Sussman SVS Series User manual

Series SVS
Steam Boiler
Installation, Operation and Maintenance Manual & Spare Parts List
Model No. _____________________________
Boiler Serial No. ________________________
National Board No. _____________________
Sa ety Valve Set Pressure ____________PSIG
Power Circuit Voltage ___________________
Control Circuit Voltage __________________
Amps ______ Phase ______ HZ ______
TABLE OF CONTENTS . . . . . . . . . . . PG.
1.Scope................................1
2. Operating Principles . . . . . . . . . . . . . . . . . . . 2
3. Speci ications . . . . . . . . . . . . . . . . . . . . . . . 3-4
4. Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
5.Wiring...............................6
6. Pre-Operation Check . . . . . . . . . . . . . . . . . . . 7
7. Pressure Controls, Operation & Testing . . . . 7
8. Start-Up and Operation. . . . . . . . . . . . . . . . . 8
9. Maintenance . . . . . . . . . . . . . . . . . . . . . . . 9-10
10. Drawings & Literature . . . . . . . . . . . . . . . . 10
11.SpareParts.........................10
12. Trouble Shooting Guide . . . . . . . . . . . . . . 11
13.Warranty...........................11
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.sussmanb ilers.c m
PUR100433 6/11 Rev 2.0
states a hazard which may
cause serious injury or
death if precautions are not followed.
signals a situation where
minor injury or product dam-
age may occur if you do not follow instructions.
IMPORTANT NOTE:
This highlights information that is especial-
ly 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:
For actory inquiries about this boiler please have available the Model no. and
Serial no., Voltage, kW and Phase o the supplied equipment. This in ormation is
available on the boiler name plateand operation.
CAUTION
!
WARNING
!

d. The boiler is equipped with an adjustable pressure
con-trol which will switch off the heaters when the
set pressure is reached. Steam pressure determines
the steam temperature. Examples of this pressure-
temperature relationship are shown below:
f. In many boilers, the pressure regulation controller is
backed up by a high pressure limit control. More
importantly, all boilers must have 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 components.
Of course, there will come a time (usually measured in
years) when the boiler shell and piping will wear away
or corrode. 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.
1. Scop
2. Op rating Principl s
2
Sussman Boilers
Installation, Op ration & Maint nanc Manual
_____________________________________
Pressure (GAUGE) Appr ximate Temp.
_____________________________________
PSIG KPa ˚F ˚C
_____________________________________
0.00 0 212 100
10.3 71 240 116
34.5 238 280 138
74.9 516 320 160
138.3 954 360 182
This manual details the installation, operation and mainte-
nance instructions, and spare parts list for Sussman Series
SVS Steam Boilers.
Refer to section 10.1 for specific drawings and bills of
material for related equipment supplied under this order.
Your SVS Steam Boiler is designed and manufactured to meet
ASME 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.
2.1 Principl s of Op ration
2.1.1 Sussman SVS electric steam boilers utilize state of
the art technology, control components, valves and acces-
sories. The Series SVS features vertically positioned heat-
ing elements which have many advantages over horizon-
tally positioned elements:
a. Since the elements are removed from the top, the boiler
requires less space.
b. Vertical steam boiler elements are less prone to scale
build-up, a major cause of element failure.
c. Boilers with vertical elements, being more compact, have
faster response time than boilers requiring larger vessels.
2.1.2 El ctric boil r op ration:
a. A steel vessel is fitted with tubular resistance type heat-
ing elements, inlet and outlet connections, a drain/ blow-
down valve(s), an air vent, a water control mechanism, a
pressure relief valve, and a temperature control. These
devices are configured with a series of electrical controls
for automatic operation.
b. When the boiler is switched on, an electronic level
sensor activates a valve which opens to allow water to
enter the boiler vessel. The water enters directly from
the mains, from a pump connected to the mains, or a
receiver tank.
c. As the boiler fills, the level sensor detects the rising
water levels, activates the heating elements and then
signals the water inlet valve to close.

