®
Chromalox
SERVICE REFERENCE
Installation, Operation
DIVISION
SALES
4
SECTION CES
and
(Supersedes PQ444)
REFERENCE
PQ444-1
RENEWAL PARTS IDENTIFICATION
161-562789-002
DATE
MAY, 1999
Type CES-6 through CES-180 Electric Steam Boiler
Standard Trim is 100 PSI — 0-90 Operating Pressure Range
Boiler Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Circuit Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
National Board No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amps . . . . . . . . . . . . . . . Phase . . . . . . . . . . . Cy . . . . . . . . . .
Important — This data file contains the National Board Registration Certificate for your boiler. It must be kept near the boiler at all times.
3 Phase Voltages*
Output
at
No./kW
of
Quantity and Rating
of Contactors
Elec
Rating Cap. Vol. 212˚F
(BHP) (kW) (Gals.) (Lbs./Hr.)
Heating
Elements
480†
Model
208
240
Type CES — 0-100 PSIG
CES-6
.6
.9
6
9
6
6
6
18
30
30
40
30
30
30
50
30
30
30
30
1-6
1-9
1-12
1-17
2-12
CES-9
27
CES-12
CES-18
CES-24
1.22 12
1.73 17
2.45 24
36.2
51.2
72.3
6
50
14.3
2-40
2-30 2-30
1-40
1-50
1-40
40
1-12
1-17
CES-30
CES-36
CES-48
2.95 29
3.47 34
4.69 46
14.3
87.4
1-30
14.3 102.5 2-50
2-50
50
2-17
1-40
14.3 138.7
2-50
1-30 1-40
2-50 1-30
1-12
2-17
2-50
14.3 174.8
2-40
2-30
2-40
2-50
4-50 2-50
6-50 3-50
8-50 4-50
2-12
2-17
4-17
6-17
8-17
CES-60
CES-72
5.91 58
6.93 68
14.3
205
307
410
4-50
6-50
—
CES-100 10.40 102 27.8
CES-135
CES-160
CES-180
13.9 136 30.5
16.1 157.5 30.5
18.4 180 30.5
1-30
475
543
—
—
7-60
7-22.5
3-60
8-60 4-60 8-22.5
* Single phase available up to and including 24 kW capacity.
† All boilers must have separate 120V Control Circuit or Transformer.
Boilers under 40 amps max are not fused.
© 2010 Chromalox, Inc.
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DIMENSIONS
CES — Dimensions (In.)
CES — Dimensions (In.)
Model
CES-6
A
B*
C
D
E
F
G
H
I
J
1
1
1
1
1
K
L
Model
CES-48
A
B*
C
D
E
F
G
H
I
J
1
1
1
K
1
1
1
1
1
1
1
L
37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2
37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2
37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2
37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2
1/2 1/2
1/2 1/2
1/2 1/2
1/2 1/2
43-1/2 26
43-1/2 26
43-1/2 26
63-1/2 30
63-1/2 32
63-1/2 32
63-1/2 32
46 17-1/2 23 34-1/2 16-1/2 24-1/2
46 17-1/2 23 34-1/2 16-1/2 24-1/2
46 17-1/2 23 34-1/2 16-1/2 24-1/2
1
1
1
3/4
3/4
3/4
3/4
3/4
3/4
3/4
CES-9
CES-60
CES-72
CES-12
CES-18
CES-24
CES-100
CES-135
CES-160
CES-180
55
21
27
36 16-3/4 37-1/2 1-1/2 1-1/4
43-1/2 26
46 17-1/2 23 34-1/2 16-1/2 24-1/2
1
1
3/4
55 20-1/2 26 37-1/2 16 37-1/2
55 20-1/2 26 37-1/2 16 37-1/2
55 20-1/2 26 37-1/2 16 37-1/2
2
2
2
1-1/4
1-1/4
1-1/4
CES-30
CES-36
43-1/2 26
43-1/2 26
46 17-1/2 23 34-1/2 16-1/2 24-1/2
46 17-1/2 23 34-1/2 16-1/2 24-1/2
1
1
1
1
1
1
3/4
3/4
*Add two inches for transformer.
INSTALLATION
Note: When installing boiler, allow sufficient room (21” minimum) to
facilitate removal of elements if and when necessary.
1. The boiler should be mounted on a solid level foundation.
2. WARNING: A minimum distance of 18” between
boiler and any combustible material must be main-
tained.
3. Complete all piping to boiler. Connect water line to tagged fitting
on the motor and pump assembly, if used, or to tagged fitting on
water control feeder.
4. When any type of feed other than a pump feed is used — the exist-
ing water supply must be 10 pounds greater than the boiler operat-
ing pressure to assure water supply maintains proper water level in
boiler. Otherwise, lack of water can cause heater failure. Keep feed
water line valves open at all times except during blowdown.
5. All water feed systems are connected to water inlet check valve.
6. Connect steam line (with Globe valve) to boiler steam outlet.
Valve should be placed as close as possible to boiler outlet and
sized per label on boiler.
7. To insure maximum efficiency of supplied kW, all piping from
outlet should be insulated.
8. Drain and relief valve piping should be in accordance with state
and local codes. Floor drain to be provided directly below unit.
9. All electrical wiring should be done by licensed electrician in
accordance with national and local electrical codes.
10. If pump is located less than 30 feet from boiler, a second
check valve is required.
