Sussman SSB 12-18 User manual

TABLE OF CONTENTS
Dimensional Information and
Component Identification .................2
Dimensional & Clearing Specifications .........3
Wiring Diagrams .........................4-5
Installation
Piping..................................6
Wiring .................................7
Pre-Operation Check ........................8
Pressure Controls Operation & Testing ........8
Operation.................................9
Blowdown ................................9
TimingSwitch............................10
Digital Timer Operation Instructions..........10
Maintenance .............................11
Optional Equipment .......................12
Auxiliary Low Water Cut Off ................12
Line Pressure Water Feed System .............12
High Pressure Water Feed System .............12
Automati Blowdown System ................13
Blowdown Separators .....................13
Control Voltage Stepdown Transformer ........13
Multistage Load Progressive Sequen ers ........13
Blowdown Separator Tanks .................14
Specification Charts .......................15
Sizing ...................................16
Gauge Glass Installation....................17
Gauge Glass Use and Care ..................18
Element Replacement ......................19
SSB Boilers have Stainless Steel all wetted metal parts. SSB
boilers shall be operated using only deionized water, having
a maximum ondu tan e of 1 mi roSiemen per m
(1 µS/ m) [minimum spe ifi resistivity of 1 megohm per m
(1ΜΩ/ m)].
Products cov r d by this manual:
Max
Series KW Range Steam Rate* BHP Design Pres. Work Pres.
______________________________________________________________________
SSB 12-180 36-542 lbs/hr 1.2-18.4 0-100 psig 85 psig
*Steam Rate- Steam @ 212 F with 50 F eed water
A Division of Sussman-Automatic Corporation
43-20 34th Street, Long Island City, NY 11101 • (718 937-4500
1-800-238-3535 • Fax: [phone] • email: [email protected]
www.sussmanboilers.com
PUR 101137SSB 2/12
states a hazard whi h
may ause serious injury or death if pre autions
are not followed.
signals a situation where
minor injury or produ t damage may o ur if you
do not follow instru tions.
IMPORTANT NOTE:
This highlights information that is espe ially
relevant to a problem-free installation.
IMPORTANT NOTE:
As you follow these instru tions, you will noti e warning and aution symbols. This blo ked information is important for the safe and effi ient
installation and operation of ele tri boilers. These are two types of potential hazards that may o ur during this installation and operation:
Model No. SSB- __________________
Boiler Serial No. _________________
National Board No. ______________
Sa ety Valve Set Pressure________
PSIG
Power Circuit Voltage ____________
Control Circuit Voltage ___________
Amps _____ Phase _____ HZ ______
IMPORTANT: This data file ontains the National Board
Registration Certifi ate approving your boiler. It must be
kept near the boiler at all times.
M A D E I N U A
!CAUTION !WARNING
SSB Installation, Operation
and Maintenance Manual

Installation, Operation & Maintenance Manual
Dim nsional Information & Compon nt Id ntification
2
_______________________________________
WATER STEAM
MODEL H W* L INLET OUTLET
_______________________________________
SSB 12–18 37" 22" 32" 1/2”NPT 1/2”NPT
_________________________________________________
SSB 24–72 47" 27" 36" 1/2”NPT 1” NPT
_________________________________________________
SSB 80–100 63" 29" 36" 1/2”NPT 1
1⁄2
”NPT**
_________________________________________________
SSB 135–180 63" 30" 38" 1/2”NPT 2” NPT**
_______________________________________
* Add 6 in hes to the width when suppled with Automati Blowdown
** Steam Outlet is 3” NPT on 15 PSI trimmed SSB-80-180.
Note: Re ommended learan e is 36 in hes all around for servi ing.
Mod l SSB
_________________________________
SYMBOL ITEM SSB12-18 SSB 24-72 SSB 100 SSB 135-180
___________________________________
A Steam Outlet 61⁄4" 10" 81⁄4" 9"
__________________________________________________________________
B Steam Outlet 101⁄4" 17" 171⁄4"18
1⁄4"
__________________________________________________________________
C M/M Drain Valve 5" 12" 17" 163⁄4"
__________________________________________________________________
D M/M Drain Valve 61⁄2" 6" 61⁄4"6
1⁄4"
__________________________________________________________________
E Che k Valve 14" 9" 17" 163⁄4"
__________________________________________________________________
F PV Drain Valve 23⁄4"2
1⁄4"2 3⁄4"2 3⁄4"
__________________________________________________________________
G PV Drain Valve 61⁄4"9
1⁄2"7 3⁄4"9 1⁄4"
__________________________________________________________________
J Clearan e 3 3⁄4"3
1⁄2" 4" 4"
__________________________________________________________________
K Che k Valve 21⁄2"2
3⁄4" 3" 3"
__________________________________________________________________
M Door Width 8 3⁄4" 14" 123⁄4"14
3⁄4"
__________________________________________________________________
A B
K
H
D
G
L
W
M
E
J
C
F

Installation, Operation & Maintenance Manual
3
Dim nsional & Cl aranc Sp cifications
Steam Outlet Operating
Pressure
Control
Hig Limit
Pressure
Control
Pressure
Gauge Safety Valve
Liquid Level
Control
Water Feed
Inlet
F
EL
D
A
B
ER
Front
Left
Drain Valve
On/Off
Switc
Gauge Glass
Assembly
Heig t
Widt Lengt
Side Elevation Front Elevation
Allow 24" all around for servi ing.
__________________________________________________
Cl aranc from combustibl surfac s
__________________________________________________
A 1" Clearan e above top of boiler
_________________________________________________________________________
B A Clearan e from Front of boiler. Prefix "C" to numeral indi ates a eptability for
loset or al ove installations; prefix a eptability for al ove installations but not
for loset installations.
_________________________________________________________________________
D 1" Clearan e from ba k of boiler.
_________________________________________________________________________
EL 1" Clearan e from left side of boiler.
_________________________________________________________________________
ER 16" Clearan e from right side of boiler.
_________________________________________________________________________
F C Indi ates type of flooring: "NC" for non- ombustible; "C" for ombustible.
_________________________________________________________________________
G- Total minimum free area in square in hes of lose ventilating openings.
_________________________________________________________________________

