Sussman ES 24A User manual

ES 24A Electric
Steam Generator
Installation, Operation and Maintenance Manual
A Division of Sussman-Automatic Corporation PN 101167 5/12
43-20 34th Street, Lon Island City, NY 11101 •[phone] • 1-800 238- 3535
Fax: [phone]
•
www.sussmanboilers.com
•
Email: [email protected]
Mo el No. ___________________________ Power Circuit Voltage ___________________
Boiler Serial No. __________________ Control Circuit Voltage __________________
National Boar No ____________________ Amps ________ Phase ________ Cy ________
IMPORTANT: This data file contains the National Board Re istration Certificate
approvin your enerator. It must be kept near the enerator at all times.
KW Design Max. Work
Model Range Steam Rate BHP Pressure Pressure*
__________________________________________________________________________________________
24A 24 73 lbs./hr 2.44 100 PSIG 90 PSIG
__________________________________________________________________________________________
*Line water pressure must be a minimum of 10 PSIG higher than generator operating pressure or you will require high pressure water fee
w/motor an pump.
Products Covered by this Manual
Refer to National and all applicable Local Codes for specific installation requirements.
NOTE: Reference heating element clearance requirements for particular boiler to allow for removal of elements.
Stan ar minimum suggeste clearance is 21 inches.
1. The boiler shoul be mounte on a soli level foun ation.
2. All piping shoul be installe by a license plumber.
3. When any type water fee other than a pump fee is use , the existing water supply pressure must be 10 PSIG
greater than boiler operating pressure to assure water supply maintains proper water level in boiler. Lack of
water can result in improper boiler operation. Keep fee water valves open at all times uring normal operation.
4. Connect steam line with customer supplie outlet valve to boiler steam outlet.
5. During normal operation, keep rain valve close .
6. If pump an boiler are plumbe within 30 ft (pipe length), a minimum of two check valves are require on boil-
er to avoi amage to pump.
NOTE: THE SAFETY VALVE SHALL NOT BE PLUMBED WITH A DRAIN
LINE SIZED LESS THAN THE OUTLET SIZE OF THE SAFETY VALVE.
Installation
!CAUTION

ES 24A Electric Steam Generator Installation, Operation and Maintenance Manual
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2
Component Identification Dimensional Information
1/4NPT Water Inlet
Connection
Electric Service Entrance
I
K
J
E
O
F
H
M
L
P
G
7
5
6B
6A
6A
1
2
3
4
5
A
B
C
8
10 912
11
Hi-Limit
Control
D
Operating
Control
Dimensional Table
Item Models 24A
A25
3⁄16
B22
1⁄8(REF)
C17
13⁄16 (REF)
D1
3⁄4
E 1611⁄16
F4
1⁄16
G2
15⁄16
H2
1⁄2
I3
1⁄2
J9
1⁄8
K2
1⁄4
L10
5⁄16
M4
5⁄16
N2
5⁄8
O8
3⁄4
P2
1⁄2
Dimensional Table Model 24A
Item Description
11⁄4NPT Strainer 93806
21⁄4NPT 120V 60HZ Solenoi , 1⁄4OBIF. 99042
33⁄8NPT Check Valve 99162
41⁄2NPT Drain Valve 99178B
51⁄2NPT Steam Outlet Nipple 100380
6A Gauge Glass Valve Set 99173C
6B Gauge Glass Tube 99074-1
71⁄2NPT 100PSIG S.Valve 99136
Dimensional Table Model 24A
Item Description
81⁄4NPT Pressure Gauge 99197
9 Hi-Limit Pressure Control 99066
10 operating Pressur Control 99966
11 Access Panel ------
12 Main On-Off Switch 92830
13 Probe Isolator 100378
14 Probe Spark Plug 90229
15 Probe 5 inch 99807F