Typical Plumbing Installation of a Steam Boiler with Condensate Return System
Insulated Steam Lines
(Pitch Down 5˚)
Heat
Exchanger
Gate
Safety
Valve
Water/Steam
Separator
Globe
Valve
Valve
(Typical
Load)
Trap
Trap
Vacuum
Breaker
Check
Valve
Check
Valve
Check
Valve
Return
Pitch Down 5˚
Cold Water
Make-Up
Vent
Boiler
Drain
Condensate
Return
Steam
Drain
Water
Condensate
Vapor
Strainer
Gate
Valve
Centrifugal
Turbine Pump
3
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WIRING
your contractor or electrical dealer for recommended type for your
system.
WARNING: Hazard of Electric Shock. Boiler must be
suitably grounded according to N.E.C. standard.
1. Be sure to use the proper wire. Electric wiring to boiler should be
in accordance with National Electrical Code or local wiring code
following wiring diagram supplied. (See recommendations on
safety switches and fusing.)
5. Be sure all electrical connections are sufficiently tightened.
6. WARNING: Substitution of components or modifica-
tion of wiring system voids the warranty and may
lead to dangerous operating conditions.
7. SPECIAL INSTRUCTIONS FOR CUSTOMERS SUPPLY-
ING THEIR OWN CONDENSATE OR PUMP SYSTEMS.
A. Check the voltage of the motor before making the wiring con-
nection. Some Chromalox boilers are supplied with dual volt-
age systems. The motor should always match the voltage of the
control circuit.
2. The unit is completely wired and pre-tested before shipment. No
internal wiring is required.
If a separate control circuit is used, the control circuit should be
connected to the control terminal block, inside access door (not
required with transformer).
3. Safety Switches — WARNING: Purchaser should use a
safety switch employing circuit breakers or fuses
between his main power source and the boiler.
4. Because of their water lines, boilers are susceptible to lightning
damage. Industrial type lightning protectors should be installed per
manufacturer’s recommendations at your service entrance. Check
B. The motor circuit should be wired into the pump control as
shown in wiring diagram (float type pump control). If boiler is
equipped with solid state pump control, refer to wiring diagram
and use terminals 5 and 2.
TYPICAL WIRING DIAGRAMS
Use Applicable wiring diagrams based on model number and power voltage.
3 Phase Voltage
3 Phase Voltage
3 Phase Voltage
240
Boiler
208
240
480
Boiler
208
240
480
Boiler
208
480
CES-6
CES-9
CES-12
CES-18
CES-24
1
1
1
1
2
1
1
1
1
2
1
1
1
1
3
CES-30
CES-36
CES-48
CES-60
CES-72
2
2
4
6
6
2
2
4
6
6
3
3
5
7
7
CES-100
CES-135
CES-160
CES-180
Export
8
8
9
10
12
10
11
13
11
14
Diagram 1
L1 L2
L3
1
GND
C1
1 HTR
1L1
1L2
1L3
FU1
FU2
1
GND
FU3
FU6
1PB
FU5
H2
FU4
H1
FU
Feed Water
Electrical
Connection
Optional Transformer
1
2
3
3
GND
X1
X2 X4
X3
3
2
1
GND
2
1
B
W
2
1
FU6
1PB
GND
GND
1LT
R
BR
Y
On
Off
B
Boiler On
IFS
Feed Water
1PS
Heater
Contactors
2PS
O
O
O
C1
C2
C3
C4
1
HTR
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
B
=
Black
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
* Boilers under 40 Amps total (not fused)
Y
G
BL
W
White
4
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TYPICAL WIRING DIAGRAMS
L1 L2
L3
1
Diagram 2
GND
C1
1 HTR
2 HTR
1L1
1L2
1L3
FU1
FU2
2
GND
FU3
C2
2L1
2L2
2L3
FU4
FU5
FU6
FU8
FU7
H1
H4
H3
H2
FU9
1TB
1PB
Optional Transformer
X1
X3
X2 X4
2
3
1
Feed Water
Electrical
Connection
2 GND
GND
C1
FU
C2
FU
2
1
B
FU9
W
4 2 6
1 2 3
1LT
R
1PB
BR
Y
On
Off
B
Boiler On
IFS
Feed Water
1PS
2PS
O
O
O
C1
C2
Heater
Contactors
1
2
HTR
HTR
Wire Color Code
Black
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
L3
L1 L2
Diagram 3
1
C1
GND
1 HTR
1L1
1L2
1L3
FU1
FU2
2
GND
FU3
2 HTR
2L1
2L2
2L3
FU4
FU5
H4
H1
H3
X3
H2
FU6
1PB
Optional Transformer
2
X1
2 GND
X2 X4
3
1
Feed Water
Electrical
Connection
GND
C1
FU
2
1
B
1 2 3
W
FU6
1LT
R
1PB
BR
Y
On
Off
B
Boiler On
IFS
Feed Water
1PS
2PS
O
O
O
Heater
Contactor
C1