Installation, Operation & Maintenance Manual
Wiring Diagram Control Circuit
4
Fi ld Wiring
Factory Wiring
120V 1PH
INPUT
Control
Terminal Block
7-Day 24 Hr
Timer
ES81600
Automatic
Blowdown System Time Delay Relay
Pilot Light
Open
Close
Motorized
Blowdown
Valve
SOLENOID
VALVE
PUMP MOTOR
C1
C2
CONTACTORS
R
RELAY
L
P1
HIGH LIMIT
PRESSURE
CONTROL
AUX LWCO
PROBE
BOILER SHELL
L1 L2
HC
COM
NO
GND LOW RESET
PILOT
LIGHT
L
LIQUID
LEVEL
CONTROL
C1
C2
C3
C4
CONTACTORS
135
OHM
COM
SEQUENCER
120V COM
1
2
3
4
P2
OPERATING
PRESSURE
CONTROL
PROPORTIONING
PRESSURE
CONTROL
MANUAL RESET
P2
P1
P2
AUX LWCO
PC BOARD
ON/OFF
SWITCH
S
M
21
3

Installation, Operation & Maintenance Manual
Wiring Diagram Pow r Circuit
H1 H3 H5 H7
FB1 FB2 FB3 FB4
FIELD WIRING
FACTORY WIRING
PILOT
LIGHT
480V
120V
NOTES:
1. Power Terminal Block only on boilers with two or more contactors
2. Power Fuses only on boilers rated 120 amperes and larger.
3. See Parts List for contactor and heating element information.
H2 H4 H6 H8
TO CONTROL
CIRCUIT HEATING
ELEMENTS
TRANSFORMER
(optional)
TB 1
TB
FB
C
H
L1
L2
L3
G
POWER FUSES
(see Note 2)
CONTACTORS C1 C2 C3 C4
SINGLE PHASE
MAIN POWER SUPPLY
L1 L2 G
T1
TERMINAL POWER BLOCK
(see note 1)
THREE PHASE
MAIN POWER
SUPPLY
5

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 lo ated with suitable learan es, refer to page 2 and 3 and Code requirements.
ALL PIPING SHOULD BE INSTALLED BY A QUALIFIED LICENSED PLUMBER IN ACCORDANCE 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. Insuffi ient water levels an result in improper boiler operation. (Keep feed water valves open at all
times during normal operation.)
2. If pump and boiler are plumbed within 30 feet (pipe length) a minimum of 2 he k valves are required to avoid damage
to pump.
3. Conne t steam line with ustomer supplied outlet valve to boiler steam outlet.
4. Provide for boiler drain onne tion, a daily blowdown is required. A "Blowdown Separator Tank" may be ne essary,
he k with lo al ode.
5. Safety valve shall be plumbed a ording to lo al ode.
6. SSB Boilers have Stainless Steel all wetted metal parts. SSB boilers shall be operated using only deionized
water, having a maximum ondu tan e of 1 mi roSiemen per m (1 µS/ m) [minimum spe ifi resistivity of 1
megohm per m (1ΜΩ/ m)].
NOTE: The safety valve shall not be plumbed with a line sized less than the outlet size of the safety valve.
Installation
Piping
Installation, Operation & Maintenance Manual
6

Installation, Operation & Maintenance Manual
7
ALL ELECTRICAL WIRING MUST BE PERFORMED BY A QUALIFIED ELECTRICIAN
IN ACCORDANCE WITH NATIONAL AND LOCAL ELECTRICAL CODES.
Assure that the power voltage and phase being supplied to the boiler
matches the power voltage and phase o the boiler. Connecting incorrect power supply can
damage boiler components or cause improper boiler operation. I the boiler power
requirements do not match the power to be supplied to the boiler the boiler must be
returned to the actory or conversion. Boilers cannot be ield converted.
ALL BOILERS ARE PRE-WIRED AND TESTED PRIOR TO SHIPMENT.
1. Ground boiler a ording to National Ele tri Code
requirements to avoid sho k.
2. Power wiring to boiler should be in a ordan e with
National and Lo al Ele tri al Code requirements fol-
lowing wiring diagram supplied. Use proper size wire.
Wire size is spe ified adja ent to field wiring terminals.
This label states the wire size [AWG or MCM], mini-
mum temperature rating (90 C) and ondu tor material
( opper only). Deviation from these requirements may
result in improper or unsafe boiler operation.
3. A dis onne t swit h employing ir uit breakers or
fuses should be installed between the main power
sour e and the boiler. This dis onne t swit h should be
lo ated near the boiler and learly marked for easy
a ess and identifi ation should the boiler need to be
turned off due to an emergen y.
4. Boiler ontrol ir uit is 120 Volt*. Unless boiler has an
optional step down transformer, a separate 120 Volt
power feed wiring is required to be onne ted to the
ontrol ir uit terminal blo k. A 15 Amp ir uit is
required for all boilers. If a 3/4 HP feed water motor
and pump assembly is onne ted to the boiler, then a
20 Amp ir uit is required.
Wiring
!CA UTI ON
5. If a separate ontrol ir uit is used, it should be on-
ne ted to the ontrol ir uit terminal blo k.
6. Remote mounted water feed systems (i.e. motor and
pump) should be onne ted to the jun tion box pro-
vided on the outside of the boiler ja ket.
7. With main power off, make sure all wiring termina-
tions are tight to avoid ar ing, arbonizing or over-
heating of onta ts.
Boilers are sus eptible to lightning
damage due to water line onne tions. An industrial type
lightning/surge prote tor should be installed a ording to
the manufa turer's re ommendation at the servi e
entran e. Consult your ontra tor or ele tri al dealer.
Substitution of omponents or modifi-
ation of wiring system voids the warranty and may lead
to dangerous operating onditions.
!CAUTION
!WARNING
*220V for 380V and 415V boilers.

