Sussman EW Series Instruction manual

Model No.
Boiler Serial No.
National Board No.
SafetyValveSet
Pressure
Power
Circuit Voltage
Control Circuit Voltage
PSIG
Amps Phase HZ
TABLE OF CONTENTS
Scope……………………………………………………. 1.0
OperatingPrinciples&Specifications……2.0
Installation…………………………………………….. 3.0 
Start‐UpandOperation………………………
4.0
Maintenance………………………………………. 5.0
IMPORTANT NOTE:
Asyoufollowtheseinstructions,youwillnoticewarningandcautionsymbols.Thisblockedinformationisimportantforthesafeandefficient
installation and operation of electric boilers. These are two types of potential hazards that may occur duringthis installation and operation:
statesahazardwhichmay
cause seriousinjuryor
death if precautions are not followed.
signalsasituationwhere
minorinjuryorproductdam-
agemayoccurifyoudonotfollowinstructions.
IMPORTANT NOTE:
This highlights information that is
especially
relevant to a problem-free
installation.
A Division of Sussman-Automatic Corporation
43-20 34th Street, Long Island City, NY 11101 • [phone]
1-800-238-3535 • Fax: [phone] • email:
[e-mail]
www.sussmanboilers.com
Rev 1 9/19
WARNING
CAUTION 

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Thismanualdetailstheinstallation,operationandmaintenanceinstructions,andsparepartslistforSussmanSeries
EWHotWaterBoilers.

SussmanhotwaterboilersaredesignedandmanufacturedtomeetA.S.M.E.andcoderegulations.Whenproperly
operatedandmaintained,youcanexpectyearsoftroublefreeservice.

Carefullyfollowtheinstructionsoutlinedinthismanualtoensureproperinstallationandperformanceofyourboiler.
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Sussmanelectrichotwaterboilersprovidesafe,versatile,easytouseheatsourcesforloworhighpressurehotwater
inindustrial,commercial,orspaceheatingapplications.

Electricboileroperation:
1.Asteelvesselisfittedwithtubularresistancetypeheatingelements,inletandoutletconnections,adrainvalve,a
waterlevelcontrol,apressurereliefvalve,andatemperaturecontrol.Thesedevicesareconfiguredwithaseriesof
electricalcontrolsforautomaticoperation.

2.Whentheboilerisswitchedon,anelectroniclevelsensorfirstdetectsifalowwaterlevelconditionexists.

Ifthesensordetectsalowwaterlevelcondition,theheaterswillnotenergizeuntilwaterisintroducedthroughthe
pipingsystem.

Ifalowwaterlevelconditiondoesnotexist,thesensorwillactivatetheelementsandimmediatelybegintoheatthe
water.

3.Inforcedrecirculatingsystems,thenecessaryflowthroughtheboilerismaintainedbyacirculationpump(by
others).

Formostcalculationpurposes,pressuredropthroughtheboilercanbeassumedtobetheequivalentof10ft.of
standardinletpipingsize

Flowthroughtheboilerentersattheinlet(bottomoftheboiler)andexitsthroughtheoutlet(topoftheboiler).

4.Theboileriscontrolledbysensingwatertemperature.

Anadjustabletemperaturecontrollerwillswitchofftheheaterswhenthesettemperatureisreached.The
temperaturecontrollerisbackedupbyahighlimittemperaturecontroller.

Intheeventthattheboilertemperatureovershootsthehighlimitsetpoint,thecontrollerwilltripandde‐energize
alltheheatingcircuits.

Thehighlimittemperaturecontrollermustthenbemanuallyresetbeforetheheaterswillcomebackon.

Note:Cyclingonthehighlimitisunacceptable.Thecauseofahighlimittripmustbedeterminedandrectified
beforeresettingthelimit.
1. Scope
2. Operating Principles and Specifications

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5.Allboilersarefittedwithapressurereliefvalvewhichwillopenifthepressureapproachesasetpointchosentobe
wellbelowthewithstandpressureoftheboilerandsystemcomponents.

