LG Electronics LG Lifes Good Boiler 10 User Manual

User Manual

& Installation Instructions

LG-10 thru LG-30

IMPORTANT – READ ALL INSTRUCTIONS BEFORE OPERATING

All steam boilers are built in accordance with ASME miniature boiler code.

NOTE: It is the responsibility of the installer to conform to any state or local codes. If further

inspection, following modification by installer, is required under state or local codes, that is

the responsibility of the local installer.

www.electrosteam.com

rev. 12282009

LG-10 thru LG-30 - User Manual

Electro-Steam Generator Corp.

TABLE OF CONTENTS

1.) INSTALLATION INSTRUCTIONS .................................................................... 4

2.) OPERATION & SEQUENCE OF EVENTS ..................................................... 5

3.) CLEANING & MAINTENANCE ................................................................... 6-14

3.1) MANUAL “BLOW DOWN” ..................................................................................... 6

3.2) CLEANING WATER LEVEL PROBES .............................................................. 6-7

3.3) CLEANING OR REPLACING HEATERS .............................................................. 8

3.4) REPLACING GLASS GAUGE AND RUBBER WASHERS .............................. 8-9

3.4.1) BRASS SIGHT GLASS (STANDARD) .................................................................. 8

3.4.1) BRASS SIGHT GLASS (SEISMIC) ....................................................................... 9

3.5) CHAMBER CLEANING & CHEMICAL TREATMENT ............................... 10-11

3.6) PRESSURE CONTROL DATA SHEET ................................................................ 12

3.7) SETTING THE PRESSURE CONTROLS ....................................................... 13-14

4.) CALCULATIONS & DATA SHEETS ........................................................ 15-17

4.1) HEATER POWER & VOLTAGE RATINGS ........................................................ 15

4.2) TOTAL POWER RATING CALCULATIONS ..................................................... 15

4.3) AMPERAGE CALCULATIONS ............................................................................ 16

4.4) ACTUAL POWER RATING CALCULATIONS .................................................. 17

4.5) STEAM CAPACITY CALCULATIONS ............................................................... 17

5.) DRAWINGS & WIRING SCHEMATICS ................................................. 18-32

5.1) PARTS LEGENDS ............................................................................................ 18-21

5.1.1) LG (LOW PRESSURE) (0-15PSI) ........................................................................ 18

5.1.2) LG (LOW PRESSURE) (MAFD) (0-15PSI) ........................................................... 19

5.1.3) LG (HIGH PRESSURE) (0-30, 0-100PSI) ..............................................................20

5.1.4) LG (HIGH PRESSURE) (MAFD) (0-30, 0-100PSI) ................................................. 21

5.2) INSTALLATION DATA SHEETS .................................................................. 22-25

5.2.1) LG (LOW PRESSURE) (0-15PSI) ........................................................................ 22

5.2.2) LG (LOW PRESSURE) (MAFD) (0-15PSI) ........................................................... 23

5.2.3) LG (HIGH PRESSURE) (0-30, 0-100PSI) ..............................................................24

5.2.4) LG (HIGH PRESSURE) (MAFD) (0-30, 0-100PSI) ................................................. 25

5.3) CONTROL WIRING SCHEMATICS .............................................................. 26-29

5.3.1) LG (LOW PRESSURE) (0-15PSI) ........................................................................ 26

5.3.2) LG (LOW PRESSURE) (MAFD) (0-15PSI) ........................................................... 27

5.3.3) LG (HIGH PRESSURE) (0-30, 0-100PSI) ..............................................................28

5.3.4) LG (HIGH PRESSURE) (MAFD) (0-30, 0-100PSI) ................................................. 29

5.4) HEATER WIRING SCHEMATICS ................................................................. 30-32

5.4.1) LG (10-30KW) (THREE PHASE) ........................................................................ 30

5.4.2) LG (10-30KW) (SINGLE PHASE) ....................................................................... 31

5.4.3) LG (10-30KW) (THREE AND SINGLE PHASE) (550-600V) ................................... 32

6.) TERMS & CONDITIONS ..................................................................................... 33

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Electro-Steam Generator Corp.

1.) INSTALLATION INSTRUCTIONS

LITTLE GIANT “LG-SERIES”

The Electro-Steam Generator design consists essentially of a high pressure chamber filled with water

that is heated by one or more submerged resistance type electric heating elements. Automatic controls

are provided to maintain the pre-set operating pressure and water level. Safety features include:

automatic low-water cutoff (manual low-water reset optional), dual pressure controls, safety valve, and

visible water level gauge. All of our generators are built in accordance with A.S.M.E. Miniature Boiler

Code and are individually inspected and stamped by an Authorized National Board Insurance Inspector.

IMPORTANT – READ ALL INSTRUCTIONS BEFORE OPERATING

Important – Set unit perfectly level, and as close as possible to the steam vessel or appliance it

will operate. For generator measurements, refer to Installation Data Drawing attached. For

interpretation of numbered items, refer to Parts Legend Drawing attached. NOTE: Ambient

temperature around this unit must not exceed 105°F.

CONNECTIONS:

Periodically check all plumbing and electrical connections for tightness; this should also be done

before initial start-up.

ELECTRICAL:

This generator must be connected to a disconnect switch protected by fuses or

circuit breakers with the proper size wire by a licensed electrician in

accordance with N.E.C. and your local codes – Voltage, KW, and Phase

requirement are marked on the nameplate.