Pr ssur Controls, Op ration and T sting
Not : All boilers are provided with one high limit
pressure ontrol and at least one operating pressure
ontrol.
1. The high limit pressure ontrol is equipped with a manual
reset feature. There is no subtra tive differential s ale
with this type of ontrol
2. All pressure ontrols are equipped with an adjusting
s rew, allowing for setting of desired operational and
high limit pressures. To redu e pressure setting, turn
adjusting s rew in dire tion that allows indi ator to point
to a lower pressure setting on the s ale. To in rease pres-
sure setting turn adjusting s rew in dire tion that allows
indi ator to point to a higher pressure on the s ale
Not : It is re ommended that the high limit ontrol be set
10psig above the desired normal operating pressure.
3. Operating pressure ontrols, have a separate differential
s ale. Differential indi ates pressure below the main
operating maximum pressure, the pressure ontrol will
re-set. The differential set point is adjusted in the same
manner by turning the adjusting s rew in the desired
dire tion to in rease or de rease the differential pressure
value.
Installation, Operation & Maintenance Manual
8
Pr -Op ration Ch ck (All Boil rs)
LWCO/PUMP CONTROL OPERATION AND TESTING
1. All valves for in oming water supply are to be fully opened.
Main dis onne t swit h is to be in the "on" position. Boiler main
swit h is to be in the "on" position. Sin e boiler will be empty
the pump or solenoid will be energized allowing the boiler to
fill with water. Control will automati ally fill boiler to proper
operating water level and the pump/solenoid will be de-ener-
gized. Conta tors will then energize, applying voltage to the
heating elements.
2. Pump swit h operation – at this point water should be visible
approximately half way up the sight glass. Slowly open the
drain valve lo ated at the bottom of the boiler. Water level in
the sight glass will begin to drop, allowing the low water ut
off/pump ontrol to energize the feed water system. Close valve
for proper operation.
3. Low water utout swit h performan e – open the drain valve
ompletely. Maintain this ondition until water level falls within
the gauge glass enough to ause the low water utout swit h to
de-energize the heating elements. All of the onta tors will be
in a de-energized or open state at this time. Close the drain
valve, water feed system will automati ally refill the boiler and
the onta tors will re-energize.
Boilers equipped with an auxiliary low water ut-off
ontrol with a manual re-set button (required as
mandatory equipment is some states): on e the orre t
operating water level has been rea hed, it will be ne -
essary to depress the reset button in order for the on-
ta tors to re-energize.
Not : For boilers equipped with an automati
blowdown system:
• For test 1 - the blowdown time lo k must be in the
“run” mode before the boiler will automati ally fill.
• For test 2 and 3 - in order for the drain valve to open
the blowdown lo k must be in the “off” mode.
(See blowdown time lo k insert) The automati
blowdown indi ator light will be on when the valve
is open. This light will remain on for the duration
of the blowdown y le (a few se onds). It may be
ne essary to y le the time lo k from the “run” to
“off” mode several times.
4. Operating pressure ontrol he k: Close steam outlet
valve [supplied by ustomer] and adjust operating pres-
sure ontrol to 20psig and the differential to 10psig.
Set the high limit pressure ontrol to 30psig. Swit h
boiler on to allow steam pressure to build-up. Pressure
gauge reading will in rease and the operating pressure
ontrol will de-energize the onta tor(s) when the pres-
sure gauge indi ates 20psig. Open steam outlet valve
to bleed off pressure. When the pressure gauge read-
ing de reases below 10psig (differential) the operating
pressure ontrol will re-energize the onta tor(s).
5. High limit pressure ontrol he k: FOR TEST PURPOSES
ONLY! Set the high limit pressure ontrol 10psig lower
than the operating pressure ontrol. Close the steam
outlet valve and swit h the boiler on to allow boiler to
build pressure. When the pressure gauge indi ates the
pressure at whi h the high limit pressure ontrol is set,
the high limit pressure ontrol re-set button will pop-
up and the ontrol will de-energize the onta tor(s).
Open the steam outlet valve to bleed off pressure. The
onta tor(s) should not re-energize on pressure drop.
The onta tor(s) should only re-energize when the pres-
sure has dropped and the high limit pressure ontrol
reset button is depressed.