3.2 Standard Boil r Acc ssori s
The following shows the standard boiler accessories for SVS steam boilers.
STANDARD BOILER ACCESSORIES
No. Description
1 Insulated ASME designed pressure vessel
2 Vented control cabinet
3 Pressure relief valve
4 Inspection and cleanout holes
5 Pressure gauge c/w isolating stopcock
6 Sight glass assembly c/w protector
7 Back flow check valve
8 Drain blowdown valve(s)
9 Flanged heaters c/w low watt density elements
10 Control circuit transformer (fused)
11 Control circuit on/off switch
12 HRC power fusing
13 Magnetic contactors
14 Indicating pilot lights
15 Electronic low water control
16 Electronic feed water control
17 Electronic high water control (not all models, check factory)
18 On/off staging up to 95 amps
18 Modulating pressure control for units over 95 amps
19 Staging controller with detail no.19
20 High pressure controller
3.3 G n ral Sp cifications
Listed below is a summary of the approximate minimum clearance
requirements, piping sizes and volumes for the various standard boiler
types and within this series.
STANDARD DESIGN PRESSURE IS 150 PSIG
Sussman Boilers
Installation, Op ration & Maint nanc Manual
3. Sp cifications
3
TABLE 2 - STEAM BOILER GENERAL SPECIFICATIONS
Up to Vessel Openings (NPT)* Normal Water Normal Steam
Max. KW
WATER CHEMICA SURFACE DRAIN STEAMOUTLET Volume Chambers
INLET TREATMENT BLOWDOWN VALVE <15 PSIG >15 PSIG GALLONS GALLONS
(103.5 KPA) (103.5 KPA) (Litres) (Litres)
120 3/4 3/4 3/4 3/4 22 9.5 4.1
(36) (15.5)
270 3/4 3/4 3/4 13 3 39 16.9
(148) (64)
648 1 3/4 3/4 1-1⁄4 4388.2 37.8
(334) (143)
1512 1-1⁄4 3/4 3/4 1-1⁄4 64173 74.5
(655) (282)
* Outlet flanged above 3” NPT

Sussman Boilers
Installation, Op ration & Maint nanc Manual
3. Sp cifications
(cont.)
4. Installation
4
3.4 Oth r Optional Equipm nt
Sussman offers the following as options for packaged steam boiler systems.
Check to see that optional equipment has been supplied as ordered.

 Feed mechanism - choose from
solenoid, pump or receiver feed packag

 Steam outlet globe valve

 Auxiliary low water cutoff

 Manual reset low water cutoff

 Timed auto blowdown system

 Timed surface blowdown system

 Vacuum breaker

 Manual surface blowdown metering valve

 High pressure alarm

 Low pressure alarm

 Audible alarm with silence

 Pilot lights for each stage
4.1 G n ral
The boiler shall be installed by quali-
fied personnel in accordance with the
instructions contained in this manual.
Furthermore, compliance with applica-
ble National and local building and
safety codes is necessary.
4.2 Pr -Installation
4.2.1 Inspect the boiler for possible dam-
age 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 effect the safe and reliable operation of the boil-
er, contact the sales office to discuss corrective action.
Have the details shown on the front of this manual
available. Do not return the unit unless advised, since
field repair may be the preferred course of action.
Returns must include a Return Authorization available
from Sussman.
4.2.2 Check the boiler nameplate data to ensure that it
corre-sponds to the supply characteristics (i.e. - volt-
age, phase, frequency, wattage and pressure relief
valve setting).
4.2.3 Consult local codes for specific requirements on the
installation of the electric boiler.

 Manual OFF/AUTO staging switch

 Voltmeter with 3 position selector switch

 Ammeter with 3 position selector switch

 kW hour meter

 Main disconnect (unfused) switch

 Main automatic breaker

 Safety door interlock switch

 Proportional controller (std. over 108 kW)

 Electronic sequencer (std. over 108 kW)

 Motor starter with overloads

 Ground fault indicator

 Epoxy sealed elements

 HRC power fusing
4.3 Mounting
4.3.1 The boiler must be positioned on an adequate base,
preferably concrete, sufficient to support its in-service
weight, and then levelled and secured inplace.
4.3.2 Adequate clearance on all sides of the boiler is required
for access and servicing. Please refer to the above dia-
gram and table for minimum clearance.
D
A
18" Max
B
C
EL
2" NPT
3⁄4" NPT
Inlet
1" NPT
Drain
3⁄4" NPT
Drain
___________________________________
Up t Minimum Clearances
Max kW AB C DE
L
120 36” 22” 24” 24” 24”
270 36” 32” 24” 24” 24”
648 48” 38” 30” 30” 24”
1512 48” 38” 30” 30” 24”