WATER SUPPLY:

Connect city water line to Y-Strainer (#6).

Purity: NOT to exceed 26,000 OHMS per CM

Temperature Range: 32°F – 140°F or 0°C – 60°C.

Pressure Range: 20PSI – 150PSI.

*CAUTION: The Pump (#8) requires clean tap water. If the water is not free of foreign matter, a 5

micron cartridge filter should be installed in the water supply line.

STEAM OUTLET:

Connect Steam Outlet Valve (#16) to piece of equipment, vessel, room, or area to be operated by

the Electro Steam Generator.

SAFETY VALVE & DRAIN:

Separately route the Safety Valve (#18) & Drain (#23) to a high temperature drain *NO PVC.

Discharging pipe of the Safety Valve (#18) should never be smaller than the valve outlet and

should be rigidly supported, placing no weight on the safety valve itself. If equipped with

Motorized Auto-Flush & Drain “MAFD” (#20), it should be routed with the Drain (#23).

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2.) OPERATION & SEQUENCE OF EVENTS

IMPORTANT – READ INSTALLATION INSTRUCTIONS BEFORE OPERATING

1. Turn on water supply from the source to the Generator.

2. OPEN all valves on the Generator except for the Manual Drain (#19).

3. Place main disconnect switch in ON position.

4. Place ON/OFF Switch (#2) in ON position.

The Water Solenoid (#7) [and Pump (#8), if high pressure] will engage and the

chamber will begin to fill with water. As the water level rises, it will make contact

with the (G OR D) and (A) probes, indicating the heaters are safely submerged. At

this time the contactor(s) will engage, supplying power to the heaters, causing

steam pressure to accumulate.

The chamber will continue to fill with water until 1 second after the water makes

contact with the (C) probe, causing the Water Solenoid (#7) [and Pump (#8), if

high pressure] to turn off.

If the contactor(s) still have not engaged at this time, you may need to press the

Safety Reset (#13) on the “Safety” Pressure Control (#12). If your generator is

equipped with a Manual Low-Water Reset (MLWR) (#3), it must be pressed at

this time to engage the contactor(s). If your generator is equipped with a Motorized

Auto-Flush & Drain (MAFD) (#20), you must wait until it closes before the

contactor(s) will engage. (approximately 3 minutes)

Steam pressure will continue to rise until is reaches its set operating pressure. This

may take up to 25 minutes. At this time, the “Control” Pressure Control (#12)

will cause the contactor(s) to disengage. The pressure will drop approximately 2-8

PSI until the “Control” Pressure Control (#12) causes the contactor(s) to

reengage, causing the pressure to rise again. The contactor(s) will continue to cycle

on and off during operation.

5. The Generator is now fully operational and will produce steam until it is turned off.

As steam is exhausted, the water level will drop until 3 seconds after it breaks

contact with the (C) probe. At this time, the Water Solenoid (#7) [and Pump (#8),

if high pressure] will engage and the chamber will again fill with water. The

chamber will continue filling until 1 second after the water makes contact with the

continue to cycle on and off during operation.

6. To shut off the Generator, place ON/OFF Switch (#2) in OFF position. Pressure will

drop naturally as the chamber cools, or the Generator may be drained manually through

Manual Drain (#19). (See Manual Blow Down 3.1)

WARNING – HOT WATER and STEAM under HIGH PRESSURE can lift drain pipes

right off the ground and cause SERIOUS INJURY. Make sure drain pipe is SECURE

and CANNOT move. The drain must be directed into a HIGH TEMPERATURE drain

(NO PVC) or outside.

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3.) CLEANING & MAINTENANCE

The following cleaning procedures are HIGHLY RECOMMENDED in order to keep your

Steam Generator in the best operating condition at all times.

3.1) MANUAL “BLOW DOWN”

A Manual “Blow Down” is an easy way to GREATLY extend the life of your Steam

Generator. Using a Motorized Auto-Flush & Drain (MAFD) of course helps, but is not a “Cure

all”. The following is the LEAST amount of times recommended to blow down your generator:

NORMAL WATER AREAS – Should be done ONCE A WEEK.

BAD WATER AREAS – Should be done ONCE A DAY.

NORMAL WATER AREAS WITH MAFD – Should be done TWICE A MONTH.

BAD WATER AREAS WITH MAFD – Should be done ONCE A WEEK.

NOTE: The best time to Blow Down your generator is after it has been running for some time,

while it is still hot.

1. Place Toggle Switch (#2) and Main Disconnect Box in OFF position.

2. Allow pressure to drop between 10 and 20 PSI.

3. Open Manual Drain (#19) slowly, allowing HOT WATER and STEAM to blow out

into the drain, cleaning out the generator.

NOTE: Blow Down your generator at any pressure you feel comfortable with. 10 to 20 PSI is

only a recommendation. You may go higher or lower, but higher is always better.

WARNING – HOT WATER and STEAM under HIGH PRESSURE can lift drain pipes right

off the ground and cause SERIOUS INJURY. Make sure drain pipe is SECURE and

CANNOT move. The drain must be directed into a HIGH TEMPERATURE drain (NO

PVC).

3.2) CLEANING WATER LEVEL PROBES

Water Level Probes are the heart of your generator. Almost all steam generator malfunctions

are caused by dirty water level probes. CLEANING your PROBES is by far the MOST

IMPORTANT maintenance step to keep your generator running properly. The following is the

LEAST amount of times recommended to clean your probes:

NORMAL WATER AREAS – Should be done TWICE A YEAR.

