Sussman ES12-18 User manual

ES & HU Installation, Operation
a n d M a i n t e n a n c e M a n u a l
A Division of Sussman-Automatic Corporation
43-20 34th Street, Long Island City, NY 11101 • [phone]
1-800-238-3535 • Fax: [phone] • email: [email protected]
www.sussmanboilers.com PUR 101137 REV 5.18

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Installation, Operation & Maintenance Manual
TABLE OF CONTENTS
Dimensional Information and
Component Identification . . . . . . . . . . . . . . . . . 3
Dimensional & Clearing Specifications . . . . . . . . . 4
WiringDiagram............................5
Installation ...............................6
Piping..................................6
Wiring .................................7
Pre-OperationCheck........................8
Setting Pressure Controls . . . . . . . . . . . . . . . . . . . . 9
Operation................................10
Blowdown.............................10-11
Digital Timer Operation Instructions . . . . . . . . . . 12
TimingSwitch ............................13
Maintenance.............................13
Standard Equipment
Auxiliary Low Water Cut Off ................14
Line Pressure Water Feed System .............14
Optional Equipment
High Pressure Water Feed System .............14
Condensate Return System ..................14
Vacuum Breaker Systems ...................15
Automatic Blowdown System ................15
Control Voltage Stepdown Transformer ........15
Blowdown Separators .....................15
Multistage Load Progressive Sequencers ........15
Condensate Return Systems . . . . . . . . . . . . . . . . . 16
Blowdown Separator Tanks . . . . . . . . . . . . . . . . . 17
SpecificationCharts........................18
Sizing...................................19
Gauge Glass Installation . . . . . . . . . . . . . . . . . 20-21
Element Replacement . . . . . . . . . . . . . . . . . . . . . . 22
Water Quality Information. . . . . . . . . . . . . . . . . . 23
states a hazard which
may cause serious injury or death if precautions
are not followed.
signals a situation where
minor injury or product damage may occur if you
do not follow instructions.
IMPORTANT NOTE:
This highlights information that is especially
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:
Mode No. _____________________________________
Boi er Seria No. _______________________________
Nationa Board No. ___________________________
Safety Va ve Set Pressure _______________ PSIG
Power Circuit Vo tage _______________________
Contro Circuit Vo tage ______________________
Amps __________ Phase _________ HZ __________
Steam Out et Va ve Size _____________ NPT
Pro ucts covere by this manual:
_________________________________________________________________________________
KW Max Design Work
Series Range Steam Rate* BHP Pressure Pressure
_________________________________________________________________________________
ES, HU 12-180 36-542 lbs/hr 1.2-18.4 0-100 psig 85 psig
_________________________________________________________________________________
*Steam Rate: Steam at 212˚ F with 50˚ F feed water
ES and HU boilers are of Carbon Steel construction.
See page 23 for Water Quality Information.
!CAUTION !WARNING
U S A
Designed, Engineered
and Assembled in the

Dimensional Information & Component I entification
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Installation Operation & Maintenance Manual
Steam Outlet Safety Valve Outlet
MODEL 100 PSIG 15 PSIG 100 PSIG 15 PSIG
ES12-18, HU40-55
1⁄2
”NPT
1⁄2
”NPT
1⁄2
”NPT
3⁄4
”NPT
ES24-36, HU75-105 1”NPT 1”NPT
1⁄2
”NPT
3⁄4
”NPT
ES48, HU140 1”NPT 1”NPT 1” NPT
3⁄4
”NPT
ES60-72, HU175-205 1”NPT 1”NPT 1” NPT 1” NPT
ES85-100, HU310 1
1⁄2
”NPT 3”NPT 1”NPT 1
1⁄4
”NPT
ES135-180, HU410-550 2”NPT 3”NPT 1”NPT 1
1⁄2
”NPT
Water inlets for all ES & HU boilers are 1/2" NPT
Drains for all ES and HU boilers are 1" NPT
Mo els: ES, HU
ES12-18 ES24-72 ES85-100 ES135-180
SYMBOL ITEM HU40-55 HU75-205 HU310 HU410-550
Height Overall Height 36" 46" 61" 61"
Length Overall Length 28" 33" 34" 36"
Width Overall Width 22" 22" 25"* 27"**
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"
B
G
A
M
F
Widt D
Lengt
J
EC
Heig t
K
Allow minimum 36 inches clearance in front of doors for servicing of heating elements.
Recommended clearance: 24 inches other sides of boiler for servicing.
* ES100 Width shown is or 480 volts with one ront mount use box, 208/240 volt that includes a ront and back mounted use box is 30" wide
** ES135 -180 Width shown is or 480 volts with one ront mount use box, 208/240 volt that includes a ront and back mounted use box is 32" wide
All 480 volt ES100-180 include a ront mounted box or uses (shown as dotted lines)
All 208 and 240 Volt ES100-180 include a ront and back mounted box or uses (shown as dotted lines)
ES72 208 Volt includes a ront mounted use box, overall width increases to 24"