Sussman Boilers
Installation, Op ration & Maint nanc Manual
4. Installation (cont.)
4.4 Plumbing
Refer to drawings in section 10.1 for size and location of
water inlet, outlet and other relevant openings.
Ensure that all plumbing connections are made according to
local regulations and applicable codes.
4.4.1 Wat r Supply
All boilers require some type of feed mechanism.
Check to ensure that the correct feed mechanism is used
for your system.
a. S len id Feed
A solenoid feed can be used if condensate is not required
to be returned to the boiler and water pressure is always at
least 10 PSIG higher than the maximum boiler operating
pressure. The solenoid on the solenoid feed is activated by
the level controller.
For connection: Pipe the water supply to the inlet side of
the solenoid valve which is pre-installed on the boiler inlet.
b. Pump Feed
A pump feed is to be used when condensate is not required
to be returned to the boiler and the water pressure is less
than 10 PSIG above the maximum required boiler operating
pressure. NOTE: The pump motor is normally powered from
a separate source.
F r c nnecti n: Pipe the water supply to the suction side of
the pump. Pipe from the pump discharge to the check
valve pre-installed on the boiler water inlet.
c. C ndensate Receiver Package
For closed loop systems, when condensate is to be returned
to the boiler, a condensate return system is required. If sup-
plied by Sussman, the system is packaged as one assembly
made up of a feed pump, a receiver tank, stand, make-up
water inlet with float control, condensate inlet, vent, drain
valve, strainer, sight glass assembly, and shut off valve.
F r c nnecti n: Pipe the codensate line to theinlet pipe at
the top of the receiver tank. Pipe the water supply to the
make-up water inlet on the end f the receiver tank.
NOTE: It is assumed that the condenste is released for a
steam trap in the heating loop. Good practice is to ensure
that the piping from the steam trap slpoes down towrds
4.5 El ctrical
The boiler must be wired by qualified personnel in strict
compliance with all codes and regulations. Except for the
optional feed water pump and automatic blowdown sys-
tem, the unit is factory pre-wired. Refer to the wiring dia-
gram included in section 10.1. Field electrical connections
are to be made as indicated on this drawing.
4.5.1 Pow r Supply
With the boiler "ON-OFF” switch in the "OFF” position and
the main electrical supply open, connect power feed lines
from a fused disconnect or breaker to the terminals
marked L1, L2, and L3 of the boiler disconnect, breaker,
or power splitter, whichever is supplied. See section 10.1 for
schematic diagram.
4.5.2 Grounding
The boiler must be properly grounded. Attach a suitable
ground wire to the ground connection point in the control
cabinet sized in accordance with national and local codes.
the receiver tank inlet. If the steam line leading into the
trap is at a lower level thatn the trap, a bleed valve just
before the trap inlet may be requiredon some systems.
4.4.2 Backflow Ch ck Valv
The boiler is equipped with a check valve. Note that the
check valve is directional. Verify that it is oriented proper-ly.
The arrow (on the side of the valve) should point towards
the boiler.
4.4.3 St am Outl t
To facilitate maintenance, a steam outlet valve is recom-
mended for most systems. This may not have been includ-
ed in your package, and is available from the factory at an
additional cost. If the outlet valve is sourced separately,
ensure that it is suitable for steam boiler use.
F r c nnecti n: Pipe the steam outlet from the boiler to
the inlet piping of a system designed to withstand a pres-
sure in excess of the boiler relief valve setting.
4.4.4 Blowdown Piping
When the boiler pressure exceeds 15 PSIG (103 KPA) most
jurisdictions prohibit the blow-off 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 blowdown piping to any sewer system.
F r c nnecti n: Pipe the blowdown valve(s) to the inlet of
a blowdown tank or a suitable drain (as appropriate).
4.4.5 Pr ssur R li f Valv
F r c nnecti n: Pipe the outlet from the pressure relief
valve to a suitable drain away from other equipment,
walkways and personnel. NOTE: Do not reduce the piping
size from the pressure relief valve. Do not install any other
valves or plugs in this piping.
4.4.6 Utilization of Full Couplings
Utilization of full couplings on the inlet and outlet piping
connection may simplify future service requirements. Hot
piping loops must be insulated after testing for leaks.
Other than personnel safety, uninsulated outlet piping will
lower steam quality.
5