BAD WATER AREAS – Should be done 3-4 TIMES A YEAR.

NOTE: The best time to clean your probes is before you turn your generator on, while it is still

cool.

1. Place Toggle Switch (#2) and Main Disconnect Box in OFF position.

2. Make sure generator is cool and the Pressure Gauge (#15) reads 0 PSI.

3. Remove cover plate, exposing the Water Level Probes (#5).

4. Use 5/16” Socket to remove wires from probes.

5. Use 13/16” Spark Plug Socket to remove probes from chamber.

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3.2) CLEANING WATER LEVEL PROBES (Continued)

6. Clean probes to remove rust and scaling.

NOTE: To clean probes you may use wire wheel, wire brush, steal wool, or Scotch-Brite.

(Wire wheel works the best) You may also want to try some sort of chemical like CLR

remover or LIME-A-WAY.

7. Reinstall probes assuring each probe’s length is assigned to its proper letter.

8. Reconnect wires to probes assuring each color is also assigned to its proper letter.

NOTE: DO NOT make wires too tight. Just tighten enough to make contact. Over

tightening can cause probe plugs to pull apart over time.

9. Reinstall cover plate.

Water Level Probe Specifications:

Letter Assignment on Chamber

Water Level Probe Length

Wire Color Assignment

4 ½”

4 ¾”

3 ¾”

D/G

4 ¾”

RED Not Used BLACK GREEN

Assignment on Dual Function Board LLCO Not Used

NOTE: The (B) Probe is not used. It is a spare probe that can be cut and used to replace any one

of the other probes.

WARNING – There MUST be NO PRESSURE in the chamber when removing probes. If you

must change probes while chamber is HOT, make sure the steam out and drain valves are open

to assure chamber will remain depressurized. DO NOT touch probes with your bare hands

while HOT, and be cautious of escaping steam from probe holes while probes are removed.

3.3) CLEANING OR REPLACING HEATERS

Heaters are located inside the control panel (#1) below the insulation barrier, bolted into the

chamber. If (3.5) Chamber Chemical/Acid Treatments are not regularly done, heaters must be

taken out at least ONCE A YEAR, cleaned with wire brush and reinstalled using a new gasket.

If you are replacing or cleaning your heater elements:

1. Place Toggle Switch (#2) and Main Disconnect Box in OFF position.

2. Make sure generator is cool and the Pressure Gauge (#15) reads 0 PSI.

3. Remove heater wires from heater(s), using an 11/32” or 3/8” Socket.

4. Unbolt and remove heater(s) using a 1/2” Socket.

NOTE: Heater(s) may be difficult to get out; you may need to use some sort of pry bar to

get them loose.

5. Clean heater(s) with wire brush. If replacing, dispose of old heater(s).

6. Reinstall heater(s) with new gasket(s).

7. Attach heater wires assuring proper wiring. *Refer to Heater Wiring Schematics

attached*

NOTE: If you are replacing a heater because of a heater failure, you must also clean the probes

and clean out the chamber, or you may have another heater failure within 48 hours.

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3.4) REPLACING GLASS GAUGE & RUBBER WASHERS OR

GLASS PACKINGS

The Sight Glass (#10) gives the operator the ability to easily monitor the actual water level

inside the chamber. If the Sight Glass (#10) gets clogged or is no longer functional, it can be very

difficult to troubleshoot a problem.

3.4.1) BRASS SIGHT GLASS (STANDARD)

GLASS GAUGE and RUBBER WASHERS

MUST be replaced EVERY SIX MONTHS

INSTALLATION:

Only properly trained personnel should install and

maintain water gauge glass and connections.

Remember to wear safety gloves and glasses

during installation. Before installing, make sure

all parts are free of chips and debris.

1. Uninstall GUARD RODS, GLASS GAUGE, and

RUBBER WASHERS. (You may need to rotate one of the

GAUGE FITTINGS to remove GLASS GAUGE)

2. Slip a new RUBBER WASHER on the new GLASS

GAUGE about an inch from the bottom.

3. Now slip the following items through the top of GLASS

GAUGE in the following order:

• FRICTION WASHER

• GLASS PACKING NUT (facing down)

• GLASS PACKING NUT (facing up)

• FRICTION WASHER

• RUBBER WASHER (inch down from top)

4. Gently insert GLASS GAUGE into GAUGE FITTINGS.

You may need to rotate GAUGE FITTINGS until

vertically aligned, after GLASS GAUGE is in.

5. Carefully raise GLASS GAUGE about 1/16” from bottom

and slide lower RUBBER WASHER down until it makes

contact with the BOTTOM GAUGE FITTING. (DO NOT

allow GLASS GAUGE to remain in contact with any metal)

6. Carefully slide upper RUBBER WASHER up as far as

possible.

7. Hand tighten both GLASS PACKING NUTS, then tighten

1/2 turn more by wrench. Tighten only enough to prevent

leakage. DO NOT OVER TIGHTEN! If any leakage

should occur, tighten slightly, a quarter turn at a time,

checking for leakage after each turn.

8. Reinstall GUARD RODS.

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3.4) REPLACING GLASS GAUGE & RUBBER WASHERS OR

GLASS PACKINGS (Continued)

The Sight Glass (#10) gives the operator the ability to easily monitor the actual water level inside the

chamber. If the Sight Glass (#10) gets clogged or is no longer functional, it can be very difficult to

troubleshoot a problem.