Substitution of components or
modification of wiring systems voids the warranty and
may lead to dangerous operating conditions.
3. Instructions for water fee control system (i.e. motor an
pump or solenoi fee ).
a. Check the voltage of the motor or solenoi before
making electrical connection.
b. The water feed circuit should be
wired to the junction box provided.
c. Motors rate greater than 1/3HP or are not 120VAC sin-
gle phase require the use of suitable motor starter.
d. Amperage/Wire Size – For correct sizing refer to the label
on the boiler locate next to the fiel wiring termi nals. This
label states the wire size (AWG or MCM), minimum temper-
ature rating (90˚C) an con uctor material (copper only).
Deviation from this information may result in improper or
unsafe boiler operation.
Ground boiler according to National
Electric Code requirements to avoid shock. Use proper sized
wire. Power wiring to boiler should be in accordance with
Local and N.E.C. requirements following wiring diagram
supplied. Wire size specified adjacent to field wiring termi-
nal block(s). Use 90˚ C copper wire only.
Purchaser shoul use a isconnect switch employing circuit break-
ers or fuses between the main power source an the boiler.
Boilers are susceptible to lightning dam-
age because of plumbing water lines. Industrial type light-
ning/surge protectors should be installed according to the
manufacturer's recommendation at your service entrance.
Consult your contractor or electrical dealer.
1. The unit is pre-wire an teste . Connect control circuit volt-
age at the control circuit terminal block.
2. With the main power off, make sure that all wiring termina-
tions are tight to avoi arcing, carbonizing an /or overheating
of contacts.
ES 24A Electric Steam Generator Installation, Operation and Maintenance Manual
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3
Wiring
!WARNING
!CAUTION
!CAUTION !WARNING
Wiring Diagram Control Circuit ES-24A–PRI Electric Boilers
Electrical Parts List
39243B Heating Element 24kw 208v 3Ph
39243C Heating Element 24kw 240v 3Ph
39243F Heating Element 24kw 480v 3Ph
102206-1 Contactor 75 amp 3 pole 120v Coil
100412A Liqui Level Control Boar 120v
90241MRT Auxiliary LWCO Boar 120v
Typical Wirin Dia ram 24A
Factory Wiring ___________
Field Wiring __ __ __ __ __
Note: *See Boiler Nameplate for
Input requirements

ES 24A Electric Steam Generator Installation, Operation and Maintenance Manual
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4
LWCO/PUMP CONTROL, OPERATION AND TESTING
1. All valves for incoming water supply are to be fully opene . Main isconnect switch to be in "ON” position. Boiler switch to be in
"ON" position. Since boiler will be empty, pump (or solenoi ) will be energize allowing boiler to fill with water. Control will allow for
automatic reaching of proper water level. Contactors will be energize , applying voltage to heating elements.
2. Pump Switch Operation – At this point, water shoul be visible approximately halfway up sight glass. Slowly open rain valve locate
at bottom of boiler. Water level will fall, allowing low water cutoff/pump control to energize fee water system. Close rain valve for
proper operation.
3. Low Water Cut-Out Switch Performance. Open rain valve completely. Maintain this con ition until water level falls within gauge glass
enough to cause low water cut-out switch to e-energize heating elements. Contactor will be in the e-energize state at this time.
Close the rain valve. For automatic resetting type low water cut-out switches, fee system will return water level to normal. Boiler is
now qualifie for proper low water cut-out an normal liqui -level operating con itions.
PRESSURE CONTROLS OPERATION AND TESTING
NOTE: ALL ES STEAM BOILERS ARE PROVIDED WITH ONE HI-LIMIT PRESSURE CONTROL AND ONE
OPERATING PRESSURE CONTROL.
1. All pressure controls are equippe with a screw allowing for setting of the esire operational an hi-limit pressures.
To re uce pressure setting, rotate screw in irection which allows in icator to point to a lower pressure setting.
NOTE: IT IS RECOMMENDED THAT THE HI-LIMIT CONTROL BE SET 1O PSIG ABOVE DESIRED NORMAL
OPERATION PRESSURE.
2. A ifferential pressure can be obtaine on all automatic re-setting operating pressure controls in the same manner as operating
pressure control is set. Differential in icate pressure below the main operating maximum pressure the pressure control will reset.
3. Pressure Control Operating Check – Close steam outlet valve (by customer) an a just operating pressure control to a low pressure
setting. Set hi-limit control at 10 PS1G above that setting. Switch boiler on to allow for steam pressure buil -up. Pressure gauge
rea ing will buil an the operating pressure control will shut off boiler at its pressure setting. Re-setting of operating pressure control
is accomplishe by blee ing off pressure through steam outlet valve (by customer) an allowing pressure to rop below set point.
4. Hi-limit Pressure Control Check – See item 3 above but, in oing so, assure for this test ur ose only, that the operating control is
set above the pressure setting of the hi-limit control. The hi-limit trip will e-energize the contactors. Resetting of the hi-limit occurs
after blee ing steam to re uce pressure insi e the boiler.
TO AVOID IMPROPER OR UNSAFE CONDITIONS, INSURE OPERATING PRESSURE CONTROL IS
RESET TO PROPER DESIRED BOILER OPERATING PRESSURE.
ONLY WITH MAIN DISCONNECT “OFF”, TIGHTEN ALL ELECTRICAL CONNECTIONS BEFORE ENERGIZING
BOILER TO PREVENT ARCING, CARBONIZING OF CONTACTS AND/OR OVERHEATING.
1. Turn on water supply. Turn main switch on. Turn boiler switch to ON position. When water appears approximately halfway up the
gauge glass, the pump or solenoi fee will automatically shut off an the contactors will switch on.
2. Operation of Low Water Cut-Off – The boiler is equippe with a probe type liqui level control which is couple to an electronic
controller (pc boar ).
3. The automatic reset operating pressure control has a visual pressure a justment. The top screw of the control a justs the scale in the
large in icator win ow. By turning the screw, the pressure setting can be a juste . Selection of esirable pressure is very easily ma e.
Some pressure controls have an a itional screw for a justment of pressure ifferential (OFF/ON pressure operating range) which is
factory set at the maximum allowable rating.
4. Close steam outlet valve. Boiler will buil up to esire pressure an shut off automatically.
5. High Pressure Control – This control will e-energize the boiler shoul pressure within the boiler excee the set pressure.
6. Slowly open steam outlet valve an use steam as nee e .
7. Boiler shoul be blown own aily (see blow own instructions on page 6).
Pre-Operation Check - All Boilers
Operation
!CAUTION
!CAUTION