1
2
HTR
HTR
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
* Boilers under 40 Amps total (not fused)
White
5
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TYPICAL WIRING DIAGRAMS
Diagram 4
1
L1 L2
L3
GND
C1
C3
3 HTR
1 HTR
2 HTR
1L1
1L2
1L3
FU1
FU2
FU7
FU8
3L1
3L2
1L3
2
GND
FU3
FU9
C2
2L1
2L2
2L3
FU4
FU5
FU6
FU10
H1
FU11
H4
2 GND
H3 H2
Optional Transformer
1PB
X1
X2
X4
X3
FU12
1TB
2
3
1
GND
Feed Water
Electrical
Connection
2
1
2 GND
B
W
FU12
1PB
1LT
R
1 GND
BR
On
Off
B
Boiler On
IFS
C1
C2
Y
C3
FU
Feed Water
3
1PS
2PS
Htr
FU
1 2 3
O
O
O
FU
4 5 6
Heater
Contactor
C1
7 8 9
C2
C3
1
2
Heater
Contactor
HTR
HTR
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
L1 L2
L3
Diagram 5
1
GND
C1
1 HTR
1L1
1L2
1L3
FU1
FU2
2
GND
FU3
C2
2 HTR
3 HTR
2L1
2L2
2L3
FU4
FU5
FU6
3L1
3L2
3L3
FU7
H1
FU8
H4
H3 H2
Optional Transformer
FU9
1PB
1TB
X4
X3
X2
X1
3
2
1
GND
Feed Water
Electrical
Connection
2
1
2 GND
C2
FU
4 5 6
C1
FU
1 2 3
B
FU9
W
1LT
R
1PB
BR
On
Off
B
Boiler On
IFS
Y
Feed Water
1PS
2PS
O
O
O
3
C1
C2
HTR
Heater
Contactors
1
2
HTR
HTR
Wire Color Code
Black
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
6
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TYPICAL WIRING DIAGRAMS
Diagram 6
1
L1 L2
L3
GND
C1
C3
C4
3 HTR
4 HTR
1 HTR
2 HTR
1L1
1L2
1L3
FU1
FU2
FU7
FU8
3L1
3L2
1L3
2
GND
FU3
FU9
C2
2L1
2L2
2L3
FU4
FU5
FU10
FU11
4L1
4L2
4L3
FU6
FU12
FU14
FU13
H1
H2
H2
1PB
Optional Transformer
FU15
X1
X3
X2 X4
Feed Water
Electrical
1TB
2
3
1
GND
Connection
2
1
2 GND
B
W
FU15
1PB
1LT
R
1 GND
BR
Y
On
Off
B
Boiler On
IFS
C1
C2
C4
C3
Feed Water
3
Htr
4
Htr
FU
10
FU
7 8 9
FU
4 5 6
1PS
FU
1 2 3
2PS
O
O
O
Heater
Contactors
C1
11 12
C2
C3
1
HTR
2
HTR
C4
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
Diagram 7
1
GND
L3
L1 L2
C1
C2
2 HTR
4 HTR
1 HTR
3 HTR
FU4
1L1
FU1
FU2
2L1
1L2
1L3
FU5
FU6
2L2
2L3
2
GND
FU3
4L1
4L2
4L3
3L1
3L2
3L3
FU8
H2 H4
FU7
H1
H3
3
GND
1TB
FU9
Optional Transformer
2
1PB
X1 X3
X2 X4
3
1
Feed Water
Electrical
Connection
2 GND
C2
GND
C1
2
1
FU
FU
B
1 2 3
4 5 6
W
FU9
1PB
1LT
R
BR
Y
On
Off
B
Boiler On
3
4
IFS
HTR
HTR
Feed Water
1PS
O
2PS
O
O
Heater
Contactor
C1
C1
1
2
HTR
HTR
Wire Color Code
Black
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
7
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TYPICAL WIRING DIAGRAMS
L2
L1
L3
Diagram 8
1
GND
C1
C5
C6
1 HTR
1L1
5 HTR
6 HTR
5L1
5L2
5L3
FU13
FU14
FU15
FU1
FU2
FU3
2
1L2
1L3
GND
C2
C3
C4
2 HTR
3 HTR
4 HTR
2L1
2L2
2L3
FU16
6L1
6L2
6L3
FU4
FU17
FU18
FU5
FU6
3L1
3L2
3L3
FU7
FU8
FU9
4L1
4L2
4L3
FU10
FU11
FU12
FU19
FU20
Feed Water
Electrical
1PB
1TB
Connection
FU21
Optional Transformer
X1
X2 X4
X3
3
1
2
3 GND
C1
C3
C2
GND
2
1
2
GND
FU
4 5 6
FU
1 2 3
FU
7 8 9
B
W
FU21
1PB
1LT
R
On
BR
B
Boiler
On
Off
IFS
Y
C4
C5
C6
Feed Water
5
6
HTR
HTR
3PS
2PS
1PS
FU
10
FU
13
FU
16
O
O
O
Heater Contactor
Heater Contactor
C1
C2
C3
11 12
14 15
17 18
3
HTR
4
HTR
1
2
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
HTR
HTR
C4
C5
C6
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
Diagram 9
L1 L2 L3
1
GND
C1
1 HTR
C3
5 HTR
6 HTR
FU1
FU2
FU3
5L1
1L1
1L2
FU7
FU8
FU9
2
5L2
5L3
GND
1L3
2 HTR
3 HTR
4 HTR
2L1
2L2
6L1
6L2
6L3
2L3
C2
3L1
3L2
FU4
FU5
FU6
3L3
4L1
4L2
4L3
FU12
FU10
FU11
H2 H4
1 GND
Feed Water
Electrical
1PB
1TB
Connection
H1 H3
3 GND
Optional Transformer
C1
C3
C2
3
GND
1
2
2
X1 X3
X2 X4
FU
4 5 6
FU
1 2 3
FU
7 8 9
GND
1
2
B
W
FU12
1PB
1LT
R
On
BR
Y
B
Boiler
5
6
On
Off
IFS
HTR
HTR
Feed Water
3PS
2PS
1PS
O
3
4
O
O
Heater Contactor
Heater Contactor
Heater Contactor
C1
C2
C3
HTR
HTR
1
HTR
2
HTR
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
8
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TYPICAL WIRING DIAGRAMS
L2
L1
L3
Diagram 10
1
GND
C1
C5
1 HTR
1L1
5 HTR
5L1
5L2
5L3
FU1
FU2
FU3
FU13
FU14
FU15
2
1L2
1L3
GND
C2
C3
C4
C6
C7
C8
2 HTR
3 HTR
4 HTR
6 HTR
7 HTR
2L1
2L2
2L3
FU4
FU16
6L1
6L2
6L3
FU5
FU6
FU17
FU18
3L1
3L2
3L3
FU7
FU8
FU9
7L1
7L2