3.4.2) BRASS SIGHT GLASS (SEISMIC)

GLASS GAUGE and GLASS PACKINGS MUST be

replaced EVERY SIX MONTHS

The Seismic Sight Glass is equipped with BALL

CHECKS in each GAUGE FITTING.

INSTALLATION:

Only properly trained personnel should install and

maintain water gauge glass and connections. Remember

to wear safety gloves and glasses during installation.

Before installing, make sure all parts are free of chips

and debris.

1. Uninstall GUARD RODS, GLASS GAUGE, and GLASS

PACKINGS. (You may need to rotate one of the GAUGE

FITTINGS to remove GLASS GAUGE)

2. Slip a new GLASS PACKINGS on the new GLASS

GAUGE about an inch from the bottom.

3. Now slip the following items through the top of GLASS

GAUGE in the following order:

• PACKING GLAND (facing down)

• GLASS PACKING NUT (facing down)

• GLASS PACKING NUT (facing up)

• PACKING GLAND (facing up)

• GLASS PACKINGS (inch down from top)

• PACKING WASHER

4. Gently insert GLASS GAUGE into GAUGE FITTINGS.

You may need to rotate GAUGE FITTINGS until

vertically aligned, after GLASS GAUGE is in.

5. Carefully raise GLASS GAUGE about 1/16” from bottom

and slide lower GLASS PACKINGS down until it makes

contact with the BOTTOM GAUGE FITTING. (DO NOT

allow GLASS GAUGE to remain in contact with any

metal)

6. Carefully slide upper GLASS PACKINGS up as far as

possible.

7. Hand tighten both GLASS PACKING NUTS, then tighten

1/2 turn more by wrench. Tighten only enough to prevent

leakage. DO NOT OVER TIGHTEN! If any leakage

should occur, tighten slightly, a quarter turn at a time,

checking for leakage after each turn.

8. Reinstall GUARD RODS.

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3.5) CHAMBER CHEMICAL/ACID TREATMENT

All Electric Steam Generator should be cleaned regularly. The following is the least amount of

times recommended to clean out your chamber:

NORMAL WATER AREAS – Should be done ONCE A YEAR.

BAD WATER AREAS – Should be done TWICE A YEAR.

If equipped with Motorized Auto-Flush & Drain “MAFD” (#20), locate the MAFD

TIMER/RELAY in the Control Panel (#1) and do steps 1-3 before the chamber treatment and

steps 4-5 after chamber treatment is done:

WARNING – Before opening Control Panel (#1), TO AVOID ELECTRICAL SHOCK, place

Main Disconnect Box and the Toggle Switch (#2) in the OFF position.

BEFORE:

1. Dial TIME ADJUSTMENT on MAFD

TIMER/RELAY all the way down to 15 seconds.

2. Make sure MAFD (#20) in the closed position.

3. Disconnect the orange wire from the normally open

(NO) terminal on the MAFD TIMER/RELAY.

AFTER:

4. Reconnect the orange wire to the normally open

(NO) terminal on the MAFD TIMER/RELAY.

5. Dial TIME ADJUSTMENT on MAFD

TIMER/RELAY up to the desired flush time (Most

commonly 3 minutes)

Chamber Treatment Instructions:

1. Turn on generator, allowing pressure to climb to 10 to 20 PSI on Pressure Gauge (#15),

and then shut off.

2. “Blow Down” Open Manual Drain (#19) slowly, allowing HOT WATER and STEAM

to blow out into the drain.

NOTE: You may Blow Down your generator at any pressure you feel comfortable with. 10

to 20 PSI is only a recommendation. You may go higher or lower, but higher is always

better.

WARNING – HOT WATER and STEAM under HIGH PRESSURE can lift drain pipes

right off the ground and cause SERIOUS INJURY. Make sure drain pipe is SECURE and

CANNOT move. The drain must be directed into a HIGH TEMPERATURE drain (NO

PVC).

3. Remove Safety Valve (#18).

WARNING – There MUST be NO PRESSURE in the chamber when removing the Safety

Valve (#18), make sure the steam out and drain are open to assure chamber will remain

depressurized. Be cautious of escaping steam from chamber while Safety Valve (#18) is

removed.

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3.5) CHAMBER CHEMICAL/ACID TREATMENT (Continued)

4. Close Manual Drain (#19) and Steam Out (#16); turn generator on until Sight Glass

(#10) shows that it is 1/2 full, and then shut off.

5. Insert funnel into coupling, where Safety Valve (#18) used to be.

6. Pour a 1/2 Gallon of hydrochloric acid (inhibited) solution (NON-FOOD

APPLICATIONS) into funnel very slowly, being careful of fumes and venting while

pouring.

NOTE: Solution can be obtained from any industrial chemical dealer.

FOR FOOD APPLICATIONS: Use FDA approved chemicals.

7. Remove funnel, reinstall Safety Valve (#18), and verify Steam Out (#16) is closed; let

solution set in generator for 1 HOUR.

8. Turn on generator, allowing pressure to climb to 5 PSI on Pressure Gauge (#15), and then

shut off.

9. Allow the pressure to drop to 0 PSI on Pressure Gauge (#15) naturally. DO NOT open

Steam Out (#16) or Manual Drain (#19) until pressure is down.