Installation, Operation & Maintenance Manual
9
Op ration
With main disconn ct “OFF”
tight n all l ctrical conn ctions b for n r-
gizing boil r to pr v nt arcing, carbonizing of
contact and/or ov rh ating
1. Set the desired operating pressure and differential pressure
on the operating pressure ontrol.
2. Set the high limit pressure ontrol. (Re ommended to be 10
psig above the operating pressure setting.)
3. Turn on water supply.
4. Turn main dis onne t swit h on.
5. Turn boiler ontrol swit h on. The water feed will begin and
ontinue until the water level rea hes half way up the gauge
glass. The water feed will automati ally shut off and the on-
ta tor(s) will energize.
Blowdown
A daily blowdown is an essential part of boiler operation. It is the best and most important part of preventative maintenan e you
an give your boiler and will add years of life to the unit. Make sure a blowdown s hedule is established and followed regularly.
MANUAL BLOWDOWN INSTRUCTIONS
1. At the end of the working day, while boiler is still
operating, turn boiler main swit h to the “OFF” posi-
tion, lose water supply valve and open dis onne t
swit h.
2. If blow down valve is plumbed into a blowdown tank,
the boiler an be dis harged at operating pressure.
3. If the blowdown valve is not plumbed into a blow-
down tank, onsult with lo al plumbing odes regard-
ing boiler dis harge.
4. When dis harge is omplete and boiler is drained,
lose the blowdown valve, open the water supply
valve, turn boiler main swit h to “ON” position and
lose dis onne t swit h.
5. When refilling is omplete, 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.
AUTOMATIC BLOWDOWN INSTRUCTIONS
(PN ES81600) 1” NPT, Starts, stops and blows down the boiler auto-
mati ally, utilizing a programmable time lo k a time-delay relay
and motorized ball valve.
If the blowdown valve is plumbed into a blow-
down tank, the boiler an be dis harged at operating pressure. If
the blowdown valve is not plumbed into a blowdown tank, onsult
with lo al plumbing odes regarding boiler dis harge.
NOTE: The manual valves from the boiler drain and the lower
float ontrol equalization tube must be fully open for the automat-
i blowdown to be effe tive.
1. Program time lo k by setting the time boiler is to turn on and
off daily. (Refer to instru tions in time lo k insert.)
2. When the time lo k turns the boiler “off” the blowdown is a ti-
vated. A red pilot light over the time lo k will ome on and
remain on while the motorized ball valve is open. The time dura-
tion 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 omplete, will be approximately at the lower gauge
glass valve. (Elements are not exposed to air between operations.)
3. Boiler will automati ally refill at next programmed on y le.
Blowdown program an be overridden to allow for uns heduled
blowdown or operational y les. Refer to the time lo k instru tion
insert.
6. Boiler steam pressure will gradually in rease to the
operating pressure ontrol set point, at whi h time
the onta tor(s) will de-energize.
7. With steam demand, the boiler steam pressure will
de rease. When the boiler pressure has dropped
below the operating pressure ontrol differential set
amount, the onta tor(s) will re-energize.
8. The boiler is equipped with float type liquid level on-
trols employing mi ro swit hes. They are extremely
sensitive and reliable and will maintain the proper
water level within the boiler pressure vessel automat-
i ally during boiler operation.
9. The boiler should be blown down daily. (See blow-
down instru tions.)
!CA UTI ON
!CAUTION

Installation, Operation & Maintenance Manual
10
Digital Tim r - Op ration Instructions
TO SET TIME & DAY OF CLOCK
1. Press M nu
2. 24h AM or PM blinking, press
+or –to select, press OK
3. Hour (12:00) blinking, press +
or –
to select, press OK
4. Minute (12:00) blinking, press
+or –to select, press OK
5. Arrows for days

blinking, press +or –to select, press OK
6. Go to step 8 to continue with programming or press M nu
to end.
TO SET TIMER ON/OFF TIMES
7. Press M nu and press OK four times to go
current time/day setting above
8. prog 01 blinking and ON symbol

displayed, press +or
–to select, press OK
9. Hour (12:00) blinking, press +or –to select, press OK
10. Minute (12:00) blinking, press +or –to select, press OK
11. Arrows for days

blinking, press +or –to select, press
OK
12. prog 02 blinking and
OFF symbol

displayed,
press +or –to select, press OK
13. Hour (12:00) blinking, press +or –to select,
press OK
14. Minute (12:00) blinking, press +or –to select, press OK
15. Arrows for days

blinking, press +or –to select. ee
possible combinations below.
16. Press M nu to end or press OK and repeat steps 8 to 15 to
set more ON/OFF times.
PROGRAMMED DAY COMBINATIONS:
Every day (arrows

on all days)
Monday to aturday
Monday to Friday
aturday and unday
Any individual day
RUN MODE
On Run mode, display will show current time/ date, on/off
status, override/automatic status, hourly on/off setting for
the day and Daylight aving Time.
ON/OFF STATUS
ON
symbol

displayed when timer is on and OFF
symbol

displayed when timer is off.
OVERRIDE/AUTOMATIC
When the timer is On , press +to manually turn
the timer
Off  and display arrow

will point to
OVR . Press +again to go back to On  and display
arrow

will point to AUTO .
When the timer is
Off  , press +to manually turn
the timer
On and display arrow

will point to
OVR .
Press +again to go back to
Off  and display arrow

will point to AUTO .
When the timer is in the override mode (

on OVR ),
timer will stay in that position until the next pro-
grammed time, at which time the arrow_will point to
AUTO and continue in the automatic mode.
HOURLY ON/OFF SETTING FOR THE DAY
Hash marks on the upper and right edges of the display
show the hourly On times for the day. Absence of hash
mark on a specific hour indicates that the timer is Off
on that hour.
DAYLIGHT SAVING TIME.
In the Run mode, use a pencil point and press +
hr for
Daylight aving Time and current time advances one
hour and +
hr displayed. To revert back to tandard
Time, press +
hr and current time falls back one hour
and +
hr display disappears.
PROGRAMMING CONFLICTS.
witch 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. Timer must be powered up during programming to
display
On/Off status.
3. During programming, if no button is pressed after 1
minute, the timer will revert back to Run mode.
Mo
Tu
We
Th
Fr
Sa
Su
14
16
18
20
22
24
+- Menu OK
Res.
+1h