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.
Boilers are susceptible to lightning damage due to water line connections.
An industrial type lightning/surge protector should be installed according to the manufacturer's
recommendation at the service entrance. Consult your contractor or electrical dealer.
Substitution of components or modification of wiring system voids
the warranty and may lead to dangerous operating conditions.
5. 1. Ground boiler according to National Electric Code
requirements to avoid shock.
5.2. 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.
5.3. 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 identifi-
cation should the boiler need to be turned off due to an
emergency.
Sussman Boilers
Installation, Op ration & Maint nanc Manual
5. Wiring
6
5.4 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.
5.5. If a separate control circuit is used, it should be con-
nected to the control circuit terminal block.
5.6. Remote mounted water feed systems (i.e. conden-
sate return, motor and pump) should be connected to
the junction box provided on the outside of the boil-
er jacket.
5.7. With main power off, make sure all wiring termina-
tions are tight to avoid arcing, carbonizing or over-
heating of contacts.
CAUTION
!
CAUTION
!
WARNING
!

Sussman Boilers
Installation, Op ration & Maint nanc Manual
6. Pr -Op ration Ch ck (All Boil rs)
7. Pr ssur Controls, Op ration and T sting
7
LWCO/PUMP CONTROL OPERATION AND TESTING
6.1. All valves for incoming water supply are to be fully
opened. Main disconnect switch is to be in the "on" posi-
tion. 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 automati-
cally 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.
6.2. Pump switch operation – at this point water should be vis-
ible 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 sys-
tem. Close valve for proper operation.
6.3. 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 automati-
cally refill the boiler and the contactors will re-energize.
Boilers equipped with an auxiliary low water cut-off con-
trol 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:
• F r test 1 - the blowdown time clock must be in the
“run” mode before the boiler will automatically fill.
• F r 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 neces-
sary to cycle the time clock from the “run” to “off”
mode several times.
NOTE: All boilers are provided with one high limit pres-
sure control and at least one operating pressure control.
7.1. The high limit pressure control is equipped with a manual
reset feature. There is no subtractive differential scale with
this type of control
7.2. 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 PSIG above the desired normal operating pressure.
7.3. 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 differen-
tial pressure value.
7.4. Operating pressure control check: Close steam outlet
valve [supplied by customer] and adjust operating pres-
sure control to 20 psig and the differential to 10 psig.
Set the high limit pressure control to 30 psig. 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 pres-
sure gauge indicates 20 psig. Open steam outlet valve to
bleed off pressure. When the pressure gauge reading
decreases below 10 psig (differential) the operating
pressure control will re-energize the contactor(s).
7.5. High limit pressure control check: FOR TEST PURPOS-
ES ONLY! Set the high limit pressure control 10 psig
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 indi-
cates the pressure at which the high limit pressure con-
trol is set, the high limit pressure control re-set button
will pop-up and the control will de-energize the contac-
tor(s). Open the steam outlet valve to bleed off pres-
sure. The contactor(s) should not re-energize on pres-
sure drop. The contactor(s) should only re-energize
when the pressure has dropped and the high limit pres-
sure control reset button is depressed.