10. Remove Safety Valve (#18).

11. Reinsert funnel, and fill generator completely to the top with clean water; let stand for an

additional 1/2 HOUR.

NOTE: Turning on the generator will not completely fill it to the top. Filling must be done

manually through the safety valve coupling.

12. Open Manual Drain (#19) to drain generator.

13. Close Manual Drain (#19); refill generator completely to the top with clean water and

open Manual Drain (#19) to flush out generator completely.

14. Reinstall Safety Valve (#18) and close Manual Drain (#19).

15. Turn on generator, allowing pressure to climb to 10 to 20 PSI on Pressure Gauge (#15),

and then shut off.

16. “Blow Down” Open Manual Drain (#19) slowly, allowing HOT WATER and STEAM

to blow out into the drain.

NOTE: You may Blow Down your generator at any pressure you feel comfortable with. 10

to 20 PSI is only a recommendation. You may go higher or lower, but higher is always

better.

WARNING – HOT WATER and STEAM under HIGH PRESSURE can lift drain pipes

right off the ground and cause SERIOUS INJURY. Make sure drain pipe is SECURE and

CANNOT move. The drain must be directed into a HIGH TEMPERATURE drain (NO

PVC).

17. Your generator is now ready for normal use and operation.

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3.6) PRESSURE CONTROL DATA SHEET

DEFINITIONS:

“CONTROL” PRESSURE CONTROL – This pressure control should be the only one controlling

the operating pressure of the generator.

“SAFETY” PRESSURE CONTROL – This pressure control is only used if the “Control” fails. It

is always set higher than the “Control”; if the operating pressure is passed, The “Safety” will turn

the heaters off.

SAFETY RESET – This reset is tripped when the “Safety” turns the heaters off. It must be

manually pushed to turn the heaters back on. This lets the user know there was a problem. If it is

tripped, the “Control” most likely failed.

PRESSURE ADJUSTING DIAL – These dials adjust the set pressure at which each pressure

control will turn the heaters off.

DIFFERENTIAL ADJUSTING DIAL – This dial is only on the “Control”. When the “Control”

turns the heaters off, the amount of pressure that is dropped before it turns the heaters back on (the

differential) can be adjusted by this dial. This dial should never have to be adjusted, unless desired.

PRESSURE GAUGE – This tells the user what pressure is in the chamber. The pressure controls

are set to this gauge.

5 PSI PRESSURE CONTROL – (Only used with “MAFD” Motorized Auto-Flush & Drain) this

control prevents the MAFD from opening when there is more than 5 pounds off pressure in the

generator.

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3.7) SETTING THE PRESSURE CONTROLS

SETTING PRESSURE CONTROLS INSTUCTIONS:

WARNING – The pressure controls must be set while all circuits are live. TO AVOID

ELECTRICAL SHOCK, DO NOT TOUCH the wires or the terminals in which they

connect while setting the pressure controls.

NOTES:

Setting the pressure controls greatly relies on your ability to tell whether the contactor(s) are

turning the heaters on or off. You should be able to hear the contactor(s), located inside the

Control Box (#1), click on and off. Familiarize yourself with this sound.

The order in which the pressure controls must be set is the “SAFETY” and then the

“CONTROL”.

In order to set the “SAFETY” you must keep the “CONTROL” at a higher pressure setting

than the “SAFETY”

Once the “SAFETY” is set, then you can

lower the “CONTROL” to its correct setting.

To INCREASE the pressure setting, when

looking down on pressure control, using your

two index fingers, turn the PRESSURE

ADJUSTMENT DIAL CLOCKWISE,

causing the BLACK INDICATOR LINE to

move DOWN the scale.

To DECREASE the pressure setting, turn the

dial COUNTER CLOCKWISE, causing the

indicator line to move UP the scale.

SETTING INSTRUCTIONS:

1. Open the pressure control covers, as shown on page 12.

2. Adjust the PRESSURE ADJUSTMENT DIAL on the

“CONTROL” so that the BLACK INDICATOR LINE is

somewhere between ½ and ¾ of the way down from the top.

3. Adjust the PRESSURE ADJUSTMENT DIAL on the

“SAFETY” so that the BLACK INDICATOR LINE is

somewhere between ¼ and ½ of the way down from the top.

4. Close the Steam Out (#16) and turn on generator. When the

contactor(s) click on, the pressure will rise. If contactor(s) do not

click on right away, you may need to press SAFETY RESET.

Continue to watch the Pressure Gauge (#15) until you hear the

contactor(s) click off. This may take up to 20 minutes.

WARNING – DO NOT allow the pressure to exceed the rating on the Safety Valve (#18). If

contactor(s) do not turn off before the pressure limit is exceeded, manually shut off

generator, open the Steam Out (#16), and DECREASE the pressure setting on the

“SAFETY” pressure control. Repeat step #4.

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3.7) SETTING THE PRESSURE CONTROLS (Continued)

5. At this point the contactor(s) should be clicked off and you should be able to click them on

and then off again by pressing the SAFETY RESET. This is a way to test if the “SAFETY”

is still controlling the pressure, and not the “CONTROL”. While setting the “SAFETY” and

the contactor(s) are off, if the SAFETY RESET does not cause the contactor(s) to click on

and off again, INCREASE the setting on the “CONTROL”

WARNING – DO NOT allow the pressure to

Pressure Control Settings

exceed the rating on the Safety Valve (#18).