4
Dimensional & Clearance Specifications
Steam Outlet Operating
Pressure
Control
Hig Limit
Pressure
Control
Pressure
Gauge
Safety Valve
Liquid Level
Control
Water Feed Inlet
F
EL
D
A
ER
Drain Valve
On/Off
Switc
Gauge Glass
Assembly
Heig t
Widt
Lengt
Allow 24" all around for servicing, 36” in front of doors, minimum.
__________________________________________________
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.
_________________________________________________________________________
G- Total minimum free area in square inches of close ventilating openings.
_________________________________________________________________________
All 480 volt ES100 - 180 include a ront mounted box or uses (shown as dotted lines)
All 208 and 240 Volt ES100 - 180 include a ront and back mounted box or uses (shown as dotted lines)
ES72 208 Volt includes a ront mounted use box.
Installation Operation & Maintenance Manual
Left Side Elevation Front Elevation

P1
C1
C2
C3
C4
P2
P2
P3
P3
(See Note 6)
C1 C2 C3 C4
H1 H3 H5
H6
ES/SSB/CU 81600
Automatic Blowdown
System (optional)
Power Circuit and
Contro Circuit use
different vo tage
Three Phase Main Power Supp y
Wiring Diagram
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Installation Operation & Maintenance Manual
NOTES:
1. Power Terminal Bloc only on boilers with two or more contactors.
2. On boilers with only one power contactor, connect power voltage to line side of contactor.
3. Power Fuses only on boilers rated 120 amperes and larger.
4. See Parts List for contactor and heating element information.
5. Element cut-off switches and second operating pressure control on ES/SSB 100-180 without sequencer
6. Refer to boiler nameplate for control and main power voltage

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Installation Operation & Maintenance Manual
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 a minimum of 36 inches clearance in front of
doors for servicing of heating elements. Recommended clear-
ance: 24 inches other sides of boiler for servicing.
Installation
3. Do not install boiler in any location where water
could freeze.
4. Do not install boiler outdoors.
5. Do not install boiler near flammable or corrosive
materials.
6. Do not install boiler in a location where leakage
from the boiler tank or piping can damage to
adjacent areas or to lower floors of the structure.
Provide a floor drain and properly sloped floor
from the boiler towards the drain or install a suit-
ably plumbed drain pan under the boiler.
Piping
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. Connect steam line with a valve to boiler steam outlet
NOTE: For best performance, a valve rated for steam serv-
ice higher than the maximum boiler pressure should be
plumbed on the steam outlet line; failure to do so can cause
heating element breakdown. See page 3 for steam outlet
valve size.
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.

