s
 High r pr ssur rating
 Lin d v ss ls (ch ck factory)
 Indoor/outdoor t mp ratur r s t controll r
 Auxiliary high t mp ratur cutoff
 High or low pr ssur cutoff
 Flow switch
 Proportional t mp ratur controll r (std.
ov r 135 kW)

Installation, Operation & Maintenance Manual
.1 General
Th boil r shall b install d by qualifi d p rsonn l in accordanc with th instructions contain d in this manual.
Furth rmor , complianc with applicabl National and local building and saf ty cod s is n c ssary.
.2 Pre-lnstallation
4.2.1 Insp ct th boil r for possibl damag du to shipping
and handling. Claims for shipping damag shall
b plac d with th carri r, and should b r port d
imm diat ly to th m.
If damag has b n sustain d during shipping that may
ff ct th saf and r liabl op ration of th boil r,
contact th sal s offic to discuss corr ctiv action.
For factory inquiri s about this boil r, pl as hav
availabl th mod l numb r, s rial numb r, voltag ,
kw, and phas of th suppli d quipm nt. This infor-
mation is availabl on th boil r nam plat .
. Installation
B
D
18"
max
ELER
A
Outlet
Inlet
Drain
Up to Minimum Cl aranc s
Max kW ABDELER
144 30” 16” 24” 24” 24”
202 36” 22” 24” 24” 24”
585 36” 32” 24” 24” 24”
1080 48” 38” 30” 24” 30”
1890 48” 38” 30” 24” 30”
. Plumbing
R f r to drawings in paragraph 6.1 for siz and location of wat r inl t, outl t and oth r r l vant op nings.
Ensur that all plumbing conn ctions ar mad according to local r gulations and applicabl cod s.
4.4.1 Inl t and Outl t
For singl boil r installations, stop valv s ar normally r quir d
on th inl t and outl t conn ctions of th boil r to allow th
boil r to b drain d and cl an d without having to drain th
ntir syst m.
Wh n th boil r is locat d high r than th r st of th syst m,
th s valv s may not b r quir d. How v r, th y
ar r comm nd d.
For multipl boil r installations in a singl syst m, stop valv s
ar always r quir d at th inl t and outl t piping
conn ctions.
For conn ction: Pip th syst m r turn piping to th boil r inl t
(at th bottom) and th syst m inl t piping to th boil r outl t
(at th top). N v r r v rs th two.
4.4.2 Mak -up Wat r
Mak -up wat r may b introduc d into th boil r through th
r turn piping syst m. Th mak -up wat r piping r quir s a
ch ck valv and a stop valv . A fill valv may b utiliz d to
control minimum syst m pr ssur .
F r c nnecti n: Pip th mak -up wat r piping, through a
ch ck valv , th n a stop valv at th syst m r turn
4.4.4 Pr ssur R li f Valv
Th boil r is quipp d with a pr ssur r li f valv to pr v nt
th boil r from xc ding th maximum allowabl working
pr ssur .
For conn ction: Pip th outl t from th pr ssur r li f valv
to a suitabl drain away from oth r quipm nt, walkways
and p rsonn l. Do not r duc th piping siz from th pr s-
sur r li f valv .
Do not install any oth r valv s or plugs in this piping.
Do not r turn th unit unl ss advis d, sinc fi ld r pair
may b th pr f rr d cours of action.
R turns must includ a R turn Authorization availabl
from Sussman.
4.2.2 Ch ck th boil r nam plat data to nsur that it corr -
sponds to th supply charact ristics (i. . - voltag ,
phas , fr qu ncy, wattag and pr ssur r li f valv s t-
ting).
4.2.3 Consult local cod s for sp cific r quir m nts on th
installation of th l ctric boil r.
.3 Mounting
4.3.1 Th boil r must b position d on an ad quat bas ,
pr f rably concr t , suffici nt to support its in-
s rvic w ight, and th n l v ll d and s cur d in plac .