6.Drainlocatedatthebottomoftheboilerareprovidedformaintenancepurposes.Boilersshouldpreferablybe
installedwithflangedconnectionsorunionswithstopvalvesontheinletandoutlettoallowtheboilertobedrained
withoutdrainingtheentiresystemandtosimplifyservicing.

7.Periodicinspectionsofthevesselinteriorwillgiveadvancednoticeofanimpendingproblem.Thelocalboiler
inspectionauthorityisavailableforguidanceintheseinstances.

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StandardBoilerFeatures

 InsulatedASMEdesignedpressure
vessel
 Ventedcontrolcabinet
 Pressurereliefvalve
 PressureandTemperaturegauges
 Drainvalve
 Flangedheaters
 Controlcircuiton/offswitch
 11Controlcircuittransformer
(fused)
 12Powerfusing
 13Magneticcontactors
 14Indicatingpilotlight
 15Electroniclowwatercontrol
 16Pushtoresetbuttonforlow
watersimulation
 17On/offstaging
 20Hightemperaturecontroller

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MODEL DIMENSIONS‐ INCHES VOLUME
(GAL.)
A B C D E F G
EW12‐EW72 28 19 17‐1/4 39‐1/2 17‐1/4 46‐1/4 19‐1/2 6
EW90‐EW180 28 18‐3/4 17‐1/4 39‐1/2 26 46‐1/4 21 14.3
EW205‐EW315 31‐1/4 19‐1/2 18 51‐1/2 27 58 24 36.4
2. Specifications
(cont.)

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WiringDiagram‐PowerCircuitandControlCircuitusedifferentvoltage

NOTES:
1.PowerTerminalBlock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.Refertoboilernameplateforcontrolandmainpowervoltage
2. Specifications
(cont.)

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General
Theboilershallbeinstalledbyqualifiedpersonnelinaccordancewiththeinstructionscontainedinthismanual.
Furthermore,compliancewithapplicableNationalandlocalbuildingandsafetycodesisnecessary.

Preinstallation
Inspecttheboilerforpossibledamageduetoshippingandhandling.Claimsforshippingdamageshallbeplacedwith
thecarrierandshouldbereportedimmediatelytothem.Ifdamagehasbeensustainedduringshippingthatmay
affectthesafeandreliableoperationoftheboiler,contactthesalesofficetodiscusscorrectiveaction.
Pleasehaveavailablethemodelnumber,serialnumber,voltage,kW,andphaseofthesuppliedequipment.This
informationisavailableontheboilernameplate.

MOUNTING
1.Theboilermustbepositionedonanadequatebase,preferablyconcrete,sufficienttosupportitsin‐serviceweight,
andthenlevelledandsecuredinplace.

Note:Wheninstallingboiler,allowsufficientroomtofacilitateremovalofelementsifandwhennecessary.

NOTE:Allowaminimumof36inchesclearanceinfrontofdoorsforservicingofheatingelements.Recommended
clearance:24inchesothersidesofboilerforservicing.

2.Donotinstallboilerinanylocationwherewatercouldfreeze.
3.Donotinstallboileroutdoors.
4.Donotinstallboilernearflammableorcorrosivematerials.
5.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suitablyplumbeddrainpanundertheboiler.

PLUMBING
Ensurethatallplumbingconnectionsaremadeaccordingtolocalregulationsandapplicablecodes.

1. InletandOutlet
Forsingleboilerinstallations,stopvalvesarenormallyrequiredontheinletandoutletconnectionsoftheboilerto
allowtheboilertobedrainedandcleanedwithouthavingtodraintheentiresystem.

Formultipleboilerinstallationsinasinglesystem,stopvalvesarealwaysrequiredattheinletandoutletpiping
connections.

Forconnection:Pipethesystemreturnpipingtotheboilerinlet(atthebottom)andthesysteminletpipingtothe
boileroutlet(atthetop).Neverreversethetwo.

2.PressureReliefValve
Theboilerisequippedwithapressurereliefvalvetopreventtheboilerfromexceedingthemaximumallowable
workingpressure.