Assure that the power vo tage and phase
being supp ied to the boi er matches the power vo tage and
phase of the boi er. Connecting incorrect power supp y can
damage boi er components or cause improper boi er opera-
tion. If the boi er power requirements do not match the
power to be supp ied to the boi er the boi er must be
returned to the factory for conversion. Boi ers cannot be
fie d 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 identi-
fication should the boiler need to be turned off due to
an emergency.
Wiring
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Installation Operation & Maintenance Manual
!CAUTION
4. Boiler control circuit is 120 Volt*. Unless boiler has an
optional step down transformer, a separate 120 Volt
power feed wiring is required to be connected to the
control circuit terminal block. A 15 Amp circuit is
required for all boilers. If a 3/4 HP feed water motor
and pump assembly is connected to the boiler, then a
20 Amp circuit is required.
5. If a separate control circuit is used, it should be
connected to the control circuit terminal block.
6. Remote mounted water feed systems (i.e. condensate
return, motor and pump) should be connected to the
junction box provided on the outside of the boiler
jacket.
7. With main power off, make sure all wiring termina-
tions are tight to avoid arcing, carbonizing or over-
heating of contacts.
Boilers are susceptible to lightning
damage due to water line connections. An industrial
type lightning/surge protector should be installed accord-
ing to the manufacturer's recommendation at the service
entrance. Consult your contractor or electrical dealer.
Substitution of components or modifi-
cation of wiring system voids the warranty and may lead
to dangerous operating conditions.
!CAUTION
!WARNING
ALL ELECTRICAL WIRING MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN
IN ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES.

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Installation Operation & Maintenance Manual
Pressure Controls, Operation an Testing
NOTE: All boilers are provided with one high limit pres-
sure 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
10% above the desired normal operating pressure (15 psig
boilers should be set to 13 psig)
3. Operating pressure controls, except low pressure (15 psig)
types have a separate differential scale. Differential
indicates pressure below the main operating maximum
pressure, the pressure control will re-set. The differential set
point is adjusted in the same manner by turning the
adjusting screw in the desired direction to increase or
decrease the differential pressure value.
4. Operating pressure control check: Close steam outlet valve
supplied by customer] and adjust operating pressure
Pre-Operation Check (All Boilers)
LWCO/PUMP CONTROL OPERATION AND TESTING
1. All valves for incoming water supply are to be fully opened.
Main disconnect switch is to be in the "on" position. Boiler main
switch is to be in the "on" position. Since boiler will be empty
the pump or solenoid will be energized allowing the boiler to
fill with water. Control will automatically fill boiler to proper
operating water level and the pump/solenoid will be de-
energized. Contactors will then energize, applying voltage to
the heating elements.
2. Pump switch operation – at this point water should be visible
approximately half way up the sight glass. Slowly open the drain
valve located at the bottom of the boiler. Water level in the
sight glass will begin to drop, allowing the low water cut
off/pump control to energize the feed water system. Close valve
for proper operation.
3. Low water cutout switch performance – open the drain valve
completely. Maintain this condition until water level falls within
the gauge glass enough to cause the low water cutout switch to
de-energize the heating elements. All of the contactors will be
in a de-energized or open state at this time. Close the drain
valve, water feed system will automatically refill the boiler and
the contactors will re-energize.
Boilers equipped with an auxiliary low water cut-off
control with a manual re-set button (required as
mandatory equipment is some states): once the correct
operating water level has been reached, it will be
necessary to depress the reset button in order for the
contactors to re-energize.
NOTE: For boilers equipped with an automatic blow-
down system:
• For test 1 - the blowdown time clock must be in the
“run” mode before the boiler will automatically fill.
• For test 2 and 3 - in order for the drain valve to open
the blowdown clock must be in the “off” mode.
(See blowdown time clock insert) The automatic
blowdown indicator light will be on when the valve
is open. This light will remain on for the duration of
the blowdown cycle (a few seconds). It may be nec-
essary to cycle the time clock from the “run” to
“off” mode several times.
control to 20 psig (10 psig for low pressure boilers) and
the differential to 10 psig (Note: Low pressure boilers do
not have a differential setting). Set the high limit
pressure control to 30 psig (13 psig for low pressure
boilers). Switch boiler on to allow steam pressure to
build-up. Pressure gauge reading will increase and the
operating pressure control will de-energize the
contactor(s) when the pressure gauge indicates 20 psig
(10 psig for low pressure boilers). Open steam outlet
valve to bleed off pressure. When the pressure gauge
reading decreases below 10 psig (differential) (3 psig for
low pressure boilers) 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 10 psig (5 psig
for low pressure boilers) 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.