If contactor(s) do not turn off before the

pressure limit is exceeded, manually shut

off generator, open the Steam Out (#16),

and DECREASE the pressure setting on

the “SAFETY” pressure control. If you

cannot get the “SAFETY” to control the

pressure, it may need to be replaced.

“Control”

“Safety”

High Pressure

(0-100 PSI)

High Pressure

(0-30 PSI)

Low Pressure

(0-15 PSI)

80 PSI

85 PSI

25 PSI

27 PSI

11 PSI 13.5 PSI

6. Open the Steam Out (#16) to exhaust some pressure. Continue pressing the SAFETY

RESET until the contactor(s) click on and remain on. The pressure should eventually begin

to rise. If it doesn’t, throttle the Steam Out (#16) somewhere between closed and open until

it does.

7. Pay attention to what the pressure reads when the contactor(s) click off. If the pressure

stopped BELOW the “SAFETY PRESSURE SETTING”, then INCREASE the pressure

setting on the “SAFETY”. If the pressure stopped ABOVE, then DECREASE the pressure

setting.

8. Continue to watch the pressure go up and down, while adjusting the “SAFETY” and

pressing the SAFETY RESET, until the pressure stops at the proper “SAFETY

PRESSURE SETTING”.

9. At this point the “SAFETY” should be set to the proper “SAFETY PRESSURE

SETTING”, and the “CONTROL” should be set somewhere above the “SAFETY”.

10. Let the pressure drop below the “OPERATING PRESSURE SETTING” and then press the

SAFETY RESET, so that the contactor(s) click on. DECREASE the pressure setting on the

“CONTROL” until the contactor(s) click off.

11. Repeat Step 10 until you no longer need to press the SAFETY RESET for the contactor(s)

to click on.

12. Continue to watch the pressure go up and down, while adjusting the “CONTROL”, until the

pressure stops at the proper “OPERATING PRESSURE SETTING”.

13. The Pressure Controls are now set.

NOTE: If at anytime the SAFETY RESET needs to be pressed after the pressure controls are

set, either one of the controls are bad, the “SAFETY” is set too low, or the “CONTROL” is

set too high.

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Electro-Steam Generator Corp.

4.) CALCULATIONS AND DATA SHEETS

4.1) HEATER POWER & VOLTAGE RATINGS

LG Model units use 3 Heaters to meet the required (KW) POWER from the customer’s

specified INPUT VOLTAGE. Each heater comes in 5 different (KW) POWER RATINGS and

4 different VOLTAGE RATINGS.

AVAILABLE HEATER RATINGS

POWER RATINGS per MODEL

3.33

5.00

6.50

8.33

9.75

VOLTAGES

MODEL UNIT

LG-10

QUAN.

3.33

5.00

6.50

8.33

9.75

208

214

208

240

230

240

480

600

LG-15

LG-20

LG-25

LG-30

HEATER VOLTAGE RATINGS per INPUT VOLTAGE (VOLTS)

Input Voltage

208 220 230 240 380 400 415 425 440 460 480 550 575 600

208

214

208

230

214

208

240

230

240

230

240

208

214

208

240

230

214

240

230

240

230

240

480

600

LG-10

LG-15

LG-20

LG-25

LG-30

NOTE: 380-425V heaters are not usually rated for 380-425V. They are usually 208-240V heaters

that have been re-stamped 380-425V and wired in series.

4.2) TOTAL POWER RATING CALCULATIONS

The HEATER POWER RATING and NUMBER OF HEATERS are used to calculate the

TOTAL POWER RATING. Since the HEATER POWER RATINGS are in Kilowatts, they

must be multiplied by 1000 to convert them to Watts.

DEFINITIONS:

= Total Power Rating

= Heater Power Rating

= Number of Heaters

MODEL UNIT

LG-10 LG-15 LG-20 LG-25 LG-30

3,333

5,000

6,500

8,333

9,750

Heater Power Rating (Watts)

X Number of Heaters

10,000

15,000

19,500

25,000

29,250

Total Power Rating (Watts)

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LG-10 thru LG-30 - User Manual

Electro-Steam Generator Corp.

4.3) AMPERAGE CALCULATIONS

The INPUT VOLTAGE, PHASE, TOTAL POWER RATING, and HEATER

VOLTAGE RATING are used to calculate the amperage.

NOTE: 380-425V heaters are not usually rated for 380-425V. They are usually 208-240V heaters

that have been re-stamped 380-425V and wired in series.

FORMULAS TO CALCULATE AMPERAGE

THREE PHASE

SINGLE PHASE

380-425V

(using 208-240V heaters)

208-240V &

440-600V

380-425V

(using 208-240V)

208-240V & 440-600V

Not possible with

odd number of

heaters

DEFINITIONS:

I = Amperage

= Input Voltage

= Total Power Rating

= Heater Voltage Rating

THREE PHASE AMP DRAW CALCULATIONS (AMPS)

Input Voltage

LG-10

208 220 230 240 380 400 415 425 440 460 480 550 575 600

27.8 29.4 23.1 24.1 16.9 13.4 13.9 14.2

41.6 36 37.7 39.3 25.4 21.8 22.6 23.2 16.5 17.3

54.1 46.8 48.9 51.1 33

65.6 69.3 57.6 60.1 39.9

81.2 85.9 67.4 70.4 49.4 39.1 40.6 41.5 32.3 33.7 35.2 25.8

11.5

8.82 9.22 9.62

13.2 13.8 14.4

LG-15

28.4 29.4 30.1 21.5 22.5 23.5 17.2

18.8

28.1

LG-20

34.7 35.5 27.6 28.8 30.1 22.1 23.1 24.1

LG-25

LG-30

SINGLE PHASE AMP DRAW CALCULATIONS (AMPS)