Sussman Boilers
Installation, Op ration & Maint nanc Manual
8. Start-Up and Op ration
The following procedures should be performed in sequence
to eliminate problems on start-up.
8.1 Start-up
It is presumed that all electrical wiring and plumbing has
been checked prior to this start-up procedure.
8.1.1 Make sure that the steam boiler valves are in the fol-
lowing positions:
Steam Outlet Open Drain Valve(s) Closed
Water Inlet(s) Open Blowdown Valve(s) Closed
8.1.2 Adjust the pressure controller to its lowest setting by
turning the large screw on the top of the controller.
8.1.3 Make sure that the electrical panel door is closed.
8.1.4 Switch to the “On” position. The green power light and
red low level light should then be illuminated indicating
that the system has power and a low water level condi-
tion exists. If the boiler was previously started, sufficient
water may be present and the red low level light will not
illuminate. The boiler solenoid valve will activate and the
water will enter the boiler until the high water level
control closes the valve. Just prior to this, the low level
indictor will de-energize the red low level light and
energize the heating element. At this point, close the
steam valve. The elements will heat the water and begin
to generate steam within a few minutes.
8.1.5 Do a first check on the piping system for leaks at con-
nection points and tighten connections as necessary.
8.1.6 Simulate a low water condition by depressing the
“push-to-test” button. The boiler contactors should open
and the red “low level light” should illuminate. The
noise indicates that the elements have been turned off
and the light indicates the control is working. You
should begin to notice a small pressure requirement. This
is not cause for concern. If the boiler has a step con-
troller it may not have had enough time at this low
demand situation to activate all the heating stages
before satisfying the pressure requirement. This is not
cause for concern.
8.1.7 Set the pressure controller (by turning the large
screw on top of the controller) to the desired pressure
setting. NOTE: The pressure control setting should not
be set at more than 90% of the relief valve setting.
For example: If relief valve setting is 100 PSI, set the
pres-sure control at 90 PSI and the differential at 8
PSI. This will allow the boiler to control the pressure
to between 82 PSI and 90 PSI.
8.1.8 Set the differential (by turning the small screw on
the top of the controller) to the minimum setting.
8.1.9 The pressure will rise on the gauge until the boiler
pressure has reached the pressure control setpoint.
Do a final check for leaks.
8.1.10 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.
8.1.11 Next, slowly open the steam outlet valve, while
maintaining pressure, until the valve is fully opened.
8.1.12 Inspect the heating system for leaks and functionali-
ty. NOTE: Initially, as the system is being heated up,
the boiler may not be able to maintain the setpoint
pressure. However, if the boiler has been properly
sized, after a short period of time the desired operat-
ing pressure will be reached and maintained automat-
ically. Undersized steam heating systems will prime
i.e. discharge excessive amounts of water through the
outlet nozzle. Boilers should not be operated under
this condition. You may wish to check factory for
assistance. The system should now be operational. It is
not normally necessary to pre-boil water to clean the
heating elements or the interior of the vessel. They
have already been semi-cleaned prior to installation
and there is no excessive grease or oil inside the boil-
er. However, if super-clean conditions make pre-boil-
ing necessary, ensure that the detergents used are not
harmful to brass, copper, silver, steel or stainless steel.
8.2 Op ration
With main disconn ct “OFF” tight n all l ctrical conn ctions b for n rgizing
boil r to pr v nt arcing, carbonizing of contact and/or ov rh ating
8.2.1 If a proper maintenance schedule is followed, all that is
required is to turn the boiler on for it to function normally.
Before restarting the boiler, ensure that:
Steam outlet valve is open
Water inlet valve(s) is open
Drain valve(s) are closed
Pressure control is set to the desired system pressure
8.2.2 Although the boiler can operate safely unattended, it
is best to shut the boiler down when it is not required
over evenings, weekends or other prolonged periods.
8.2.3 Water treatment may be necessary in some hard
water areas since excessive scale build up on internal
boiler components will result in heating element
failure and costly repairs. Refer to section 9.6 for a
discussion on this subject.
8
CAUTION
!