Forconnection:Pipetheoutletfromthepressurereliefvalvetoasuitabledrainawayfromotherequipment,
walkwaysandpersonnel.Donotreducethepipingsizefromthepressurereliefvalve.
3. Installation

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Donotinstallanyothervalvesorplugsinthispiping.

3.DrainPiping
Mostjurisdictionsprohibitthedrainfromtheboilerfrombeingdirectlydischargedintothesewersystem.However,
inallcases,youmustcheckwithlocalauthoritiestoensurecompliancewithlocalregulationspriortotheconnection
ofanydrainpipingtoanysewersystem.

Alllowpointsinthepipingsystemshouldbeequippedwithdrains.Provisionsshouldbemadeforseparateshutoff
anddrainvalvesonindividualequipmentsothattheentiresystemdoesnothavetobedrainedforserviceofa
particularitem.

4.CirculationPumps
Selectapumpwhoseenergyheadexceedsthecalculatedenergyheadforthesystematthedesignflowrate.Flow
ratecanbeadjustedwithaglobevalve.

5.ExpansionTanks
Someclosedsystemsrequireanexpansiontank.

6.ProvisionsforDismantling
Utilizationofunionsontheinletandoutletpipingconnectionsarerecommendedtosimplifyfutureservice
requirements.

8.Insulation
Toconserveenergyandprotectpersonnel,hotpipingloopsshouldbeinsulatedaftertestingforleaks.

WIRING
ALLELECTRICALWIRINGMUSTBEPERFORMEDBYAQUALIFIEDELECTRICIANINACCORDANCEWITHNATIONAL
ANDLOCALELECTRICALCODES.

CAUTION:Assurethatthepowervoltageandphasebeingsuppliedtotheboilermatchesthepowervoltageand
phaseoftheboiler.Connectingincorrectpowersupplycandamageboilercomponentsorcauseimproperboiler
operation.Iftheboilerpowerrequirementsdonotmatchthepowertobesuppliedtotheboilertheboilermustbe
returnedtothefactoryforconversion.Boilerscannotbefieldconverted.

ALLBOILERSAREPRE‐WIREDANDTESTEDPRIORTOSHIPMENT.
1.GroundboileraccordingtoNationalElectricCoderequirementstoavoidshock.

2.PowerwiringtoboilershouldbeinaccordancewithNationalandLocalElectricalCoderequirementsfollowing
wiringdiagramsupplied.Usepropersizewire.Wiresizeisspecifiedadjacenttofieldwiringterminals.Thislabel
statesthewiresize[AWGorMCM],minimumtemperaturerating(90C)andconductormaterial(copperonly).
Deviationfromtheserequirementsmayresultinimproperorunsafeboileroperation.

3.Adisconnectswitchemployingcircuitbreakersorfusesshouldbeinstalledbetweenthemainsourceandthe
boiler.Thisdisconnectswitchshouldbelocatedneartheboilerandclearlymarkedforeasyaccessandidentification
shouldtheboilerneedtobeturnedoffduetoanemergency.

4.Pump(suppliedbyothers)andboilercontrolcircuitmustbeinterlockedtoensurethatthepumpisrunningwhen
boilerisenergized.
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5.Withmainpoweroff,makesureallwiringterminationsaretighttoavoidarcing,carbonizingoroverheatingof
contacts.
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CAUTIONBoilersaresusceptibletolightningdamageduetowaterlineconnections.Anindustrialtypelighting/surge
protectorshouldbeinstalledaccordingtothemanufacturer’srecommendationattheserviceentrance.Consultyour
contractororelectricaldealer.

WARNINGSubstitutionofcomponentsormodificationofwiringsystemvoidsthewarrantyandmayleadto
dangerousoperatingconditions.