Installation, Operation & Maintenance Manual
11
Maint nanc
24-Hour and 7-Day Tim Switch s
HAZARD OF ELECTRIC SHOCK.
DISCONNECT ALL ELECTRICAL POWER BEFORE WORKING
ON BOILER.
Sussman Ele tri Steam Boilers are designed for years of trou-
ble-free performan e. To establish a good preventative mainte-
nan e program, we suggest that the fa ility maintenan e per-
son or engineer familiarize themselves with these simple rules.
1. Daily blowdown at pressure is essential for ideal boiler
performan e. Extended periods of operation may require
more frequent blowdown. If the boiler is not equipped
with an automati blowdown, in order to safeguard the
heating elements, it is re ommended to turn both the main
dis onne t swit h and the boiler swit h to the off position
before manually blowing down the boiler.
2. The sight glass should be he ked frequently to assure the
boiler has adequate water.
3. The sight glass should be he ked daily for damage (i.e.
s rat hes, erosion, leaks et .) The sight glass should be
repla ed if damaged. (See insert.)
4. A monthly inspe tion should be made of the internal wiring.
Open the a ess door and he k all ele tri al onne tions
for tightness. Repla e any wires that show signs of damage.
NOTE: The ele tri al power MUST be shut off during this
maintenan e pro edure.
7. Heating element mounting bolts should be he ked and
tightened to a torque of 22 ft.-lbs. If there are indi ations
of steam leaks from an element, repla e the element
gasket.
8. A monthly he k for leaks should be made; any loose or
damaged fittings should be tightened or repla ed.
9. Every four months the boiler float ontrol should be
he ked for proper operation. The lower equalization
olumn an be examined visually and manually to see if is
lear and lean. If there are signs of s ale or mineral
deposit buildup the float ontrol must be disassembled and
leaned.
One of the lower heating elements should be removed. If
s ale or mineral deposits have begun to form all elements
should be removed leaned and reinstalled using new
element gaskets.
Operating and high limit pressure ontrol operation should
be he ked. Pressure ontrols should be removed and
leaned if ne essary. Water feed supply he k valves should
be inspe ted and repla ed if ne essary.
10. If the boiler is equipped with an ele troni auxiliary low
water ut-off every four months the probe should be
removed and he ked for deposits. The probe should be
leaned and reinstalled.
PROGRAMMING
F or ele tri steam boilers
equipped with Automati
Blowdown Systems
ES 81600, refer to the fol-
lowing instru tions for
time lo k
operation and settings.
Timer settings for blow-
down operation are at
the dis retion of the owner/operator.
The weekly program dial shows the seven days of
the week and AM/PM imprints for ea h day.
The time swit h is set by pushing the aptive trippers
to the outer ring position for the entire period that
the load is to be turned ON, i.e., 2 hours to ea h trip-
per on the 7-day dial. When the tripper is pushed to
the inside, the swit h is in the OFF position.
SETTING TIME
To set the urrent time and day of week, turn
the minute hand lo kwise. Do not set the time
by rotating “Outer” Dial.
Turn the minute hand lo kwise 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' lo k).
Example for 7-day program dial Monday 10:30
AM.Turn the minute hand lo kwise until Monday
10:30 AM is aligned with the triangle on the inner
dial.The hour and minute hand will show exa tly
10:30.
FOR MANUAL OVERRIDE
Manual override an be a omplished at the
dis retion of the owner/operator as follows.
3-WAY MANUAL OVERRIDE SWITCH
I = permanent ON I
= automati
O = permanent OFF
O
IMPORTANT: It is re ommended that for periodi
and effe tive blowdown,the override swit h be set
in the automati setting.
!CAUTION

Optional Equipm nt
Installation, Operation & Maintenance Manual
Standard Equipm nt
12
AUXILIARY LOW WATER CUT OFF
• For model SSB boilers SSB81017MR
(with manual reset).
Senses water level ele troni ally using a resistan e
probe. When a low water ondition is dete ted,
the onta tor ontrol voltage ir uit is interrupt-
ed and the heating elements are de-energized.
When water level returns to proper levels voltage
is restored to the onta tor oils and the ele-
ments are re-energized. For ontrols with a man-
ual reset button voltage to the onta tor oils 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 orre t water level is a hieved.
LINE PRESSURE WATER FEED SYSTEM
• For model SSB boilers PN PN SSB99117
Water feed system used to supply makeup water
to the boiler when in oming water line pressure
is 10 psig greater than the operating pressure of
the boiler. Completely fa tory plumbed and
wired; 0-100psig range; 1/2” NPT size. Consists of
strainer, solenoid valve (120/1/50-60Hz), and he k
valve for automati feed. For SSB boilers PN
SSB99117 omponents are of stainless steel on-
stru tion.
HIGH PRESSURE WATER FEED SYSTEM
• For model SSB12-72 PN SSB38002
• For model SSB100-180 PN SSB38020
Used to supply makeup water and to maintain on-
stant water level when the boiler operating pressure
is equal to or greater than in oming water line pres-
sure and ondensate is not returned to the boiler.
• SSB38002A – Range is 0 – 100 psig, 1/2” NPT size on-
sisting of strainer, solenoid valve and 1/3 HP 120/1/60
motor and pump.
• SSB38020A – Range is 0 – 125 psig, 3/4” NPT size on-
sisting of strainer solenoid valve and 1/2 HP 120/1/60
motor and pump.
These assemblies are mounted on rubber sho ks and
se ured to a steel base mounting plate. These units
require field plumbing and wiring to the boiler.
SSB38002 and SSB38020 pump omponents are of
stainless steel onstru tion.
AUTOMATIC BLOWDOWN SYSTEM
• Extends life of boiler
• Saves labor osts
• Starts the boiler automati ally every day
• Shuts down the boiler every day
• Automati ally blows down the boiler every day
• Completely programmable, an skip days, different
start and shutdown times, different operational dura-
tions.
• SSB81600 for all model boilers.
A stainless steel, motor driven straight-through, self-
leaning ball valve with Teflon seats handles parti les
and dirty fluid without the use of an up-stream strain-
er or other leaning devi e. A timer (Standard analog
time lo k is set for two hour time intervals, optional
digital time lo k an be programmed to one minute
intervals.) and ele troni time delay relay ontrol the
boiler and the blowdown valve. A pilot light indi ates
when the blowdown valve is open. The valve shall be
plumbed to a proper drain or re epta le. An
automati blowdown system an be installed on any
boiler, regardless of size operating pressure or operat-
ing duty y le.