Setting Pressure Controls
1. To set the controls turn the operating pressure
controller to its highest setting
2. Using the pressure gauge on the boiler adjust the
high limit pressure controller to the desired set point.
This is done by starting the boiler and having it build
pressure to desired set point (as shown on the boiler
pressure gauge).
3. Once the desired set point (always set the high limit
pressure controller to at least 10% above the required
operating pressure) is reached, turn the power off of
the boiler and isolate the boiler by closing the steam
outlet valve.
4. Proceed to lower the high limit pressure control set
point until the high limit reset switch pops up.
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Installation Operation & Maintenance Manual
5. Once the high limit control is set proceed to set the
operating pressure control in the same way as the
high pressure was set as outlined in steps 2-4. There
is no reset button on the operating controller so you
will have to listen for a click.
6. Once the operating pressure controller is set you will
need to set the differential pressure (not applicable
for the 15 psi model as the default differential is set
to 3 psi). The differential is set by bringing the boiler
up to pressure and tripping the operating pressure
controller then slowly letting down the pressure.
When the operating pressure controller clicks back in
that is where the differential is set. Between these
two points is where the boiler will operate. The
smaller the differential is the more the boiler will
cycle on and off and the larger the differential the
wider the pressure swings will be.
Hig Limit Pressure Control
High Limit Pressure
Adjustment Screw
Differential Pressure
Adjustment Screw
High Limit Pressure
Reset Button
Operating Pressure
Adjustment Screw
Operating Pressure Control

10
Installation, Operation & Maintenance Manual
Operation
With main isconnect “OFF” tighten all
electrical connections before energizing boiler to prevent
arcing, carbonizing of contact an /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.
NOTE: Adjust steam outlet valve such that the boiler
pressure does not drop more than 20% below reset.
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.)
!CA UT IO N
Blow own
A daily blowdown is an essential part of boiler operation.
It is the best and most important part of preventative
maintenance you can give your boiler and will add years
of life to the unit. Make sure a blowdown schedule is
established and followed regularly.
In extremely hard water areas, blowdown may be
necessary more than once a day. If there is a particular
problem that applies to your local water condition (i.e.
high concentrations of minerals etc.) we recommend a
consultation with a reputable local water treatment-
engineering firm. Pre-treating the boiler feed water may
reduce mineral accumulation enough to allow a daily
blowdown to be sufficient.
MANUAL BLOWDOWN INSTRUCTIONS
1. At the end of the working day, while boiler is still
operating, turn boiler main switch to the “OFF”
position, close water supply valve and open disconnect
switch.
2. If blow down valve is plumbed into a blowdown tank,
the boiler can be discharged at operating pressure.
3. If the blowdown valve is not plumbed into a blowdown
tank, consult with local plumbing codes regarding
boiler discharge.
4. When discharge is complete and boiler is drained, close
the blowdown valve, open the water supply valve, turn
boiler main switch to “ON” position and close
disconnect switch.
5. When refilling is complete, turn off the boiler unless
further operation is needed.
6. If boiler is equipped with a “Manual Re-set Auxiliary
Low Water Cut-off” (as required in some states) the re-
set button must be pushed before the boiler will begin
developing steam. Do not push re-set button until the
boiler has refilled with water.

Installation Operation & Maintenance Manual
11
Blow own
(cont.)
AUTOMATIC BLOWDOWN INSTRUCTIONS
(PN ES81600) 1” NPT, Starts, stops and blows down the boil-
er 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.
DURATION ADJUSTMENT INSTRUCTIONS
Hazard of Electric Shock. Disconnect all
power supplies before making any adjustments
Using a small flathead screwdriver, rotate the adjustment
screw to the desired setting.
IMPORTANT: Do not set less than 10 seconds. Do not force
screw past min and max stops, screw does not rotate more
than 300 degrees
FACTORY RECOMMENDED SETTINGS:
• 100 psig Trim: 50% turn (shown, 30 seconds)
• 15 psig Trim: 100% turn (shown, 60 seconds)
!CAUTION
0
sec
60
sec
MAX
MIN*
30
sec
10 sec
Back
!WARNING