Input Voltage

LG-10

208 220 230 240 380 400 415 425 440 460 480 550 575 600

48.1 50.9 39.9 41.7

72.1 62.4 65.2 68.1

93.8 81.1 84.8 88.5

19.1

20.8 15.3

16.7

28.6 29.9 31.3 22.9

LG-15

Not possible with odd

number of heaters

37.2 38.9 40.6 29.8 31.1 32.5

47.7 49.9 52.1 38.2 39.9 41.7

55.9 58.4 60.9 44.7 46.7 48.8

LG-20

114

141

120 99.8 104

149 117 122

LG-25

LG-30

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Electro-Steam Generator Corp.

4.4) ACTUAL POWER RATING CALCULATIONS

Because the HEATER VOLTAGE RATINGS only come in 4 different voltages, and there

are so many different voltages in the field, the TOTAL POWER RATING is only completely

accurate if the VOLTAGE IN is exactly equal to the HEATER VOLTAGE RATING. This

means, in most cases, the TOTAL POWER RATING is not completely accurate. The

AMERAGE and INPUT VOLTAGE can be used to calculate the ACTUAL POWER

RATING.

FORMULAS TO CALCULATE ACTUAL POWER RATINGS

THREE PHASE

SINGLE PHASE

DEFINITIONS:

I = Amperage

= Actual Power Rating

= Input Voltage

ACTUAL POWER RATING CALCULATIONS (KW)

Input Voltage

208 220 230 240 380 400 415 425 440 460 480 550 575 600

11.2 9.18

11.1 9.26 9.97 10.5

8.4

9.18

8.4

9.18

LG-10

LG-15

LG-20

LG-25

LG-30

13.7 15

16.3 16.7 15.1 16.3 17.1 12.6 13.8

12.6 13.8

19.5 17.8 19.5 21.2 21.7 19.7 21.2 22.2 16.4 17.9 19.5 16.4 17.9 19.5

23.6 26.4 23 25 26.3 29.1 24.9 26.1 21 23 25 21 23 25

29.3 32.7 26.9 29.3 32.5 27.1 29.2 30.6 24.6 26.9 29.3 24.6 26.9 29.3

4.5) STEAM CAPACITY CALCULATIONS

Steam Capacity Calculations are based on the impossible feed water temperature of 212°F.

WARNING – Anything above 140°F will cause damage to water solenoid and pump.

NET STEAM CAPACITY CALCULATIONS

Feed Water

@ 212°F

Feed Water

@ 140°F, 90% of 212°F

Feed Water

@ 100°F, 80% of 212°F

Feed Water

@ 60°F, 75% of 212°F

MODEL

UNIT

34.5 LB/hr - 15.7 Kg/hr

31.1 LB/hr – 14.1 Kg/hr

27.6 LB/hr – 12.5 Kg/hr

25.9 LB/hr – 11.8 Kg/hr

LG-10

LG-15

LG-20

LG-25

LG-30

51.7 LB/hr - 23.5 Kg/hr

69.0 LB/hr - 31.3 Kg/hr

86.0 LB/hr - 39.0 Kg/hr

103.5 LB/hr - 47.0 Kg/hr

46.5 LB/hr – 21.1 Kg/hr

62.1 LB/hr – 28.2 Kg/hr

77.4 LB/hr – 35.1 Kg/hr

93.2 LB/hr – 42.3 Kg/hr

41.4 LB/hr – 18.8 Kg/hr

55.2 LB/hr – 25.0 Kg/hr

68.8 LB/hr – 31.2 Kg/hr

82.8 LB/hr – 37.6 Kg/hr

38.8 LB/hr – 17.6 Kg/hr

51.8 LB/hr – 23.5 Kg/hr

64.5 LB/hr – 29.3 Kg/hr

77.6 LB/hr – 35.2 Kg/hr

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COM

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COM

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COM

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Electro-Steam Generator Corp.

Electro-Steam Generator Corporation Terms and Conditions of Sale

These terms and conditions apply to all goods or services Seller provides. Seller recognizes no other terms and conditions unless approved in writing

by Seller’s authorized representative. Seller rejects any additional terms and conditions that may be contained in any document provided previously

or subsequently by your company.

CHANGES: Changes made after fabrication has begun shall be submitted in writing, signed by the purchaser. Purchaser agrees to pay the cost of any changes. The

specifications and prices are subject to change without notice.

CLAIMS: Title passes to the buyer upon delivery to the carrier, unless otherwise indicated. Safe delivery is the responsibility of the carrier. Damaged merchandise, if

accepted, should be noted on the delivery receipt and on the freight bill before acceptance of shipment. Make claim promptly.

CONTINGENCY: All contracts are contingent upon fire, strikes, accidents, delays in transit, acts of God or other causes beyond our control.

LOCAL CODES: All steam boilers are built in accordance with ASME miniature boiler code. NOTE: It is the responsibility of the installer to conform with any state

or local codes. If further inspection following modification by the installer is required under state and local codes that is the responsibility of the local installer

FREIGHT TERMS: F.O.B. FACTORY, NO FREIGHT ALLOWED. All charges for unloading and transportation to job site are at the buyer’s expense.