Sussman Boilers
Installation, Op ration & Maint nanc Manual
9. Maint nanc
9
HAZARD OF ELECTRIC SHOCK.
DISCONNECT ALL ELECTRICAL POWER BEFORE WORKING ON BOILER.
Sussman electric steam boilers, when properly maintained,
will provide many years of trouble free service. To establish
a good preventative maintenance program, it is recom-
mended that the following maintenance procedures be
adhered to.
9.1 Blowdown
Blowdown is an essential part of boiler maintenance.
A regularly followed blowdown schedule should result
in extended boiler life.
The blowdown schedule should be based on the min-
eral content of the water and whether the boiler is
used in a closed or open system (closed systems utilize
a condensate receiver package). For softer water con-
ditions, or for closed systems, weekly blowdown may
be sufficient. In open systems, with hard water condi-
tions, daily blowdown is recommended.
Water treatment does not eliminate the need for
blow-down.
9.2 Manual Blowdown Proc dur
9.2.1 De-energize the boiler.
9.2.2 Close the water inlet valve.
9.2.3 It is best to allow the pressure to drop to 15-20
PSIG before opening the blowdown valve.
9.2.4 Open the main drain blowdown valve.
9.2.5 Allow the boiler to drain for 10-15 seconds then
close the valve.
9.2.6 Open the level control column drain valve for 10-15
seconds.(NOTE: Periodically, reverse the sequence of
5.2.5 and 5.2.6. During inspection, if excessive scale
inside the vessel is evident, it is best to increase
blowdown frequency, not time.)
9.2.7 Open the water inlet valve.
9.2.8 Restore the boiler “ON-OFF” switch to the “ON ”
position.
9.3 Automatic Blowdown (optional)
The automatic blowdown package includes/features the
following:
24 hour, 7 day electronic clock
Adjustable cycle time (minimum 1 second)
Electric solenoid type automatic drain valve com-
plete with strainer or motorized ball valve (no
strainer).
Standard bypass loop on drain.
9.3.1 The blowdown time and duration is achieved
through adjustment of the type 42/2 dual channel
timer located in the boiler control enclosure. Refer
to the timer manual included with this package for
instructions on setting. You must first set the cor-
rect time and date followed by the time and dura-
tion of each blowdown cycle.
9.3.2 As with manual blowdown, a 15-20 second blow-down
duration should suffice. In systems using a motorized ball
valve add 10 seconds to the set cycle time to allow the
valve to open.
9.3.3 Open any valves in series with the automatic valve and
close any valves that are in parallel.
9.4 El ctrical V rification
To avoid risk of electrical shock, disconnect the
power supply to the boiler prior to and during electrical servicing.
9.4.1 All electrical connections in the power circuit should be
inspected and re-tightened periodically.
9.4.2 Every 4 months, the following verifications are to be made:
a. Check the operation of the low water cutoff control by
using the "push-to-test” button. When depressed, all ener-
gized heating circuits should immediately go off until the
button is released.
b. Remove, clean and reinstall all controller electrodes.
To ensure that the wires are reconnected to the correct ter-
minals, we recommend that the first electrode be removed,
cleaned and reinstalled; then the second and so on.
c. If it is suspected that the boiler steam output has dropped,
you may wish to verify that all heating elements are func-
tioning.
d. Check all fuses for continuity.
e. Visually inspect all conductors and contactors for signs of
overheating.
f. Ensure that all electrical connections are tight.
9.5 M chanical V rification
9.5.1 Scale Build-Up
Even with regular blowdown, boiler systems involving the
heating of large volumes of water may result in a significant
amount of solids being deposited within the shell and on the
heating elements. Regularly inspect the heating elements
through the manhole or handhole. Maintenance frequency
will depend on water conditions and operating conditions.
9.5.2 Heavy scale buildup on the heating elements results in
higher sheath running temperatures resulting in lower heater
life and premature failure. This type of failure is not covered
under your warranty. Ensure that the following procedure is
completed after the first month of operation and as required
thereafter.
a. If the heating elements are heavily scaled (1⁄16”or more
buildup), all elements require removal and cleaning. Refer to
section 9.6.
b. Make sure the safety valve is in good working order.
c. Clean the upper and lower piping of the level control assembly.
CAUTION
!
CAUTION
!

Sussman Boilers
Installation, Op ration & Maint nanc Manual
9. Maint nanc (cont.)
10. Drawings & Lit ratur
9.6 Cl aning Proc dur s for H avy Scal Buildup
9.6.1 Mechanical
Disconnect power to the boiler by opening the main disconnect.
Remove the flange heaters from the boiler. NOTE: The heater
gaskets may not be reusable and replacement gaskets should be
on hand. Remember to mark the electrical wire connections and
nozzle location for each heater.
Remove scale by scraping with wire brush, dull metal blade, or
by light sandblasting. If sandblasting, take care not to damage
the element sheath since normal wall thickness is .030” to
.035”(0.8mm).
Reinstall the heaters, preferably after fitting with new gaskets.
Ensure that all plumbing connections are water tight.
Reconnect the main power and restart the boiler.
Check once more for leaks when the boiler is up to pressure and
correct if necessary.
9.6.2 Chemical
Due to regional variations in water content, Sussman cannot rec-
ommend the use of chemicals. Consult a specialist in boiler water
treatment for any questions on this subject.
Refer to section 10.1 drawings to verify the exact part number for the spare parts you require.
Have all information on the front of this manual available when ordering any spare parts.
Description Manufacturer Catalog No.
Fuse Gould ATM 3/4 A4J25
ATM 2 A4J30
ATM 6 A4J35
ATM 10 A4J40
TRM1 A4J45
A4J15 A4J50
A4J20 A4J60
Magnetic Furnas 42CF35AF
Contactor 42DF35AF
42CF35AJ
Cutler-Hammer C25DNF340A
Relay FEME RCPTFU8 2D10 24V
RCPTFU113D10 24V
RCPTFU82D10 110V
RCPTFU113D10 110V
Level Control Electromatic SV210
Relay SV220
S195
Electrode Holder Warrick 3B1A
Electrode Warrick 1/4” brass (specify length)
Pilot Light Leecraft 32RN2111T (RED)
32RN2112T (GREEN)
32RN2113T (AMBER)
32RN2115T (WHITE)
32RG1811 (RED)
32RG182115T (white)
ZA2BV03/ZA2BV6/SP122 (GREEN)
ZA2BV01/ZA2BV6/SP122 (WHITE)
ZA2BV04/ZA2BV6/SP122 (RED)
ZA2BV05/ZA2BV6/SP122 (AMBER)
10.1 Drawings
The following mechanical and electrical drawings have
been included in this manual:


Boiler Assembly


Electrical Schematic
10.2 Lit ratur
The following manufacturers’ literature, as required, may
be included with this manual.
L404A-D,F; L604A,L,M Pressuretrol®Controller Honeywell
91A,B,D Proportioning Pressure Controller Honeywell
digi16, digi32 or digi42 Electronic Time Switch Grasslin
807D Pump Instruction
11. Spar Parts
10
Description Manufacturer Catalog No.
Step Controller
Johnson Controls R26AA-9200 4 step
R26AB-9200 6 step
R26AC-9200 8 step
Consulab 710-4Y-4 step 710-10Y-10 step
710-6Y-6 step 710-20Y-20 step
710-8Y-8 step 710-32Y-32 step
Pressure Honeywell L91B1035
Controller L91b1050
L404A1586
L404A1594
L404A1602
High Limit Honeywell L404C1113
Pressure L404C11475
Controller L404A1602
Flange Sussman CXI10063-55 15kW
Heaters CXI10063-60 18kW
(see Note 1) CXI10063-65 12kW
CXI10063-75 12kW
CXI10063-80 9kW
CXI10063-100 9kW
CXI10168-10 135kW
CXI10168-17 90kW
CXI10168-18 135kW
CXI10220-07 90kW
CXI10220-10 45kW
CXI10221-03 180kW
CXI10221-04 135kW
CXI10221-05 90kW
CXI10221-06 45kW
CXI10221-09 180kW
CXI10221-10 135kW
CXI10221-11 90kW
CXI10221-12 45kW
NOTES:
1. To order, specify quantity and catalog number of the part.
2. You must also specify flange heater voltage rating and phase.
3. All parts are shipped F.O.B. factory, freight extra.

Sussman Boilers
Installation, Op ration & Maint nanc Manual
12. Troubl shooting Guid
13.0 Warranty
11
B iler Pr blems
“System On”pilot light
does not illuminate
Low water condition
High limit condition
Heater fuses fail
Main fuses blown
Does not fill
Leaks water
Reset button trips
Does not heat
Will not reach
set temperature
Pressure relief
valve opens
Heaters continually
burn out
Does not maintain
temperature
Ch ck Points 12345678910 11 12 13
Pilot Light Burnt Out x
Faulty On-Off Switch xxx
Breaker Reset xxx
Main Power Switch xxx
Main Power Fusing xxx
Flange Heater Failed xx x x x
Magnetic Contactor xx xx x
Electrodes & Relay xx xx x
Pressure Controller xxxxx
Staging Switch xxxxx
Pressure Relief Valve xxxx
Pressure Gauge xx
Outlet Valve Closed xx
Air in System xx x x
High Limit Controller xxxxx
Scale Build-up xx
Heater Fuse xxxx
Control Transformer xxx
Control Circuit Wiring xx xx
Power Circuit Wiring xxx x
Supply Voltage Too High xxx x
Supply Voltage Too Low xxx
System Undersized xx
Leak at Heater Flange xxx
Piping Leak xxx
Inllet Valve Closed xx x
12.1 Fail d H at rs
Sussman boiler flange heaters are of the highest quality. When properly maintained,
they should provide many years of service.
All heaters undergo a series of rigorous mechanical and electrical inspections. In the
event that a heater fails, it is likely that the cause is low water or scale build-up.
Multiple coincident failures are almost certainly the result of a low water conditions.
Keep in mind that if new heaters are installed in a boiler where the cause of failure
has not been corrected, they too may fail.
12.2 Troubl Shooting Guid
Sussman offers a Limited Warranty for this equipment, a copy of which has been included as part ofthe important documents
included with the boiler. Any questions should be referred to Sussman.