5L3
FU13
FU20
FU21
4L1
4L2
4L3
FU10
FU11
FU12
6 HTR
8L1
FU22
8L2
8L3
FU23
FU24
FU25
H1 H3
FU26
H4
Feed Water
Electrical
H2
1PB
1TB
Connection
FU27
Optional Transformer
3
1
2
GND
X1
X2 X4
X3
3 GND
C8
22
C5
C7
C6
1
2
2
B
W
GND
16
17 18
13
14 15
19
20 21
FU27
1PB
1LT
R
23 24
On
BR
Y
B
Boiler
8
7
HTR
On
HTR
Off
IFS
Feed Water
C1
C4
C2
C3
5
6
3PS
1PS
O
O
O
HTR
HTR
C1
C2
C3
10
1
2
3
4
5
6
7
8
9
11 12
3
HTR
4
HTR
Heater Contactor
Heater Contactor
1
HTR
2
HTR
C4
C5
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
C6
C7
C8
2PS
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
Diagram 11
L1 L2 L3
FU1
FU2
FU3
1
GND
C1
1 HTR
C3
C4
5 HTR
5L1
5L2
5L3
1L1
1L2
FU7
FU8
FU9
2
GND
1L3
2 HTR
3 HTR
4 HTR
2L1
2L2
2L3
6 HTR
7 HTR
6L1
6L2
6L3
C2
3L1
3L2
FU4
5L1
7L2
5L3
FU10
FU11
FU12
FU5
FU6
3L3
4L1
4L2
4L3
8 HTR
8L1
8L2
8L3
FU14
H4
FU13
FU15
1PB
Feed Water
Electrical
1 GND
3 GND
7HTR
1TB
H1 H3
H2
Connection
Optional Transformer
C1
C2
C3
C4
X1 X3
X2 X4
3
2
1
2
GND
FU
GND
FU
FU
FU
7 8 9
10
1
2
4 5 6
1 2 3
11 12
B
W
8
HTR
FU15
1PB
1LT
R
On
BR
Y
B
Boiler
On
5
HTR
6
HTR
Off
IFS
Feed Water
3PS
1PS
O
3
HTR
4
HTR
O
O
C1
C2
C3
C4
Heater Contactor
Heater Contactor
1
2
HTR
HTR
2PS
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
9
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TYPICAL WIRING DIAGRAMS
Diagram 12
L2
L1
L3
1
GND
C1
C5
C6
C7
1 HTR
1L1
5 HTR
5L1
5L2
5L3
FU1
FU2
FU3
FU13
FU14
FU15
2
1L2
1L3
GND
C2
C3
C4
2 HTR
3 HTR
4 HTR
6 HTR
7 HTR
2L1
2L2
2L3
FU4
FU16
6L1
6L2
6L3
FU5
FU6
FU17
FU18
3L1
3L2
3L3
7L1
7L2
5L3
FU7
FU8
FU9
FU19
FU20
FU21
4L1
4L2
4L3
FU10
FU11
FU12
Feed Water
Electrical
FU22
H1
FU23
H4
1PB
H2
H3
1TB
Connection
FU24
Optional Transformer
X3
X1
X4
X2
3 GND
C5
C7
3
C6
1
2
GND
2
1
2
16
17 18
GND
13
14 15
19
20 21
B
W
FU24
1PB
7
HTR
1LT
R
On
BR
Y
B
Boiler
On
C1
FU
C2
FU
C3
FU
Off
C4
IFS
5
HTR
6
Feed Water
HTR
FU
10
3PS
1PS
O
O
O
C1
C2
C3
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
1
2
3
4
5
6
7
8
9
11 12
3
HTR
4
HTR
1
2
HTR
HTR
C4
C5
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
B
=
2PS
BR = Brown
C6
C7
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
Diagram 13
L2
L1
L3
1
GND
C1
C3
C4
1 HTR
5 HTR
1L1
5L1
5L2
5L3
FU1
FU2
FU3
FU7
FU8
FU9
2
1L2
1L3
GND
2 HTR
3 HTR
4 HTR
6 HTR
7 HTR
2L1
2L2
2L3
6L1
6L2
6L3
C2
3L1
3L2
3L3
7L1
7L2
5L3
FU4
FU5
FU6
FU10
FU11
FU12
4L1
4L2
4L3
Feed Water
Electrical
1PB
1TB
Connection
FU13
H1
FU14
H4
FU15
H2
X3
H3
3 GND
Optional Transformer
C1
C2
C3
C4
X1
X4
X2
2
3
1
2
FU
10
FU
5
GND
GND
FU
2
FU
8
1
4
6
2
1
3
7
9
11 12
B
7
HTR
W
FU15
1PB
1LT
R
On
BR
Y
B
Boiler
On
5
HTR
6
HTR
Off
IFS
Feed Water
3PS
2PS
3
4
1PS
O
O
O
C1
C2
C3
HTR
HTR
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
1
HTR
2
HTR
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
Wire Color Code
Black
C4
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
10
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TYPICAL WIRING DIAGRAMS
Diagram 14
Typical Export Boiler
346V 3Ø 50 HZ
L2
L1
L3
1
GND
C1
C3
C4
1 HTR
1L1
3 HTR
4 HTR
3L1
3L2
3L3
FU1
FU2
FU3
FU7
FU8
FU9
2
1L2
1L3
GND
C2
2 HTR
2L1
2L2
2L3
4L1
4L2
4L3
FU4
FU5
FU6
FU10
FU11
FU12
Feed Water
Electrical
3
GND
1PB
Connection
FU13
1TB
1CR
C1
C2
C3
C4
2
GND
1
FU
10
FU
5
GND
FU
2
FU
8
4
6
1
3
7
9
11 12
220 VAC Single Phase Control Circuit
3
GND
3
4
1
2
HTR
HTR
B
W
FU13
1LT
R
1
1PB
1
HTR
2
HTR
On
BR
Y
B
Boiler
On
Off
IFS
9.9
CR
2PS
1PS
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
O
O
C1
C2
C3
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Wire Color Code
Black
C4
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
1CR-1
1CR-2
Customer Pump
Connection
B
W
Y
G
BL
W
White
PRE-OPERATION CHECK
After proper wiring and piping of boiler system is complete, testing of
controls can start. Before testing controls, it is recommended that
all contactor fusing be removed. This is to prevent possible element
failure under test conditions.