Installation, Operation & Maintenance Manual
Optional Equipm nt (cont.)
13
BLOWDOWN SEPARATORS (see page 14)
• For models SSB12-48 PN BDT-ASME36
• For models SSB60-180 PN BDT-ASME42
A separator a epts the flash steam and effluent
from the boiler blowdown and redu es the tempera-
ture and pressure to insure a safe dis harge of water
and sludge. Steam flash and pressure are absorbed
and pass harmlessly to the outside via a vent. The
separator design utilizes a water seal at the outlet,
whi h permits the operator to introdu e old water
from the bottom to mix with the hot water and boil-
er steam in the blowdown separator. This redu es
outlet temperature to a safe dis harge level.
These separators require spe ifi plumbing from the
boiler blowdown valve and require onne tion to a
old water supply. (If the separator is less than half
full of water after the boiler is blown down old
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 assem-
bly are in luded.
CONTROL VOLTAGE STEPDOWN
TRANSFORMER
• Provides 120 Volt (220 Volt export) from main power
supply. Fa tory wired and fused.
MULTISTAGE LOAD PROGRESSIVE
SEQUENCERS
A urate ontrol is provided by automati progressive
sequen ing in the use of energy and minimizing wear on
ele tri al omponents. The sequen ers are designed to
apply power progressively to larger KW boilers. A fa tory
installed pressure sensitive sequential ontrol rea ting to
steam boiler pressure progressive energizes or de-ener-
gizes heating elements through power onta tors. A
delay between sequen er steps before start-up and
between ea h subsequent step eliminates power surges.
Ea h sequen er is mat hed and fa tory pre- set to boiler
system requirements. Ele troni progressive sequen ers
give a urate ontrol of multi-stage loads of the type
used in steam boilers. Features in lude progressive
sequen ing (first on- first off) that equalizes the operat-
ing time of ea h load. Integral solid-state light emitting
diodes show a tive stages. Should a power interruption
o ur, all elements are instantly de-energized for safety.
Upon resumption of power the ontrol will re-stage the
loads one at a time.

Installation, Operation & Maintenance Manual
14
Blowdown S parator Tanks- Sp cifications and Data
Mod ls BDT-ASME 36, 42
D
A
H
G
The Sussman Separator design incorporates a water
seal at the outlet which permits the operator to
introduce cold water rom the bottom to mix with
the hot water and boiler steam blowdown in the
separator. This reduces the outlet temperature to
a level that makes it sa e or discharge.
Note: 1BHP is approximately 10KW.
Dim nsions and F atur s Sugg st d Hook-Up to Boil r
"C" Drain
Temperature
Gauge
Pressure Gauge
"E" Vent
"B" Inlet
Water Gauge
Hand ole Assembly
3" x 4"
(except BDT-ASME 36)
"F" Cold Water Inlet
& Was out Drain
Maximum Boiler Working Pressure: 250 psi
Maximum Blowdown Separator Pressure: 65 psi
Blowdown Separators are sized in accordance with National Board Standards
Constru ted in a ordan e with Se tion 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
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 atmosp ere must be full size
Tempered
Blowdown
to Drain
Standard Equipm nt
• 0-100 lb. Pressure Gauge
• 0-200˚ Temperature Gauge
• Water Level Gauge

Installation, Operation & Maintenance Manual
Sp cifications St am Gaug
Pr ssur /
T mp ratur
Chart
15
__________________________________________
Boiler Bhp Lbs/Hr 3-Ph
Model No. KW Rating Steam** Volts*** Amps
__________________________________________
208 34
SSB-12* 12 1.22 36.2 240 29
480 15
__________________________________________
208 50
SBS-18* 18 1.84 54.2 240 44
480 22
__________________________________________
208 67
SSB-24* 24 2.45 72.3 240 58
480 29
__________________________________________
208 84
SSB-30 30 3.06 90.4 240 73
480 37
__________________________________________
208 100
SSB-36 36 3.67 108 240 87
480 44
__________________________________________
208 134
SSB-48 48 4.90 145 240 116
480 58
__________________________________________
208 167
SSB-60 60 6.12 181 240 145
480 73
__________________________________________
208 200
SSB-72 72 7.35 217 240 174
480 87
__________________________________________
208 300
SSB-100 108 11.2 325 240 260
480 130
__________________________________________
208 400
SSB-135 144 14.7 434 240 347
480 173
__________________________________________
SSB-160 158 16.2 475 240 379
480 190
__________________________________________
SSB-180 180 18.4 542 240 434
480 217
__________________________________________
* Single phase available
** @ 212˚ F
*** Other voltage available
________________
Gauge Temperature
Pressure
PSIG F˚ C˚
________________
15 179 82
________________________
10 192 89
________________________
5203 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
________________________