4.3.2 Ad quat cl aranc on all sid s of th boil r is r quir d
for acc ss and s rvicing. Pl as r f r to th
following diagram and tabl for minimum cl aranc

Installation, Operation & Maintenance Manual
5
4.4.5 Slowdown Piping
Most jurisdictions prohibit th blow-off from th boil r
from b ing dir ctly discharg d into th s w r syst m.
How v r, in all cas s, you must ch ck with local authoriti s
to nsur complianc with local r gulations prior to th
conn ction of any blowdown piping to any s w r syst m.
For connection: Pip th blowdown valv (s) to th inl t
of a blowdown tank or a suitabl drain (as appropriat ).
4.4.6 Circulation Pumps
If a circulation pump (optional) was not suppli d with your
boil r, s l ct a pump whos n rgy h ad xc ds th cal-
culat d n rgy h ad for th syst m at th d sign flow
rat . Flow rat can b adjust d down with a glob valv .
For connection: Pip th inl t and outl t of th circula-
tion pump to th piping syst m. Ensur that th pump
outl t is on th boil r inl t sid of th piping syst m. Pip
th glob valv in parall l with th pump to allow throt-
tling of th flow rat .
4.4.7 Expansion Tanks
Som clos d syst ms r quir an xpansion tank.
4.4.8 Drain and Shut-off
All low points in th piping syst m should b quipp d
with drains. Provisions should b mad for s parat shut-
off and drain valv s on individual quipm nt so that th
ntir syst m do s not hav to b drain d for s rvic of a
particular it m.
4.4.9 Air Control and V nting
High points in th piping syst m should b v nt d with
automatic or manual air v nts.
4.4.10 Provisions for Dismantling
Utilization of unions on th inl t and outl t piping con-
n ctions may simplify futur s rvic r quir m nts.
4.4.11 Insulation
To cons rv n rgy and prot ct p rsonn l, hot piping
loops should b insulat d aft r t sting for l aks.
. Plumbing (cont.)
.5 Electrical
Th boil r must b wir d by qualifi d p rsonn l in strict complianc with all cod s and r gulations.
R f r to th wiring diagram includ d in paragraph 6.1 and any sp cific diagrams suppli d.
4.5.1 Pow r Supply
With th boil r "On-off” switch in th "On” position
and th main l ctrical supply op n, conn ct th
pow r f d lin s from a fus d disconn ct or br ak r
to th t rminals mark d L1, L2, and L3 of th boil r
disconn ct, br ak r, or pow r splitt r, which v r is
suppli d. S paragraph 6.1 for sch matic diagram.
3.5.2 Grounding
Th boil r must b prop rly ground d. Attach a suit-
abl ground wir to th ground conn ction point in
th control cabin t siz d in accordanc with national
and local cod s.
Th following proc dur s should b p rform d in s qu nc to liminat probl ms on start-up.
5.1 Start-up
It is pr sum d that all l ctrical wiring and plumbing has
b n ch ck d prior to this start-up proc dur .
5.1.1 Mak sur that th hot wat r boil r valv s and switch s
ar in th following positions:
5.1.2 Allow th boil r and syst m to compl t ly fill and v nt.
5.1.3 Adjust th t mp ratur controll r to its low st s tting, by
turning th dial on th front of th control.
5.1.4 Mak sur that th l ctrical control pan l door is clos d.
5.1.5 Ensur that th syst m ( xt rnal to th boil r) is fully
pr par d for op ration and that p rsonn l ar awar
that th syst m is b ing start d up.
5.1.6 Start th circulation pump (if includ d*). Adjust th flow
rat through th syst m to th d sir d flow rat using th
glob valv pip d in parall l with th circulation pump.
*som sid arm syst ms do not r quir a pump.
5.1.7 Ch ck th syst m piping for l aks.
5.1.8 Th pr s nc of air in th syst m is indicat d by nois in
th piping circuit. Any air should b v nt d b for proc d-
ing with th start-up. Air v nting proc dur s may r quir
r p ating.