A. OPERATING AND TESTING THE McDONNELL &
MILLER LOW WATER CUTOFF CONTROL.
1. Be sure all valves from incoming water supply are fully open.
Turn boiler switch to “ON” position, pump or solenoid
valve will energize, allowing boiler to fill with water. Proper
water level is automatically reached with level control sup-
plied. Pump or solenoid feed will shut off at proper water level.
Contactor(s) will energize, supplying power voltage to ele-
ments.
WARNING: Be sure all electrical connections are tight
before energizing boiler. Reset all manual reset con-
trols by pushing reset buttons on: (1) high limit control
located on top of boiler and (2) McDonnell & Miller
located on the side of boiler.
Cut-off
and
Alarm
Pump
Switch
Low-Water
Cut-Off
Terminals
2. Checking operation of pump switch. (Figure 1) With water
level visible in sight glass, partially open drain valve at bottom
of boiler. If automatic blowdown supplied, push manual blow-
down switch until valve open light is on, hold for few seconds.
Water level will fall, allowing float to trip pump switch to
“ON” position. Close drain valve or release manual blowdown
switch.
Adjusting
Screws
Alarm
Circuit
Terminals
Pump
Circuit
Pump motor or solenoid valve will energize and water level
will resume to normal level in sight glass.
Terminals
3. Checking low water cutout switch operation, open drain
valve completely. If automatic blowdown supplied, push in
and hold manual blowdown switch until water level falls
enough to trip cutout switch. Close drain valve or release man-
ual blowdown switch. If low water cutout is automatic reset,
pump or solenoid will return water level to normal. If low
water cutout is manual reset, then manual reset button on
McDonnell & Miller low water cutoff control must be pushed
to complete circuit. Turn off boiler. Reinstall contactor
fuses.
Pump
Switch
Line
Figure 1 — Automatic Reset Low-Water Cutoff Junction Box
11
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OPERATION
To check operation of the controls, close steam outlet valve and adjust
ADJUSTING OPERATING PRESSURE CONTROLS
1. Chromalox boilers are supplied with operating and high limit pres-
sure controls. One is used for controlling the operating pressure of
the boiler while the other is used as a high limit control. To deter-
mine the difference in the controls, the high limit has a manual reset
lever on top of the case. Also, there is no differential scale present.
2. On all controls, the pressure adjusting screw on the top of the case
sets the desired pressure. Turning the screw counterclockwise
reduces the pressure setting (CUT OUT) (See Figure 2). High limit
control should be set at 10 psig above the operating pressure of the
boiler.
operating pressure control to a low pressure setting. Also, set high limit
control at 10 psig above operating pressure control. Turn on boiler, and
allow pressure to build up. When pressure gauge reading approaches
set point of pressure control, the switch will trip and shut off boiler.
Turn off boiler.
To reset pressure control, bleed off enough pressure in the boiler by
opening steam outlet drain, or blowdown valve to allow the operating
control to reset.
4. HIGH LIMIT PRESSURE CONTROL OPERATION
The high limit is tested in the same manner but with the operating
control set above the pressure setting of the high limit. (Figure 3)
3. The differential adjusting screw on the operating control is set in the
same manner as the pressure adjusting screw. The CUT OUT set-
ting minus the differential setting, equals CUT IN pressure of the
operating control.
CAUTION: This is for test purposes only!
When the high limit trips, turn off boiler and reset high limit to
proper setting. The manual reset level must be pushed to resume
operation upon startup.
Differential Adjusting Screw
Pressure Adjusting Screw
Manual Reset Lever
Pressure
Adjusting
Screw
Differential
Setting
Indicator
Terminal 1 Open on
Pressure Rise
Terminal 1 Open on
Pressure Rise
Terminal 2
Common
Pressure
Setting
Indicator
Terminal 2
Common
Cutout
Pressure
Indicator
Figure 1
CES-12 through CES-72, one pressure control supplied; CES-100 through CES-
180, two pressure controls supplied.
Figure 2
OPERATION
than mineral content, take this into consideration in determining
which schedule is to be followed.
RECOMMENDED START-UP PROCEDURES
1. Close globe valve on steam outlet side of boiler. (Customer Supplied)
2. Turn on boiler and allow pressure to build up to operating pressure.
3. Only open globe valve at quarter turns at first, introducing smaller
amounts of steam into process. Avoid opening globe valve all at
once. This will eliminate the possibility of evacuating the boiler of
water caused by the suddenly increased boiling of the water in the
vessel as the pressure is reduced. On boilers where constant pres-
sure is not maintained, globe valve should be kept partially closed.
This will maintain a constant head on the boiler and stabilize any
fluctuation in boiler water level.
1. At end of the working day, while boiler is still operating, turn
switch to the OFF position and close water supply valve. De-ener-
gize wall mounted safety switch.