Installation, Operation & Maintenance Manual
Sizing
16
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
( F˚)
_________________________________________________________
40 .3347 .3355 .3375 .3388 .3406 .3422 .3431 .3447 .3458
_________________________________________________________
50 .3318 .3326 .3345 .3359 .3376 .3392 .3401 .3417 .3429
_________________________________________________________
60 .3288 .3296 .3316 .3329 .3347 .3363 .3372 .3388 .3400
_________________________________________________________
70 .3259 .3267 .3287 .3300 .3318 .3334 .3343 .3359 .3370
_________________________________________________________
80 .3229 .3238 .3278 .3271 .3288 .3305 .3313 .3329 .3341
_________________________________________________________
90 .3200 .3208 .3238 .3242 .3259 .3275 .3284 .3300 .3312
_________________________________________________________
100 .3171 .3179 .3199 .3212 .3229 .3246 .3255 .3271 .3283
_________________________________________________________
110 .3142 .3150 .3170 .3183 .3200 .3217 .3225 .3242 .3253
_________________________________________________________
120 .3112 .3210 .3140 .3154 .3171 .3287 .3196 .3212 .3224
_________________________________________________________
130 .3083 .3091 .3111 .3124 .3142 .3160 .3167 .3183 .3195
_________________________________________________________
140 .3054 .3062 .3082 .3095 .3113 .3129 .3137 .3154 .3165
_________________________________________________________
150 .3025 .3032 .3052 .3066 .3083 .3099 .3108 .3124 .3136
_________________________________________________________
160 .2995 .3003 .3029 .3036 .3054 .3070 .3079 .3095 .3107
_________________________________________________________
170 .2966 .2974 .2994 .3001 .3025 .3041 .3050 .3066 .3077
_________________________________________________________
180 .2937 .2945 .2964 .2978 2995 .3011 .3020 .3036 .3048
_________________________________________________________
190 .2907 .2915 .2935 .2948 .2966 .2982 .2981 .3007 .3019
_________________________________________________________
200 .2878 .2886 .2906 .2919 .2937 .2953 .2962 .2978 .2989
_________________________________________________________
Exampl :
Need a boiler to produ e 450 lbs. steam/hr. at 75 psig with the available feedwater temperature 50˚ F.
From the hart above, find .3417 KW/Lb. of steam 450 lbs. steam/hr. x .3417= 153.8 KW boiler required

IMPORTANT NOTE: Read all warnings and
instructions be ore per orming installation or
maintenance. Sa ety glasses and gloves should be
worn at all times when working with or examining
water gauge glass and connections. Pressure in gener-
ator to be at zero be ore proceeding. Improper instal-
lation or maintenance o gauge glass and connections
can cause immediate or delayed breakage resulting in
bodily injury and/or property damage.
1. Apply Teflon tape or pipe dope to pipe threads.
Install top gauge fitting (fitting without a drain
valve) into the uppermost tapping. Wren h tighten
the fitting until it is snug and the glass outlet is
pointing at five o' lo k (about 1/8 turn from its
final downward verti al position).
2. Install the bottom gauge fitting (the fitting with a
drain valve) until it is snug and the glass outlet is
pointing dire tly upward. Verify top and bottom
fittings are threaded into the tappings the same
number of turns (distan e A= distan e B).
3. Remove glass pa king nut, fri tion washer (or pa k-
ing gland, depending upon the model), and glass
pa king from the fittings, and pla e them, in the
same order, on to both ends of the gauge glass.
Push both pa kings about an in h up the gauge
glass.
4. Gently insert one end of the glass into the top
gauge fitting. Keeping the glass inside the top fit-
ting, gently rotate the top gauge fitting lo kwise
until verti ally aligned with the bottom gauge,
then insert glass into bottom fitting until glass bot-
toms out on the shoulder inside the bottom fitting.
5. Carefully raise glass about 1/16" and slide lower
glass pa king down until the glass pa king onta ts
the lower gauge fitting. DO NOT allow the glass to
remain in onta t with any metal!
6. Carefully slide upper glass pa king up as far as
possible.
7. Hand tighten both glass pa king nuts, then tighten
1/2 turn more by wren h. Tighten only enough to
prevent leakage. DO NOT OVER TIGHTEN! If any
leakage should o ur, tighten lightly, a quarter turn
at a time, he king for leakage after ea h turn.
IMPORTANT NOTE:
Read all warnings and instructions be ore per orming
installation or maintenance.
Saf ty glass s and glov s
should b worn at all tim s wh n working
with or xamining wat r gaug glass and
conn ctions.
Pr ssur in g n rator to b at z ro b for
proc ding.
Improp r installation or maint nanc of
gaug glass and conn ctions can caus
imm diat or d lay d br akag r sulting
in bodily injury and/or prop rty damag .
Installation, Operation & Maintenance Manual
Gaug Glass Installation
17
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

