Sussman ES Installation, Operation And Maintenance Manual
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Table of Contents
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Model No. ______________________
Boiler Serial No. _________________
National Board No. ______________
Safety Valve Set Pressure________
Power Circuit Voltage ____________
Control Circuit Voltage ___________
Amps _____ Phase _____ HZ ______
IMPORTANT: This data file contains the National
Board Registration Certificate approving your boiler.
It must be kept near the boiler at all times.
Products covered by this manual:
Series
KW Range
Steam Rate*
______________________________________________________________________
ES, HU
12-180
36-542 lbs/hr 1.2-18.4 0-100 psig
SSB
12-180
36-542 lbs/hr 1.2-18.4 0-100 psig
*Steam Rate- Steam @ 212 F with 50 F feed water
SSB Boilers have Stainless Steel all wetted metal parts. SSB
boilers shall be operated using only deionized water, having
a maximum conductance of 1 microSiemen per cm
(1 µS/cm) [minimum specific resistivity of 1 megohm per cm
(1ΜΩ/cm)].
ES and HU boilers are of Carbon Steel construction.
See page 23 for Water Quality Information.
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:
states a hazard which may
cause serious injury or
death if precautions are not followed.
PSIG
Max
BHP
Design Pres.
Work Pres.
85 psig
85 psig
age may occur if you do not follow instructions.
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
www.sussmanboilers.com
ES, SSB & HU
:
TABLE OF CONTENTS
Component Identification . . . . . . . . . . . . . . . . . 2
Dimensional & Clearing Specifications. . . . . . . . . 3
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Installation
Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pre-Operation Check . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Controls, Operation & Testing . . . . . . . 10
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Timing Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . 14
Condensate Return Systems . . . . . . . . . . . . . . . . 16
Blowdown Separator Tanks . . . . . . . . . . . . . . . . . 17
Specification Charts . . . . . . . . . . . . . . . . . . . . . . . 18
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gauge Glass Installation . . . . . . . . . . . . . . . . . 20-21
Element Replacement . . . . . . . . . . . . . . . . . . . . . . 22
for Carbon Steel Boilers . . . . . . . . . . . . . . . . . . 23
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
signals a situation where
minor injury or product dam-
. . . . . . . . . . . . . . . . 14
. . . . . . . . . . . . . 14
. . . . . . . . . . . . . 14
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IMPORTANT NOTE:
This highlights information that is especial-
ly relevant to a problem-free installation.
Made in USA
PUR 101137
2/07
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Summary of Contents for Sussman ES
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Page 1: Table Of Contents
Sizing ........19 ES and HU boilers are of Carbon Steel construction. -
Page 2: Sussman Boilers
Steam Outlet 6-1/4" 10" 8-1/4" 9" __________________________________________________________________ Steam Outlet 10-1/4" 17" 17-1/4" 18-1/4" _________________________________________________ ES 135–180; HU 410–550 61" 30" 36" 1/2”NPT 2” NPT __________________________________________________________________ M/M Drain Valve 5" 12" 17" 16-3/4" SSB 12–18 36" 20" 28" 1/2”NPT 1/2”NPT _________________________________________________ __________________________________________________________________ M/M Drain Valve 6-1/2"... -
Page 3: Dimensional & Clearing Specifications
Sussman Boilers Installation, Operation & Maintenance Manual Dimensional & Clearance Specifications Pressure Operating High Limit Gauge Steam Outlet Pressure Pressure Control Control Safety Valve On/Off Switch Gauge Glass Assembly Height MM 150 Liquid Level Control (see note 3) Water Feed Inlet... -
Page 4: Wiring Diagrams
Detailed ES81017/81017MR auxiliary low water cut off wiring. d. Detailed SSB auxiliary low water cut off wiring. e. ES81600 Auto blowdown wiring diagram. f. Detailed sequencer package wiring diagram. Wiring Diagram Control Circuit ES and SSB Electric Boilers (Basic Control Circuit) 120V 1PH INPUT FIELD WIRING CONTROL... - Page 5 1. Power Terminal Block only on boilers with two or more contactors 2. Power Fuses only on boilers rated 20 amperes and larger. 3. See Parts List for contactor and heating element information. ES Electric Boilers with Manual Reset Auxiliary Low Water Cutoff 120V 1PH INPUT...
- Page 6 OPERATING LIQUID PRESSURE PRESSURE LEVEL CONTROL CONTROL CONTROL PROPORTIONING PRESSURE CONTROL 135 OHM CONTACTORS SEQUENCER ES Electric Boiler with Auxiliary Low Water Cutoff 120V 1PH INPUT CONTROL TERMINAL FIELD WIRING BLOCK FACTORY WIRING ON-OFF SWITCH PILOT SOLENOID VALVE LIGHT PUMP MOTOR...
- Page 7 Sussman Boilers Installation, Operation & Maintenance Manual Wiring Diagram Control Circuit ES and SSB Electric Boilers with Automatic Blowdown System 120V 1PH FIELD WIRING INPUT FACTORY WIRING CONTROL TERMINAL BLOCK PILOT LIGHT 7-DAY 24-HR OPEN TIMER CLOSE ES81600 MOTORIZED AUTOMATIC...