2. If blowing-down into a receptacle, allow pressure to decrease to
15-20 psi before opening blowdown valve.
3. It is preferable to connect the blowdown valve directly into a
drainage system. If this is done, the boiler can be discharged at
operating pressure.
4. When discharge is complete and boiler is drained — (a) close the
blowdown valve; (b) open water supply valve; (c) put boiler switch
in the ON position; and, (d) close wall mounted safety switch.
5. When refilling is complete, turn off the boiler switch unless further
operation is desirable.
6. If you have been supplied with a Manual Reset Low Water control
as required in some states, the reset button on the control must be
pushed before boiler will begin developing pressure. (Do not push
reset until boiler has filled with water.)
Note: For best boiler performance, a 1/4” less steam valve
than size of safety valve should be plumbed as close as practi-
cable to steam outlet. Where 1/2” safety valve is used on boil-
er, a 1/4” steam valve is recommended.
MANUAL BLOWDOWN INSTRUCTIONS
Blowdown is an essential part of boiler operation. It is the best
preventative maintenance you can give your boiler and will add
years of life to the unit. Make sure a blowdown schedule is estab-
lished and followed regularly.
The use of chemical boiler cleaning compounds in these boilers
voids all warranties unless approved by manufacturer. Some com-
pounds will damage copper sheathed heating elements to shorten
useful life.
In extremely hard water areas, blowdown is necessary once a
day. In soft water areas, once each week. If there is a particular
problem which applies to your own local water condition other
12
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OPERATION
AUTOMATIC BLOWDOWN INSTRUCTIONS
OPERATION— Set the “BOILER PROGRAMMED DUTY”
(IF FURNISHED)
switch to “BOILER ON” if the boiler is to be shut down each night.
Set it to “24-HOUR DUTY” if the boiler is to remain on continuous-
ly 24-hours per day (except during blowdown).
The Automatic Blowdown is a device which automatically starts
up your boiler in the morning; shuts it down at night and blows down
(partially drains) the main boiler drain and the low water cut-off col-
umn for a predetermined time interval each working day.
The heart of the unit is an electrically operated straight through
type ball valve. It is specially designed to handle dirty, corrosive flu-
ids and particles without requiring cleaning or the use of a strainer.
Both the valve and the boiler are controlled by an electric control
unit which indicates with pilot lights when the drain valve is in the
opened or closed position and when the boiler is ON or OFF. In addi-
tion to the automatic control function, the unit has a push button which
momentarily de-energizes the boiler and opens the drain valve regard-
less of the time of day.
Set the tabs on the large timer for the ON and OFF times desired
for the boiler, screw in the small black day-skip tabs if is to remain off
during the weekend, etc.
If the boiler is on 24-hour duty, set the OFF tab for the time that is
desired for blowdown. the ON tab can be ignored, but must remain on
timer.
The small time delay relay controls the time that the drain valve
remains open. The time is controlled by adjusting knob marked
Blowdown cycle. Counterclockwise decreases, clockwise increases
blowdown time. Time must be adjusted by trial.
Timer
Boiler On
Valve Open
Valve Closed
Programmed Duty
24 Hour Duty
Manual Drain
Automatic Blowdown Control Cabinet
The unit may also be used to blow down boilers which run con-
tinuously, day and night.
INITIAL TESTING — Set the switch marked “Programmed
duty/24 Hour duty” located on the panel box to the “ON” position.
On the large timer set the “ON” tab at about 8 AM and the “OFF”
tab at about 8 PM. Set the blowdown cycle dial at “O”.
Valve Actuator
Turn the large timer by hand until the “ON” tab passes the “TIME
NOW” indicator so the “TIME NOW” arrow indicates 10 AM.
Energize the main feed to the “LINE TERMINALS” of the unit.
The “BOILER ON” pilot light as well as the “VALVE CLOSED”
light should glow.
Hold down the “DRAIN” button for about six seconds. The
“BOILER ON” light should go out immediately as well as the
“VALVE CLOSED” light. It takes about 4 seconds for the drain valve
to open fully at which time the “DRAIN VALVE OPEN” light should
light. As soon as the “DRAIN” button is released the valve begins to
close. When it reaches the closed position, the “VALVE CLOSED”
and the “BOILER ON” should light up again.
Display View of Automatic Blowdown Control Cabinet
Now turn the wheel on the large timer until the “OFF” tab passes
the “TIME NOW” arrow. The “BOILER ON” light should go out and
the valve should begin to open. Once the “VALVE OPEN” light goes
on, the valve should remain open for a few seconds and then auto-
matically close. The “VALVE CLOSED” light should light and the
“BOILER ON” light should remain off.
Blowdown Cycle
30's
Cycle
Adjustment
80's
0's
Boiler On
Valve Closed
Valve Open
On/Off Switch
Indicator Light
Indicator Light
Terminal Block
7 Day Clock
Support
2
3
1FU
15A
w
Clock
Prorammed Duty
24 Hour Duty
3
A
B
1
7-Day Timer
Switch
PB Switch
Fuse
Control
Relay
(2.3)
1
1CL
1CL
8
1
2
4
G
Ball Valve
Control
(5)
Boiler On
1TR
Time Delay Relay
1PB
1LT
R
1CR
3
B
PR
P
6
Manual Drain
1
4
2
2
Y
3
2
6
2
10
Terminal Block
Component Layout
2
7
11
8
1CR
Boiler Control
(3)
Replace with
Motorized
Amp Fuse Only
2PB
2LT
R
1TR
2B
2A
O
8
7
R
B
/
R
Valve Closed
Exterior Side
3
Blowdown Valve
Valve Open
M
W
2
3LT
R
0
BL
O
11
10
/
BL
1A
1B
Wiring Diagram for Automatic Blowdown
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OPTIONAL EQUIPMENT FOR STEAM BOILERS
AUXILIARY LOW WATER CUTOFF
Operation
Operation of this control is accomplished by sensing a minute AC
current flowing between submerged contact probe in the boiler shell.