Thefollowingproceduresshouldbeperformedinsequencetoeliminateproblemsonstart‐up.
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START‐UP
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Itispresumedthatallelectricalwiringandplumbinghas beencheckedpriortothisstart-upprocedure.
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1.
Makesurethatthehotwaterboilervalvesandswitches  areinthefollowingpositions:


WaterOutlet  Open

WaterInlet(s)  Open 

DrainValve(s)  Closed 

SlowdownValve(s)  Closed 

WaterMake‐up/FeedWaterOpen 

Circulation Pump  Off

MainPower   Off
 ServiceLoopIsolatingValvesOpen
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2. Allowtheboilerandsystemtocompletelyfillandvent.
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3.
Adjustthetemperaturecontrollertoitslowestsetting,by  turningthedialonthefrontofthecontrol. 
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4. Makesurethattheelectricalcontrolpaneldoorisclosed. 
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5.
Ensurethatthesystem(externaltotheboiler)isfully  preparedforoperationandthatpersonnelareaware  thatthesystemis
beingstartedup.

6. Startthecirculationpump.Adjusttheflowratethroughthesystemtothedesiredflowrate.Confirmbalancedflowthrough
multipleboilers.

7. Checkthesystempipingforleaks.

8.
Ventanyairintheboilersorsystemproceedingwiththestart‐up.Airventingproceduresmay  requirerepeating. 

9. TurnontheboilerbyswitchingtheControlSwitchtoON.Thepowerlightshouldbeonandtheheatingelements
shouldenergizeprovidedthatthelowwaterlevelswitchisnottripped.Ifthered“lowlevel”pilotlightison,
thenthelevelsensorisdetectingalowwaterlevelconditionandwillnotenergizetheelements.Whentheboiler
4.Start-Up and Operation

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fills,thelightshouldshutoffandtheelementswillenergize.
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10. SetthetemperaturecontrollertothedesiredtemperaturesettingbypressingtheMENUbuttononthe
controller. 
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Notethatthetemperaturecontrolshouldbesetlowerthanthehighlimitcontrollersetting.Thehighlimit
controllerissettopreventexceedingthemaximumallowabletemperatureasshownontheboiler
nameplate.
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11. Setthetemperaturedifferential(byremovingthecontrollercoverandturningthesmalldialontheside)tothe
minimumsetting.Notethatfinetuningofthetemperaturecontrolmayberequiredforyourspecificapplication.
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12. Thepointersonthetridicator(attheoutletoftheboiler)shouldbegintoriseuntilthetemperaturereachesthe
setpointofthetemperaturecontroller.

13. Atthispoint,thecontrollerwillde‐energizetheheaters.

14. Doafinalcheckforleaksandfunctionalityoftheboilerandsystem.

15. Thesystemshouldnowbeoperational.

16. Itisnotnormallynecessarytopre‐boilwatertocleantheheatingelementsoftheinteriorofthevessel.They
havealreadybeensemi‐cleanedpriortoinstallationandthereisnoexcessivegreaseoroilinsidetheboiler.
However,ifpre‐boilingisdesired,ensurethatthedetergentsusedarenotharmful.

Watertreatmentmaybenecessaryinhardwaterareas,sinceexcessivescalebuilduponinternalboiler
componentswillresultinheatingelementfailureandcostlyrepairs.
Sussmanhotwaterboilers,whenproperlymaintained,willprovidemanyyearsoftroublefreeservice.Toestablisha
goodpreventativemaintenanceprogram,itisrecommendedthatthefollowingmaintenanceprocedurestobe
adheredto.

ELECTRICALVERIFICATION
1. Allelectricalconnectionsinthepowercircuitshouldbeinspectedandre‐tightenedperiodically.
2. Everyfourmonths,thefollowingverificationsaretobemade.
a. Remove,cleanandreinstallallcontrollerelectrodes.
b. Ifmorethanoneelectrodeissupplied,toensurethatthewiresarere‐connectedtothecorrect
terminals,werecommendthatthefirstelectrodeberemoved.Cleanandreinstalled:thenthesecond
andsoon.
c. Checkallfusesforcontinuity.
d. Visuallyinspectallcontactorsforsignsofoverheating.
e. Ensurethatallelectricalconnectionsaretight.
MECHANICALVERIFICATION
Regularlyinspecttheheatingelementsbyremoving.Maintenance  frequencywillDependon waterconditionsandoperatingconditions. 

5.0 Maintenance