12
Installation Operation & Maintenance Manual
Digital Timer - Operation Instructions
DAYLIGHT SAVING TIME:
The timer does not automatically adjust for
daylight saving time and the time will have
to be adjusted manually.
PROGRAMMED COMBINATIONS:
Switch OFF commands have priority over
switch ON commands.
NOTES:
1. The timer is set according to the boiler operation.
When the timer is
ON the boiler is ON and the
blowdown is
OFF .
2. During programming, if no button is pressed
after 30 seconds, the timer will revert back to
normal operating mode.
3. After programming, the override button
( ) may need to be pressed to change the
ON/OFF status for the current day and time.
TO SET TIME & DAY OF CLOCK
1. Hold down the image of clock button for steps 2-4
2. Press the “
Day ” button to cycle through the days
which are listed on the top line
3. Press the “h+” button to increase the current hour.
Note: this will also change the AM/PM as it is listed
to the right of the minutes.
4. Press the “
m+ ” button to increase the current minute.
TO SET TIMER ON/OFF TIMES
(there are 7 different programs that can be set)
5. Click the “ Timer ” button to go into the timer mode.
6.
Program 1 ON will be the first to come up.
This will be when the boiler turns on.
Set the day and time the same way you set the timer in
steps 2-4.
7. Hit the “
Timer ” button to save the entry and move
onto the next setting.
8. The next setting will be
Program 1 OFF .
This will be when the boiler turns off. Once the boiler
is turned off the automatic blowdown system will
activate. Follow steps 2-4 to set the date and time. Hit
the “
Timer ” button to save the settings.
9. Repeat steps 6-8 to set programs 2-7.
ON/OFF STATUS:
Pressing the image of a hand with a pointed
finger button ( ) changes the current mode of
the timer. If
ON is indicated on the display the boil-
er is currently running and if
OFF is indicated the
boiler is off/blowing down. Once one of the pro-
grams are started the indicator will automatically
turn to the
ON position and when one of the pro-
grams ends it will automatically be set to the
OFF
position.

Maintenance
Mechanical Timer
13
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 preventative
maintenance program, we suggest that the facility
maintenance person or engineer familiarize themselves with
these simple rules.
1. 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.
2. The sight glass should be checked frequently to assure the
boiler has adequate water.
3. 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.)
4. 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.
5. Heating element mounting bolts should be checked and
tightened to a torque of 22 ft.-lbs. If there are indications of
steam leaks from an element, replace the element gasket.
6. A monthly check for leaks should be made; any loose or
damaged fittings should be tightened or replaced.
7. Every four months the boiler float control should be checked
for proper operation. The lower equalization column can be
examined visually and manually to see if is clear and clean. If
there are signs of scale or mineral deposit buildup the float
control must be disassembled and cleaned.
One of the lower heating elements should be removed. If
scale or mineral deposits have begun to form all elements
should be removed cleaned and reinstalled using new
element gaskets.
Operating and high limit pressure control operation should
be checked. Pressure controls should be removed and
cleaned if necessary. Water feed supply check valves should
be inspected and replaced if necessary.
8. 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.
Installation Operation & Maintenance Manual
PROGRAMMING
F or electric steam boilers
equipped with Automatic
Blowdown Systems
ES 81600, refer to the
following instructions
for time clock operation
and settings.
Timer settings for blowdown operation are at
the discretion of the owner/operator.
The weekly program dial shows the seven days of
the week and AM/PM imprints for each day.
The time switch is set by pushing the captive trippers
to the outer ring position for the entire period that
the load is to be turned ON, i.e., 2 hours to each trip-
per on the 7-day dial. When the tripper is pushed to
the inside, the switch is in the OFF position.
SETTING TIME
To set the current time and day of week, turn
the minute hand clockwise. Do not set the time
by rotating “Outer” Dial.
Turn the minute hand clockwise until the day of
the week and the time of day on the outer dial is
aligned with the triangle marker on the inner dial
(two o'clock).
Example for 7-day program dial Monday 10:30
AM .
Turn the minute hand clockwise until Monday 10:30
AM is aligned with the triangle on the inner dial.
The hour and minute hand will show exactly 10:30.
FOR MANUAL OVERRIDE
Manual override can be accomplished at the
discretion of the owner/operator as follows.
3-WAY MANUAL OVERRIDE SWITCH
I = permanent ON I
= automatic
O = permanent OFF
O
IMPORTANT: It is recommended that for periodic
and effective blowdown, the override switch be set
in the automatic setting.
!CAUTION