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Page 8: Piping
Sussman Boilers Installation, Operation & Maintenance Manual Wiring Diagram Control Circuit SSB Electric Boilers with Manual Reset, Auxiliary Low Water Cutoff 120V 1PH INPUT FIELD WIRING CONTROL FACTORY WIRING TERMINAL BLOCK SOLENOID VALVE ON-OFF SWITCH PILOT LIGHT RELAY HIGH LIMIT... -
Page 9: Wiring
Sussman Boilers Installation, Operation & Maintenance Manual Wiring 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 of the boiler. -
Page 10: Pre-Operation Check
Sussman Boilers Installation, Operation & Maintenance Manual Pre-Operation Check (All Boilers) LWCO/PUMP CONTROL OPERATION AND TESTING Boilers equipped with an auxiliary low water cut-off 1. All valves for incoming water supply are to be fully opened. Main disconnect switch is to be in the "on" position. Boiler main control with a manual re-set button (required as switch is to be in the "on"... -
Page 11: Operation
Sussman Boilers Installation, Operation & Maintenance Manual Operation With main disconnect “OFF” 6. Boiler steam pressure will gradually increase to the tighten all electrical connections operating pressure control set point, at which time before energizing boiler to prevent arcing, car- the contactor(s) will de-energize. -
Page 12: Timing Switch
24-Hour and 7-Day Time Switches PROGRAMMING F or electric steam boilers equipped with Automatic Blowdown Systems ES 81600, refer to the following instructions for time clock operation and settings. Timer settings for blowdown operation are at the discretion of the owner/operator. -
Page 13: Maintenance
Sussman Boilers Installation, Operation & Maintenance Manual Maintenance HAZARD OF ELECTRIC SHOCK. 5. A monthly inspection should be made of the internal DISCONNECT ALL ELECTRICAL wiring. Open the access door and check all electrical POWER BEFORE WORKING ON BOILER. connections for tightness. Replace any wires that show signs of damage. -
Page 14: Optional Equipment
Optional Equipment AUXILIARY LOW WATER CUT OFF • For model ES & HU boilers P/N ES81017 & ES81017MR (w/ manual reset). • For model SSB boilers p/n SSB81017 & SSB81017MR (w/ manual reset). Senses water level electronically using a resistance probe. When a low water condition is detected, the contactor control voltage circuit is interrupted and the heating elements are de-energized. -
Page 15: Vacuum Breaker Systems
Optional Equipment (cont) VACUUM BREAKER SYSTEMS • For model ES boilers P/N ES89369 • For model SSB boilers P/N SSB89369 A vacuum breaker will prevent a boiler from flooding as a result of the steam condensing internally and creating a vacuum after boiler shutdown. -
Page 16: Condensate Return Systems
Sussman Boilers Installation, Operation & Maintenance Manual Condensate Return Systems Models 38083V & 38084V " DIA COVER PLATE EASY ACCESS FOR MAINTENANCE VENT SAFETY BAR " VENT WITH SAFETY BAR CONDENSATE RETURN FLASH TUBE VENT (label) FLOAT VALVE COLD WATER INLET 39010-F OVERFLOW OUTLET 1"... -
Page 17: Blowdown Separator Tanks
4" 2" 18" 54" The Sussman Separator design incorporates a water Maximum Boiler Working Pressure: 250 psi seal at the outlet which permits the operator to Maximum Blowdown Separator Pressure: 65 psi introduce cold water from the bottom to mix with... -
Page 18: Specification Charts
Sussman Boilers Installation, Operation & Maintenance Manual Steam Gauge Specifications Pressure/ Temperature __________________________________________ Chart ________________ Boiler Lbs/Hr 3-Ph __________________________________________ Model No. KW Rating Steam** Volts*** Amps Gauge Temperature Pressure F˚ C˚ ________________ PSIG ES-12* 1.22 36.2 __________________________________________ ________________________ ________________________ ES-18* 1.84... -
Page 19: Sizing
Sussman Boilers Installation, Operation & Maintenance Manual Sizing Use the following Table to determine KW Boiler rating when steam load and feedwater temperatures are known. ___________________________________________________________________ Feed Water ___________________________________________________________________ ( F˚) .3347 .3355 .3375 .3388 .3406 .3422 .3431 .3447 .3458 .3464... -
Page 20: Gauge Glass Installation
Sussman Boilers Installation, Operation & Maintenance Manual Gauge Glass Installation IMPORTANT NOTE: Read all warnings and instruc- tions before performing installation or maintenance. Top Gauge Safety glasses and gloves should be worn at all times Fitting when working with or examining water gauge glass and connections. - Page 21 Sussman Boilers Installation, Operation & Maintenance Manual Gauge Glass Installation - Use and Care DO NOTs DO NOT use glass if it contains any scratches, chips, or any other visible signs of damage. DO NOT reuse any tubular glass or glass packings.
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Page 22: Element Replacement
Sussman Boilers Installation, Operation & Maintenance Manual Element Replacement READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK Before Installing your new elements be sure the McDonnell Miller low water cut-off and aux. low Boiler with 1” Steam Equalizing Pipe water cutoff (if supplied) is operating properly. The float chamber and... -
Page 23: Water Quality Information
Sussman Boilers Installation, Operation & Maintenance Manual Water Quality Information for Carbon Steel Boilers FOR OPTIMUM RESULTS, THE FEEDWATER SUPPLY SHOULD BE TESTED PRIOR TO INITIAL STARTUP, IF THE MINERAL CONTENT EXCEEDS THE FOLLOWING RECOMMENDED LIMITS, VARIOUS EXTERNAL TREATMENT PROCESSES (WATER SOFTENER, REVERSE OSMOSIS, ETC,) MAY BE USED TO CORRECT THE PROBLEM. -
Page 24: Warranty
Limited Warranty THIS WARRANTY SUPERCEDES ALL PRIOR WARRANTY COVERAGE. Sussman-Automatic Corporation hereby extends to the original purchaser of its Industrial Steam and Hot Water Boilers, Steam Superheaters and Heat Exchanger products (“Boiler Products”) a warranty against defects in materials and workman- ship for the period indicated below.
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