Installation, Operation & Maintenance Manual
Gaug Glass Installation - Us and Car
18
DO NOTs
• DO NOT use glass if it ontains any s rat hes, hips, or
any other visible signs of damage.
• DO NOT reuse any tubular glass or glass pa kings.
• DO NOT subje t gauge glass to bending or torsional
stresses.
• DO NOT over tighten glass pa king nuts.
• DO NOT allow glass to tou h any metal parts.
• DO NOT ex eed the re ommended pressure of the
gauge or gauge glass.
• DO NOT lean the gauge or gauge glass while pressur-
ized or in operation.
DO's
• DO verify proper gauge has been supplied.
• DO examine gauge glass and pa kings arefully for
damage before installation.
• DO install prote tive guards and utilize automati ball
he ks where ne essary to help prevent injury
in ase of glass breakage.
• DO inspe t the gauge glass daily, keep maintenan e
re ords, and ondu t routine repla ements.
• DO prote t glass from sudden hanges in tempera-
tures su h as drafts, water spray, et .
MAINTENANCE
Examine the gauge glass regularly for any signs
of louding, s rat hing, erosion, or orrosion. The
glass should be inspe ted daily until the need for
repla ement be omes apparent. This will help
establish the routine inspe tion and routine
repla ement s hedules.
CLEANING
Use ommer ial non-abrasive glass leaners to
keep glass lean. Do not use wire brushes or any
other abrasive materials whi h ould s rat h the
glass.
INSPECTION
Examine the surfa e of the glass for s rat hes,
orrosion, hips, ra ks, surfa e flaws, or ni ks. To
do this, shine a very bright on entrated light at
an angle of about 45 degrees.A defe tive glass
will glisten as the light strikes imperfe tions. Glass
whi h appears loudy or roughened, and will not
respond to leaning, should be repla ed.
STORING
Keep gauge glass in original pa kaging until
ready to install.

Installation, Operation & Maintenance Manual
El m nt R plac m nt
19
READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK
Before Install ng your new elements be sure the
low water cut-off and aux. low water cutoff ( f suppl ed) s operat ng
properly. The float chamber and lower equal zer column of the l qu d
level control must be completely clear of sludge or other fore gn matter.
Fa lure to do th s may cause the mmed ate burn-out of the new
elements. If the un t s probe equ pped, check cond t on of the probes
and solator.
All elements are thoroughly checked before sh pment The manufacturer
cannot be respons ble for burn-outs caused by a faulty low water cut-off.
The lower equal zer column can best be exam ned by break ng the un ons
on e ther s de and then v sually and manually exam n ng the p p ng w th
your f nger or probes to see f t s clear and clean.
1. D sconnect bo ler from electr c power supply at ma n safety sw tch or fuse panel.
Then turn bo ler sw tch to “OFF" pos t on.
2. Close water supply valve on ncom ng water supply l ne. Dra n bo ler completely of water.
3. Open bo ler door to access heat ng element.
4. D sconnect w re (electr c) leads connect ng element to ma n power system of bo ler.
Aga n, note w re connect ons to fac l tate re-assembly. Proceed to remove and d scard
(6) bolts from flange.
IMPORTANT: Note the w re connect ons to fac l tate re-assembly (see w r ng schemat c).
Remove and d scard s x (5/16"-18) bolts from flange. Do not reuse these bolts.
5. Thoroughly clean bo ler flange of all fore gn mater al. Be certa n no part of old gasket
rema ns on flange.
6. Apply "Sl c-T te" Gasket Compound (or equal) to both surfaces of new gasket suppl ed
w th replacement element. Proceed to nstall element flange assembly w th gasket
between bo ler flange and element flange. In do ng th s, be careful to al gn flange holes
so element w re connect on term nals on element assembly are n l ne w th prev ously
d sconnected w re leads to fac l tate easy connect ons.
NOTE: Observe mark ngs on element flange. Install element mark ng “TOP” on top.
7. Use only new element flange bolts. T ghten all (6) element flange bolts to a torque value
of 22 lb-ft each (see llustrat on).
8. Connect all w res to the term nals. T ghten all element term nals to a torque value of
20 lb- n each (see llustrat on). Make sure all w res are clean and br ght to assure good
electr cal contact.
9. Check that the w res are correctly connected to the contactor term nals and are t ghtened
to a torque value of 45 lb- n. (see llustrat on). Make sure all w res are clean and br ght to
assure good electr cal contact.
10. Open water valve to allow water supply to reach bo ler feed mechan sm.
11. As bo ler automat cally ref lls, observe the new flange assembly for poss ble leaks. If water
s not ced, the bolts must be re-t ghtened. Before do ng th s, turn the bo ler off at the
ma n fuse safety sw tch.
12. When bo ler reaches work ng pressure, check flange assembly aga n for leaks.
Follow ma ntenance nstruct ons prov ded w th the bo ler.
Torqu Valu s:
Element Flange Bolts: 22 lb-ft
Element Term nals: 20 lb- n
Contactor Term nals: see Torque chart
For Illustrativ Purpos s Only.
Pow r wiring shown in approximat
factory-install d location
Torque
Wrench
Torque
Wrench
Torque
Wrench
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
TORQUE VALUES
Element Flange Bolts 22 lb-ft
Element Terminals 20 lb-in
Conta tor Terminals 50 amp 25 lb-in
60 amp 45 lb-in
75 amp 75 lb-in
!CAUTION
!CAU TIO N

A Division of Sussman-Automatic Corporation
43-20 34th Street, Long Island City, NY 11101 • (718 937-4500
1-800-238-3535 • Fax: [phone] • email: [email protected]
www.sussmanboilers.com
PUR 101137SSB 2/12
M A D E I N U A