Installation Operation & Maintenance Manual
Stan ar Equipment for ES & HU Optional Equipment
14
AUXILIARY LOW WATER CUT OFF
• For model ES & HU boilers PN ES81017MR
(with 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.
To test AUX LWCO, press and hold the manual reset
button on the side of the boiler for 5 seconds.
A blinking light on the PC board indicates the board is
having difficulty sensing water (either due to a dirty
probe or low conductivity in the water). Holding the
reset button for 30 seconds should reset the board back
to function. See next section for maintenance schedule in
locales where water quality requires regular treatment.
LINE PRESSURE WATER FEED SYSTEM
• For model ES & HU boilers PN ES99117
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; 0-100 psig range;
1/2” NPT size. Consists of strainer, solenoid valve
(120/1/50-60Hz), and check valve for automatic feed.
HIGH PRESSURE WATER FEED SYSTEM
• For model ES12-72 PN ES38002A
• For model ES100-180 PN ES38020A
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 conden-
sate is not returned to the boiler.
• ES38002A – 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 – 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.
CONDENSATE RETURN SYSTEM (see page 16)
• For model ES12-72 PN ES38083V; for model
ES85-180 PN ES38084V.
These systems are used whenever condensed steam can
be collected for reuse in the boiler. Returning the conden-
sate 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 fit-
ting is located on the condensate tank top for atmospher-
ic 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 assem-
bly 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 prop-
er drain line. The motor is required to be wired to the
boiler.

Optional Equipment
15
VACUUM BREAKER SYSTEMS
• For model ES boilers PN ES89369
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.
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-clean-
ing 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 elec-
tronic time delay relay control the boiler and the blow-
down valve.
A pilot light indicates when the blowdown valve is open.
The valve shall be plumbed to a proper drain or recepta-
cle. An automatic blowdown system can be installed on
any boiler, regardless of size operating pressure or operat-
ing duty cycle.
CONTROL VOLTAGE STEPDOWN
TRANSFORMER
• Provides 120 Volt (220 Volt export) from main power
supply. Factory wired and fused.
Installation Operation & Maintenance Manual
BLOWDOWN SEPARATORS (see page 17)
• For models ES12-48 - PN BDT-ASME36
• For models ES60-180 PN BDT-ASME42
A separator accepts the flash steam and effluent from the
boiler blowdown and reduces the temperature and pressure
to insure a safe discharge of water and sludge. Steam flash
and pressure are absorbed and pass harmlessly to the out-
side via a vent. The separator design utilizes a water seal at
the outlet, which permits the operator to introduce cold
water from the bottom to mix with the hot water and boiler
steam in the blowdown separator. This reduces outlet tem-
perature to a safe discharge level.
These separators require specific plumbing from the boiler
blowdown valve and require connection to a cold water sup-
ply. (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.
MULTISTAGE LOAD PROGRESSIVE
SEQUENCERS
Accurate control is provided by automatic progressive sequenc-
ing in the use of energy and minimizing wear on electrical
components. The sequencers are designed to apply power pro-
gressively to larger KW boilers. A factory installed pressure sen-
sitive sequential control reacting to steam boiler pressure pro-
gressive energizes or de-energizes heating elements through
power contactors. A delay between sequencer steps before
start-up and between each subsequent step eliminates power
surges. Each sequencer is matched and factory pre- set to boil-
er 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.