5.1.9 Mov th boil r “On-Off” switch to th “On” position.
Th gr n pow r light should b illuminat d and th h at-
ing l m nts should n rgiz provid d that th low wat r
l v l switch is not tripp d.
If th r d “low l v l” light is on, th n th l v l s nsor is
d t cting a low wat r l v l condition and will not n rgiz
th l m nts. Wh n th boil r fills, th light should shut off
and th l 0m nts will n rgiz .
5. Start-Up and Operation
• Wat r Outl t Op n
• Wat r Inl t(s) Op n
• Drain Valv (s) Clos d
• Slowdown Valv (s) Clos d
• Wat r Mak -up/
F d Wat r Op n
• Circulation Pump Off
• Main Pow r Off
• S rvic Loop
Isolating Valv s Op n

Installation, Operation & Maintenance Manual
6
5.1.10 Simulat a low wat r condition by d pr ssing th “push-to-
t st” button. Th boil r contactors should op n and th r d
“low l v l light” should illuminat .
Th nois (caus d by th contactors switching op n)
indicat s that th l m nts hav b n turn d off and
th light indicat s th control is working.
5.1.11 S t th t mp ratur controll r (by turning th dial on th
front of th controll r) to th d sir d t mp ratur s tting.
N te that the temperature c ntr l sh uld be set l wer than
the high limit c ntr ller setting. The high limit c ntr ller is
set t prevent exceeding the maximum all wable tempera-
ture as sh wn n the b iler nameplate.
5.1.12 S t th t mp ratur diff r ntial (by r moving th controll r
cov r and turning th small dial on th sid ) to th mini-
mum s tting. Not that fin tuning of th t mp ratur con-
trol may b r quir d for your sp cific application.
5.1.13 Th point rs on th pr ssur /t mp ratur gaug (at th
outl t of th boil r) should b gin to ris until th t m-
p ratur r ach s th s t point of th t mp ratur con-
troll r.
At this point, th controll r will d - n rgiz th h at rs.
5.1.14 Do a final ch ck for l aks and functionality of th boil r
and syst m.
5.1.15 Th syst m should now b op rational.
5.1.16 It is not normally n c ssary to pr -boil wat r to cl an
th h ating l m nts or th int rior of th v ss l. Th y
hav alr ady b n s mi-cl an d prior to installation and
th r is no xc ssiv gr as or oil insid th boil r.
How v r, if sup r-cl an conditions mak pr -boiling n c-
ssary, nsur that th d t rg nts us d ar not harmful
5.1 Start-up (cont.)
5.2 Operation
5.2.1 If a prop r maint nanc sch dul is follow d, all that
is r quir d is to turn th boil r on for it to function
normally.
B for r starting th boil r r p at 4.1 as r quir d.
5.2.2 Although th boil r can op rat saf ly unatt nd d, it
is b st to shut th boil r down wh n it is not
r quir d ov r v nings, w k nds or oth r prolong d
p riods. This will sav n rgy.
5.2.3 Wat r tr atm nt may b n c ssary in som hard
wat r ar as, sinc xc ssiv scal buildup on int rnal
boil r compon nts will r sult in h aling l m nt fail-
ur and costly r pairs. R f r to paragraph 5.4 for a
discussion on this subj ct.
Sussman hot wat r boil rs, wh n prop rly maintain d, will provid many y ars of troubl fr s rvic . To stablish a good
pr v ntativ maint nanc program, it is r comm nd d that th following maint nanc proc dur s b adh r d to.
6.1 Electrical Verification
To avoid risk of electrical shock, disconnect the power supply
to the boiler prior to and during electrical servicing.
6.1.1 All l ctrical conn ctions in th pow r circuit should
b insp ct d and r -tight n d p riodically.
6.1.2 Ev ry four months, th following v rifications ar to
b mad .
a. Ch ck th op ration of th low wat r cutoff control
by using th "Push-to-t st” button. Wh n d pr ss d,
all n rgiz d h ating circuits should imm diat ly go
off until th button is r l as d.