INSTALLATION: No installation or job supervision charges are included.

ORDERS: All orders resulting from this quotation are subject to acceptance by the factory. No production will begin until receipt of purchaser’s signed order and

credit approval.

PAYMENT TERMS: Within Continental U.S.A., net 30 days, with approved credit from the date of invoice (not date of arrival of goods). Payment in full without

retainer and/or any unauthorized sums deducted is expected.

RETURNS OF MATERIAL: No goods will be accepted for return without a return authorization number from the factory. A 25% restocking fee is charged on returns,

freight prepaid.

TAXES: No taxes of any kind are included. All prices herein and/or contracts shall be subject to increase without notice by the amount of present or future sales or excise

tax levied or charged, either by Federal, State or any other assessing agency.

PATENTS: Seller agrees to indemnify Purchaser against any proven claim and assessed liability for infringement of any United States patent arising from the

manufacture or sale of any apparatus furnished by Seller to Purchaser.

THE FOREGOING STATES SELLER’S ENTIRE LIABILITY FOR CLAIMS OR PATENT INFRINGEMENT. Seller shall have no liability whatsoever if the claim

of infringement arises out of the Sellers compliance with Purchasers specifications. Seller shall have no liability whatsoever if a claim of infringement is based upon

the Purchasers use of the equipment as part of a patented combination where the other elements of the combination are not supplied by Seller, or in the practice of a

patented process. Where the specifications, process, design are supplied by Purchaser, then Purchaser agrees to indemnify the Seller in like manner.of the claim or suit;

and (c) purchaser provides all information and assistance to Electro-Steam Corporation, at purchaser’s expense, as is reasonably necessary for the defense of the claim

or suit. Electro-Steam Generator Corporation may, at its option, intervene in any suit or action brought against the purchaser on such claim.

ELECTRO-STEAM GENERATOR CORPORATION LIMITED WARRANTY:

Electro-Steam Generator Corporation fully warrants that all equipment and service supplied shall conform to the description in the quotation and agrees to repair

or replace F.O.P. shipping points any parts, excepting expendable items, that fail due to defects in material or workmanship. The pressure vessel; (steam chamber)

are warranted to the original Purchaser for a period of five years from the date of shipment from our factory. Mechanical and electrical components, along with

accessories and hoses, are warranted for a period of one (1) year from date of shipment from our factory. IN NO EVENT SHALL ELECTRO-STEAM

GENERATOR CORPORATION’S WARRANTY BE EXTENDED BEYOND THE WARRANTY LIABILITY PROVIDED BY THE SUPPLIER OR

MANUFACTURER OF COMPONENT PARTS INCORPORATED IN THIS EQUIPMENT. THERE ARE NO OTHER WARRANTIES OF ANY KIND,

EXPRESSED OR IMPLIED, AND SPECIFICALLY EXCLUDED BUT NO BY WAY OF LIMITATION ARE THE IMPLIED WARRANTIES OF FITNESS

FOR PARTICULAR PURPOSE AND MERCHANTABILITY.

All claims for incorrect products or replacement must be made and settled prior to installation. Electro-steam Generator Corporation assumes no liability for the

expense of repairs made outside its factory. Any claims for labor and/or parts will be denied unless written authorization is given by Electro-Steam Generator

Corporation prior to work being done.

IT IS UNDERSTOOD AND AGREED THAT ELECTRO-STEAM GENERATOR CORPORATION’S LIABILITY, WHETHER IN CONTRACT, IN TORT,

UNDER ANY WARRANTY, IN NEGLIGENCE OR OTHERWISE, SHALL NOT EXCEED THE COST OF REPAIR OR REPLACEMENT, F.O.B. SHIPPING

POINTS OF DEFECTIVE PARTS. UNDER NO CIRCUMSTANCES SHALL ELECTRO-STEAM GENERATOR CORPORATION BE LIABLE FOR SPECIAL,

INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. THE PRICE STATED FOR THE EQUIPMENT IS A CONSIDERATION IN LIMITING

ELECTRO-STEAM GENERATOR CORPORATION’S LIABILITY. NO ACTION, REGARDLESS OF FORM, ARISING OUT OF THE TRANSACTIONS OF

THIS AGREEMENT MAY BE BROUGHT BY PURCHASER MORE THAN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED. THE

WARRANTY FOR THIS EQUIPMENT

OR SERVICE PROPOSED IN THIS QUOTATION IS AS STATED IN THE AFOREMENTIONED PARAGRAPHS. IT IS NOT RESTATED NOR DOES IT

APPEAR IN ANY OTHER FORM.

This warranty supersedes all prior verbal or written warranties.

INSURANCE: Buyer represents that they have a program of Insurance which adequately protects their interest, and that of their employees and agents, including

damage to plant, property and equipment, personal injury of any kind, directly or indirectly related in any way to the equipment, service, repair or parts supplied by

Seller. Accordingly, Buyer waives any claim against Seller for the foregoing, and on behalf of its Insurance Company, any right of subrogation in connection

therewith.

LAW: This Agreement shall be governed by the internal laws of the State of New Jersey, USA, and any claims arising hereunder shall be prosecuted in the United

States District Court having jurisdiction of causes of action arising in the District in which Seller is located.

rev 06042007

33 of 33

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