Con ensate Return Systems
16
NOTES:
1. Motor/Pump is closed - Coupled design
2. Pump capacity as follows:
3. Normal cold water level approximately 1/2 to 5/8 up to visible part of gauge glass.
Installation Operation & Maintenance Manual
Mo els 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
DC
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
7-7
/8"
SIGHT GLASS
99074-1
SITE GLASS ASSY
PN 99173C
1
/2" DRAIN VALVE
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

17
Blow own Separator Tanks- Specifications an Data
Models BDT-ASME 36, 42, 48, 54
Installation Operation & Maintenance Manual
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 boil-
er steam blowdown in the separator. This reduces the out-
let temperature to a level that makes it safe for discharge.
NOTE: 1BHP is approximately 10KW.
Dimensions an Features Suggeste Hook-Up to Boiler
"C" Drain
Temperature
Gauge
Pressure Gauge
"E" Vent
"B" Inlet
Water Gauge
Inspection Port
(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
Constructed in accordance with Section VII Division I ASME Boiler
& Pressure Vessel Code
BOILER DIMENSIONS SHIPPING
________________________________________________
HP ABCDEFGHWEIGHT
_______________________________________________________________________
BDT-ASME 36 0-5 18" 1" 2" 12" 2" 2" 14" 32" 125
_______________________________________________________________________
BDT-ASME 42 6-25 24" 1" 2" 16" 2-1⁄2" 2" 18" 42" 230
_______________________________________________________________________
BDT-ASME 48 26-59 30" 1-1⁄4" 2" 16" 3" 2" 18" 48" 260
_______________________________________________________________________
BDT-ASME 54 60-100 38" 1-1⁄2" 3" 16" 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
Stan ar Equipment
• 0-100 lb. Pressure Gauge
• 0-200˚ Temperature Gauge
• Water Level Gauge

Specifications Steam Gauge
Pressure/
Temperature
Chart
18
Installation Operation & Maintenance Manual
__________________________________________
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
__________________________________________
208 236
ES-85 84 8.5 256 240 204
480 102
__________________________________________
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
** Steam at 212°F with 50°F feed water. See page 19 for sizing.
*** 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
19
Use the following Table to determine KW Boiler rating when steam load and feedwater temperatures are known.
___________________________________________________________________
Feed Water 0210 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 .3417 .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
Note: Add 20% to required kW for contingencies
Installation Operation & Maintenance Manual

IMPORTANT NOTE: Read a warnings and instructions
before performing insta ation or maintenance. Safety g ass-
es and g oves shou d be worn at a times when working
with or examining water gauge g ass and connections.
Pressure in generator to be at zero before proceeding.
Improper insta ation or maintenance of gauge g ass and
connections can cause immediate or de ayed breakage
resu ting in bodi y injury and/or property damage.
1. Apply Teflon tape or pipe dope to pipe threads. Install
top gauge fitting (fitting without a drain valve) into the
uppermost tapping. Wrench tighten the fitting until it is
snug and the glass outlet is pointing at five o'clock
(about 1/8 turn from its final downward vertical
position).
2. Install the bottom gauge fitting (the fitting with a drain
valve) until it is snug and the glass outlet is pointing
directly upward. Verify top and bottom fittings are
threaded into the tappings the same number of turns
(distance A= distance B).
3. Remove glass packing nut, friction washer (or packing
gland, depending upon the model), and glass packing
from the fittings, and place them, in the same order, on
to both ends of the gauge glass. Push both packings
about an inch up the gauge glass.
4. Gently insert one end of the glass into the top gauge
fitting. Keeping the glass inside the top fitting, gently
rotate the top gauge fitting clockwise until vertically
aligned with the bottom gauge, then insert glass into
bottom fitting until glass bottoms out on the shoulder
inside the bottom fitting.
5. Carefully raise glass about 1/16" and slide lower glass
packing down until the glass packing contacts the lower
gauge fitting. DO NOT allow the glass to remain in
contact with any metal!
6. Carefully slide upper glass packing up as far as possible.
7. Hand tighten both glass packing nuts, then tighten 1/2
turn more by wrench. Tighten only enough to prevent
leakage. DO NOT OVER TIGHTEN! If any leakage should
occur, tighten lightly, a quarter turn at a time, checking
for leakage after each turn.
IMPORTANT NOTE: Read all warnings and instructions
before performing installation or maintenance.
Safety glasses an gloves
shoul be worn at all times when working
with or examining water gauge glass an
connections.
Pressure in generator 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 property amage.
Gauge Glass Installation
20
Installation Operation & Maintenance Manual
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