ES 24A Electric Steam Generator Installation, Operation and Maintenance Manual
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5
Blow own is an essential part of boiler operation. It is one of the best preventative maintenance steps you
can take. Make sure a blow own sche ule is establishe an followe regularly.
In har water areas, blow own is necessary at least once a ay. In soft water areas, once a week. If there
is a particular problem which applies to your own local water con ition other than mineral content, take
this into consi eration in etermining whichsche ule is to be followe .
1. At the en of the working ay, while boiler is still operating, turn switch to the OFF position an close
water supply valve. De-energize wall mounte safety switch.
2. It is preferable to connect the blow own valve irectly into a rainage system when allowe by local
co es. If this is one, the boiler can be ischarge at operating pressure. Consult local plumbing co es
before oing so.
3. If blowing- own into a receptacle, allow pressure to ecrease to 15-20 PSIG before opening blow-
own valve.
4. When ischarge is complete an boiler is raine :
1. Close the blow own valve 3. Put boiler switch in the ON position
2. Open water supply valve; 4. Close wall mounte safety switch.
5. When refilling is complete, turn off the boiler switch unless further operation is esirable.
6. If you have been supplie with a Manual Reset Low Water Control as require in some states, the
reset button on the control must be pushe before boiler will begin eveloping pressure. (Do not push
reset until boiler has fille with water.)
HAZARD OF ELECTRICAL SHOCK. DISCONNECT ALL POWER BEFORE
WORKING ON BOILER.
Sussman Electric Steam boilers are esigne for years of trouble-free performance. To establish a goo
preventative maintenance program, we suggest that the buil ing maintenance person or engineer famil-
iarize themselves with these simple rules.
1. The sight glass shoul be checke aily to ensure that boiler has a equate water.
2. A monthly inspection shoul be ma e of the internal wiring. All electrical connections shoul be
checke for tightness. A check for water leaks shoul also be ma e an any loose fittings imme iately
tightene .
3. Every four months, the low water cut-off an pump control shoul be checke to insure that it is func-
tioning properly.
4. Every four months, the probe an isolator shoul be checke for eposits an cleane , if necessary.
This is accomplishe by removing the inspection plate, removing the probe (with a stan ar socket
wrench) cleaning an replacing.
5. Every four months, the heating elements shoul be remove . If scale has begun to form, the element
shoul be cleane an the boiler shoul be raine an flushe .
NOTE: NEW BOLTS AND GASKET SHOULD BE USED WHEN RE-INSTALLING THE
ELEMENT TO ASSURE PROPER SEALING.
Blowdown
Maintenance
!CAUTION

Before Installing your new elements be sure the
McDonnell Miller low water cut-off an aux. low
water cutoff (if supplie ) is operating properly. The float chamber an
lower equalizer column of the MM control must be completely clear of
slu ge or other foreign matter. Failure to o this may cause the imme-
iate burn-out of the new elements. If the unit is probe equippe ,
check con ition of the probes an isolator.
All elements are thoroughly checke before shipment The manufactur-
er cannot be responsible for burn-outs cause by a faulty low water
cut-off.
The lower equalizer column can best be examine by breaking the
unions on either si e an then visually an manually examining the
piping with your finger or probes to see if it is clear an 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 oor to access heating element.
4. Disconnect wire (electric) lea s connecting element to main power system of boiler.
Again, note wire connections to facilitate re-assembly. Procee to remove
an iscar (6) bolts from flange.
IMPORTANT: Note the wire connections to facilitate re-assembly (see wiring schematic).
Remove an iscar 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 ol gasket
remains on flange.
6. Apply "Slic-Tite" Gasket Compoun (or equal) to both surfaces of new gasket supplie
with replacement element. Procee to install element flange assembly with gasket
between boiler flange an element flange. In oing this, be careful to align flange holes
so element wire connection terminals on element assembly are in line with previously
isconnecte wire lea s 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).
. 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 an bright to assure goo
electrical contact.
9. Check that the wires are correctly connecte to the contactor terminals an are tight-
ene to a torque value of 45 lb-in. (see illustration). Make sure all wires are clean an
bright to assure goo electrical contact.
10. Open water valve to allow water supply to reach boiler fee mechanism.
11. As boiler automatically refills, observe the new flange assembly for possible leaks.
If water is notice , the bolts must be re-tightene . Before oing this, turn the boiler
off at the main fuse safety switch.
12. When boiler reaches working pressure, check flange assembly again for leaks.
Follow maintenance instructions provi e with the boiler.
ES 24A Electric Steam Generator Installation, Operation and Maintenance Manual
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6
Element Replacement
Torque Values:
Element Flange Bolts: 22 lb-ft
Element Terminals: 20 lb-in
Contactor Terminals: see Torque chart
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
READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK
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
!CAUTION
!CAUTION