When this minute AC current is conducted through an external cir-
cuit resistance up to 40,000 ohms or less, a signal of sufficient magni-
tude is present to trigger the SCR and, in turn energize the control
relay.
As the water level in the boiler drops below the level of the probe,
the AC current is broken and the control relay is de-energized. The
control will not energize until sufficient water is present in the boiler.
Optional manual reset may require reset prior to heaters being ener-
gized after level 13 brought to normal.
flows through one side of the balancing relay. The “close” contacts in
the relay make, causing the motor to drive toward its closed position. As
the motor runs, the wiper on the feedback potentiometer moves in a
direction to balance the circuit. When the circuit is again in balance, the
balancing relay contacts open and the motor stops.
Similarly if the pressure of the controlled medium falls, the wiper on
the controller potentiometer moves toward B, and the “open” contacts
in the balancing relay make. The motor drives towards its open position
until circuit balance is achieved.
The slightest change in the pressure of the controlled medium will
cause a change in the number of elements energized to compensate for
it, thus keeping the pressure constant. This process is called modulation.
PROPORTIONAL PRESSURE CONTROL ONLY SUPPLIED
WITH SEQUENCER
WARNING: Control will not work with de-ionized or de-
mineralized water.
Main Setting — Turn the adjustment screw until the indicator is
opposite the low point of the desired throttling range. That is, if the pres-
sure is to be held at a minimum of 50 psi, set the indicator at 50 psi. The
pressure will them be maintained between 50 psi and a higher pressure
equal to the 50 psi plus the throttling range.
Typical Wiring for
Auxiliary Low Water Cutoff
THROTTLING RANGE SETTING (L91B)
After setting the indicator for the minimum pressure, turn the throt-
tling range adjustment screw until the throttling range indicator points to
the desired throttling range on the scale. This scale is graduated from
“min” to “F”. The value of each division varies with the scale range of
the instrument.
Electronic Resistance Sensing
Amplifier for Auxiliary
Low Water Cutoff
PRESSURE
SCALE RATING
0-15 psi
VALUE EACH
DIVISION ON SCALE
2.2 psi
480V
3
1
60 HZ
L2
5-150 psi
3.6 psi
GND
L1
L3
C1
FU
FU
FU
1 HTR
Pressure scale rating will vary depending on pressure control supplied.
CHECKOUT
2
GND
After the controller has been installed, wired, and set, it should be
tested with the system in operation. First allow the system to stabilize.
Then observe the operation of the controller while raising and lowering
its set point. Pressure should increase when the set point is raised and
decrease when the set point is lowered. Use accurate pressure testing
equipment when checking out the controller. Do not rely on inexpensive
gauges. The controllers are carefully calibrated at the factory.
If the motor or actuator runs the proper direction when the set point
is adjusted, it can be assumed that the controller is operating properly. If
it runs in the wrong direction, reverse the B and W wires. Observe the
action of the motor to see if it stabilizes. If the motor is moving con-
stantly, widen the proportioning range a little at a time, until the system
is stable.
Fuses Supplied
on Boilers Rated
Over 40 Amps.
FU2
H1 H3 H2 H4
FU1
480V/120V
1.5 KVA
1
2
3
X3
X2 X4
X1
GND
2
1
B
W
FU3
1PB On
1LT
R
BR
B
Boiler On
Off
W
W
3
2
2
2
2
3
6
Auto
Blow
Down
6
System
1PS
Y
Feed Water
(Solenoid Pump)
1PS
O
W
O
L1 L2
Adjusting Screw
O
2PS
BL
Differential Adjusting Screw
Heater
Contactor
BL
C1
H
NO
C
C1
R
LWCO Probe
Aux. Low
Water Cutoff
PROPORTIONING PRESSURE CONTROL FOR
SEQUENCER AND SCR CONTROLS
Typical Operation
Pressure variations cause the bellows to expand or contract.
Linkage between the bellows and the potentiometer wiper causes the
wiper to move across the windings on the potentiometer. This varies
the resistance between R and B, and between R and W, causing an
unbalance in the circuit connected to the controller.
A proportioning pressure control is used to regulate a motor driven
or solid state sequencer. The controller potentiometer, the feedback
potentiometer in the motor and a balancing relay in the motor form an
electric bridge circuit. As long as the pressure of the controlled medi-
um remains at the set point of the controller, the circuit is balanced;
i.e., equal currents flow through both sides of the balancing relay and
the relay contacts are open. When the circuit is balanced, the motor
does not run.
R
W
B
If the pressure of the controlled medium rises, the wiper in the con-
troller moves toward W. This unbalances the circuit so a larger current
(L91B)
Proportioning Pressure Control used with Sequencer Control
14
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OPTIONAL EQUIPMENT FOR STEAM BOILERS
IF A CONTROLLER SEEMS TO OPERATE IMPROPERLY
BOILER SEQUENCE — SOLID STATE
If the controller is suspected of operating improperly, it may be
further checked as follows:
Solid State Progressive Sequencer
The solid state progressive sequencer provides accurate elec-
tronic control of multi-stage loads of the type used in Chromalox
steam boilers. It features progressive sequencing (first on-first off)
which equalizes the operating time of each load. This control gives
visual indication of each energized stage by means of integral
solid state light emitting diodes. In the event of power interrup-
tion, all heating elements are immediately de-energized for safety.
