Rev 1 9/19 A Division of Sussman-Automatic Corporation 43-20 34th Street, Long Island City, NY 11101 • (718) 937-4500 1-800-238-3535 • Fax: (718) 937-4676 • email: seb@sussmancorp.com...
Sussman Boilers Installation, Operation & Maintenance Manual 1. Scope 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. 2. Operating Principles and Specifications 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 ...
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Sussman Boilers Installation, Operation & Maintenance Manual 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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Sussman Boilers Installation, Operation & Maintenance Manual 2. Specifications (cont.) 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 ...
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Sussman Boilers Installation, Operation & Maintenance Manual 2. Specifications (cont.) 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 ...
Sussman Boilers Installation, Operation & Maintenance Manual 3. Installation 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. ...
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Sussman Boilers Installation, Operation & Maintenance Manual 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 ...
Sussman Boilers Installation, Operation & Maintenance Manual 5. With main power off, make sure all wiring terminations are tight to avoid arcing, carbonizing or overheating of contacts. 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. 4.Start-Up and Operation The following procedures should be performed in sequence to eliminate problems on start‐up. START‐UP It is presumed that all electrical wiring and plumbing has been checked prior to this start-up procedure.
Sussman Boilers Installation, Operation & Maintenance Manual fills, the light should shut off and the elements will energize. 10. Set the temperature controller to the desired temperature setting by pressing the MENU button on the controller. 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. 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. 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. 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. ...
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