6. Maintenance
b. R mov , cl an and r install all controll r l ctrod s.
If mor than on l ctrod is suppli d, to nsur that
th wir s ar r -conn ct d to th corr ct t rminals,
w r comm nd that th first l ctrod b r mov d,
cl an d and r install d; th n th s cond and so on.
c. Ch ck all fus s for continuity.
d. Visually insp ct all contactors for signs of ov rh ating.
. Ensur that all l ctrical conn ctions ar tight.
6.2 Mechanical Verification
6.2.1 Scal Build-Up
R gularly insp ct th h ating l m nts through th manhol or hand-hol . Maint nanc
fr qu ncy will d p nd on wat r conditions and op rating conditions.
!CAUTION

Installation, Operation & Maintenance Manual
7
7.0 Gauge Glass Installation, Use and Care
IMPORTANT NOTE: Read all warnings and instructions
before performing installation or maintenance. Safety glass-
es 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 T flon tap or pip dop to pip thr ads. Install
top gaug fitting (fitting without a drain valv ) into th
upp rmost tapping. Wr nch tight n th fitting until it is
snug and th glass outl t is pointing at fiv o'clock
(about 1/8 turn from its final downward v rtical
position).
2. Install th bottom gaug fitting (th fitting with a drain
valv ) until it is snug and th glass outl t is pointing
dir ctly upward. V rify top and bottom fittings ar
thr ad d into th tappings th sam numb r of turns
(distanc A= distanc B).
3. R mov glass packing nut, friction wash r (or packing
gland, d p nding upon th mod l), and glass packing
from th fittings, and plac th m, in th sam ord r, on
to both nds of th gaug glass. Push both packings
about an inch up th gaug glass.
4. G ntly ins rt on nd of th glass into th top gaug
fitting. K ping th glass insid th top fitting, g ntly
rotat th top gaug fitting clockwis until v rtically
align d with th bottom gaug , th n ins rt glass into
bottom fitting until glass bottoms out on th should r
insid th bottom fitting.
5. Car fully rais glass about 1/16" and slid low r glass
packing down until th glass packing contacts th low r
gaug fitting. DO NOT allow th glass to r main in
contact with any m tal!
6. Car fully slid upp r glass packing up as far as possibl .
7. Hand tight n both glass packing nuts, th n tight n 1/2
turn mor by wr nch. Tight n only nough to pr v nt
l akag . DO NOT OVER TIGHTEN! If any l akag should
occur, tight n lightly, a quart r turn at a tim , ch cking
for l akag aft r ach turn.
IMPORTANT NOTE: R ad all warnings and instructions
b for p rforming installation or maint nanc .
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.
Vessel Wall
Gauge Glass
Glass Packing
Nut
Glass Packing
T p Gauge
Fitting
Guard R d
Fricti n Washer
( r Packing Gland)
B tt m
Gauge
Fitting
Drain Valve
A
B
!WARNING

Installation, Operation & Maintenance Manual
7.0 Gauge Glass Installation, Use and Care (cont.)
8
DO NOTs
• DO NOT us glass if it contains any scratch s, chips, or
any oth r visibl signs of damag .
• DO NOT r us any tubular glass or glass packings.
• DO NOT subj ct gaug glass to b nding or torsional
str ss s.
• DO NOT ov r tight n glass packing nuts.
• DO NOT allow glass to touch any m tal parts.
• DO NOT xc d th r comm nd d pr ssur of th
gaug or gaug glass.
• DO NOT cl an th gaug or gaug glass whil pr ssur-
iz d or in op ration.
DO's
• DO v rify prop r gaug has b n suppli d.
• DO xamin gaug glass and packings car fully for
damag b for installation.
• DO install prot ctiv guards and utiliz automatic ball
ch cks wh r n c ssary to h lp pr v nt injury
in cas of glass br akag .
• DO insp ct th gaug glass daily, k p maint nanc
r cords, and conduct routin r plac m nts.
• DO prot ct glass from sudd n chang s in t mp ratur s
such as drafts, wat r spray, tc.