ES 24A Electric Steam Generator Installation, Operation and Maintenance Manual
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7
IMPORTANT NOTE: Rea all warnings an instructions
before performing installation or maintenance. Safety glasses
an gloves shoul be worn at all times when working with or
examining water gauge glass an connections. Pressure in gen-
erator to be at zero before procee ing. Improper installation or
maintenance of gauge glass an connections can cause imme-
iate or elaye breakage resulting in bo ily injury an /or prop-
erty amage.
1. Apply Teflon tape or pipe ope to pipe threa s. Install top
gauge fitting (fitting without a rain valve) into the upper-
most tapping. Wrench tighten the fitting until it is snug an
the glass outlet is pointing at five o'clock (about 1/8 turn
from its final ownwar vertical position).
2. Install the bottom gauge fitting (the fitting with a rain
valve) until it is snug an the glass outlet is pointing irectly
upwar . Verify top an bottom fittings are threa e into the
tappings the same number of turns ( istance A= istance B).
3. Remove glass packing nut, friction washer (or packing
glan , epen ing upon the mo el), an glass packing from
the fittings, an place them, in the same or er, on to both
en s of the gauge glass. Push both packings about an inch
up the gauge glass.
4. Gently insert one en of the glass into the top gauge fitting.
Keeping the glass insi e the top fitting, gently rotate the top
gauge fitting clockwise until vertically aligne with the bot-
tom gauge, then insert glass into bottom fitting until glass
bottoms out on the shoul er insi e the bottom fitting.
5. Carefully raise glass about 1/16" an sli e lower glass pack-
ing own until the glass packing contacts the lower gauge
fitting. DO NOT allow the glass to remain in contact with
any metal!
6. Carefully sli e upper glass packing up as far as possible.
7. Han 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 shoul occur,
tighten lightly, a quarter turn at a time, checking for leakage
after each turn.
IMPORTANT NOTE: Read all warnin s and instructions before performin 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.
Gauge Glass Installation
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
!WARNING

A Division of Sussman-Automatic Corporation
PN 101167 5/12
43-20 34th Street, Lon Island City, NY 11101 •718-937-4500 •1-800 238- 3535
Fax: [phone] •www.sussmanboilers.com •Email: [email protected]
ES 24A Electric Steam Generator Installation, Operation and Maintenance Manual
_____________________________________________________________________________
8
For optimum results, the fee water supply shoul be teste prior to initial start-up. If the
mineral content excee s the following recommen e limits, various external treatment processes (water sof-
tener, reverse osmosis, etc.) may be use to correct the problem.
NOTE: An analysis of the on-site boiler fee water must be ma e by a
recognize an reliable water treatment company to ascertain the existing
con ition an treatment require .
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 Ωcm (50,000 ohm-centimeter)
Blow own the boiler on at least a once-a- ay basis. If boiler water or fee -water are
outsi e the above limits, a more frequent blow own is require .
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
Water quality can affect efficiency or result in boiler amage if neglecte . Boiler fee water contains impuri-
ties in solution an suspension. These impurities concentrate in the boiler since the steam generate is
essentially pure. The concentration of these impurities increases as more fee water is intro uce into the
boiler an steam is pro uce . If the suspen e soli s are allowe to concentrate beyon certain limits, a
eposit or “scale” will form on the boiler’s internal surfaces. This eposit can interfere with proper boiler
operation an cause boiler failure.
The concentration of these impurities is generally controlle by the fee water quality an by blow own.
Blow own refers to removing a portion of the boiler water with high soli s concentration an replacing it
with make-up water of a lower concentration.
Water Quality Information for Carbon Steel Boilers