MAINTENANCE
Examin th gaug glass r gularly for any signs of
clouding, scratching, rosion, or corrosion. Th glass
should b insp ct d daily until th n d for r plac -
m nt b com s appar nt. This will h lp stablish th
routin insp ction and routin r plac m nt sch dul s.
CLEANING
Us comm rcial non-abrasiv glass cl an rs to k p
glass cl an. Us dilut d acids such as Hydrochloric
(muriatic) acid wh n r gular cl an rs do not s m to
work. Do not us wir brush s or any oth r abrasiv
mat rials which could scratch th glass.
INSPECTION
Examin th surfac of th glass for scratch s, corro-
sion, chips, cracks, surfac flaws, or nicks. To do this,
shin a v ry bright conc ntrat d light at an angl of
about 45 d gr s. A d f ctiv glass will glist n as th
light strik s imp rf ctions. Glass which app ars cloudy
or rough n d, and will not r spond to cl aning,
should b r plac d.
STORING
K p gaug glass in original packaging until r ady to
install.
8.1 Drawings
Th following m chanical and l ctrical drawings hav b n includ d in this manual:
 Boil r Ass mbly  El ctrical Sch matic
8.2 Literature
Th following manufactur rs’ lit ratur , as r quir d, may b includ d with this manual.
 T678B Dual bulb two stag t mp ratur controll r Hon yw ll
 T475A Outdoor r s t control Hon yw ll
 L4008A,B,E,I; L6008A,G,H Aquastat® controll rs Hon yw ll
 T775A,B,C,D R mot t mp ratur controll r & Add ndum Hon yw ll
8. Drawings and Literature
 T675A,B; T687A t mp ratur controll rs Hon yw ll
 T991 A Proportional t mp ratur controll r Hon yw ll
 T991 B Proportional t mp ratur controll r Hon yw ll
 F61 S ri s standard flow rat switch Johnson Controls

Installation, Operation & Maintenance Manual
9. Troubleshooting Guide
9
9.1 Failed Heaters
• Sussman boil r flang h at rs ar of th high st quality.
Wh n prop rly maintain d, th y should provid many y ars of s rvic .
• All h at rs und rgo a s ri s of rigorous m chanical and l ctrical
insp ctions. In th v nt that a h at r fails, it is likely that the cause is
low wat r or scal build-up condition.
Boiler Problems
“Syst m On” pilot light
do s not illuminat
Low wat r condition
High limit condition
H at r fus s fail
Main fus s blown
Do s not fill
L aks wat r
R s t button trips
Do s not h at
Will not r ach
s t t mp ratur
Pr ssur r li f
valv op ns
H at rs continually
burn out
Do s not maintain
t mp ratur
Check Points 123 5678910 11 12 13
Pilot light burnt out x
Faulty on-off switch xxx
Br ak r r s t xxx
Main pow r switch xxx
Main pow r fusing xxx
Flang h at r fail d xx x x x
Magn tic contactor xx xx x
El ctrod s & r lay xx xx x
T mp ratur controll r xxxxx
Staging switch xxxxx
Pr ssur r li f valv xxx x
Pr ssur gaug xx
Outl t valv clos d xx
Air in syst m xx x x
High limit controll r xxxxx
Scal buildup xx
H at r fus xxxx
Control transform r xxx
Control circuit wiring xx xx
Pow r circuit wiring xxx x
Supply voltag too high xxx x
Supply voltag too low xxx
Syst m und rsiz d xx
L ak at h at r flang xxx
Piping l ak xxx
Inl t valv clos d xx x
• Multipl coincid nt failur s ar almost c rtainly th r sult in
a low wat r condition.
• K p in mind that if n w h at rs ar install d in a boil r
wh r th caus of failur has not b n corr ct d, th y too
may fail.
9.2 Trouble
Shooting
Guide
Warranty
Sussman offers a Limited Warranty for this equipment, a copy of which has been included as part of the important documents
included with the boiler. Any questions should be referred to Sussman.