When power resumes, the control will restage the loads one at a
time.
1. Leave the controller installed where it is, but disconnect all power
to the boiler.
2. Loosen the cover screw below the main scaleplate and remove the
cover.
3. Disconnect the wires from the controller.
4. Connect an ohmmeter between controller terminals B and W to
measure the resistance of the potentiometer in the controller. The
ohmmeter should read about 135 ohms on an L91B.
5. Connect the ohmmeter between controller terminals W and R and
raise the set point of the controller above the actual pressure being
measured. The ohmmeter should read the full value of the poten-
tiometer measured in step 4 (135 ohms for an L91B).
6. Slowly lower the set point of the controller while observing the
ohmmeter reading. The resistance should drop to zero at some set
point below the actual pressure.
The solid state sequencer operates on 120V AC/60 Hz and
each output is relay switched with a load rating of 125 VA at 120V
AC.
The input to the sequencer is a 0-135 OHM potentiometer sup-
plied on the operating pressure control. The sequencer has a sen-
sitivity control which is adjustable from min. to max. This sensi-
tivity control defines the amount of resistance (pressure) deviation
allowed before adding or subtracting a load. Potentiometer resis-
tance should decrease with increasing pressure. Connections are
made to red and white terminals of proportional pressure control.
See Wiring Diagram 337-300164-452 for Boiler With Solid State
Sequencer.
7. An approximation of the proportioning range can be made by
observing the change in set point required for a resistance change
from zero to full value.
8. When the controller is operating properly, reconnect the wires,
replace the cover, tighten the cover screw, and reset the controller
to the desired value.
9. Reconnect power to the controlled motor.
Main Scale
Adjusting
Screw
Proportioning Range
Adjusting Screw
R
W
B
Main Scale
Setting
Indicator
Set Point
Increase
Ohmmeter
Solid State Sequencer
B
R
W
Increases to
135 Ohms
Terminals are not Labeled, but Screw-Heads are
Color Coded Red (R), White (W) and Blue (B).
Typical wiring for boilers equipped with Auto Blowdown System and/or
Solid State Sequencer.
480V 3Ø 60 HZ
Optional Transformer
Boiler
On
Auto
Blowdown
System
Feed Water
Solenoid Valve
Sequencer
Pressure
Heater Contactor
Control
Heater Contactor
Heater Contactor
480/120V
5 Step
Control
Heater Contactor
15
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WATER FEED SYSTEMS
Automatic water feed is required on all CES Boilers:
Installation
LOW PRESSURE FEED
1. Locate feed on level floor or platform.
Note: Water Pressure feeds must be at least 10 psi greater than steam
pressure.
2. Connect water line to tagged fitting on feed.
3. Connect piping from discharge to water inlet check valve on boil-
er with minimum of 90˚ bends or other restrictions.
4. All electrical wiring should be done by licensed electricians in
accordance with local and national electrical codes. Refer to boil-
er instruction for manual wiring diagram.
Low Pressure
(Solenoid Feed)
Pressure
Range
Boiler
Volts
Inlet (In.)
CES Series
ES-99117
120
1/2
0-100 psi
5. If pump is located less than 30 feet from boiler, a second check
valve is required.
C
Automatic Low Pressure Water Feed
Low pressure water feed systems are used to supply make up
water to the boiler where incoming water line pressure is 10 psig or
greater than the operating pressure of the boiler. It consists of strainer,
solenoid valve and check valve.
E
B
D
A
F
Installation
The low pressure water feed systems are optional, and are factory
plumbed and wired to the boiler. However, CES series boilers which
are shipped from stock, the ES-99117 feed is shipped separately for
field installation.
Automatic High Pressure Water Feed
Pump Motor and Piping Assembly
Pump Motor Dimensions
Field Installation
Pipe
Dimensions (In.)
Note: The low pressure feed is to be plumbed to the inlet of the fac-
tory mounted check valve located on the make up water inlet to the
boiler. The plumbing and wiring are to be conducted by licensed per-
sonnel in accordance with national and local electrical codes. For
wiring refer to wiring diagrams supplied with the boiler.
Assembly
Pressure Size
Model No. H.P.
Range
0-100
0-150
NPT
1/2”
3/4”
A
B
C
D
E
F
ES-38002
ES-38020
1/3
1/2
12
12
10
10
11 7-3/8 6-1/2 7-1/2
11 7-3/8 6-1/2 7-1/2
HIGH PRESSURE FEED
High pressure makeup water pumps are used when water pressure
does not exceed boiler pressure by more than 10 psi and when con-
densate water is not returned to the boiler. Note: Consult factory or
sales office for motor/pump sizing for appropriate water feed system.
CONDENSATE RETURN SYSTEMS
Chromalox condensate return systems are used wherever con-
densed steam can be collected for reuse in the boiler. Significant ener-
gy can be saved by returning condensate to the boiler. The condensed
water is free from corroding minerals and carries a substantial amount
of heat which does not have to be replenished.
WARNING: Hazard of Electric Shock. Water feed system
must be effectively grounded in accordance with the
National Electrical Codes to eliminate shock hazard.
IMPORTANT: Vacuum breaker is required whenever using a con-
densate return system.
1/2" Water Fill
1-1/4" NPT Cond. Return
1/2" Water Fill
1-1/4" NPT Vent
H
18”
Frame
Member
1/2" NPT
Drain
See Detail
Pump
Support
Leg
Detail Pump Mount
Dimensions (In.)
26 and 33 Gal. Condensate Return System
Condensate
Model
For
Max
Storage Tank
Pump Discharge
Conn. (NPT)
Condensate
Boiler Model Pressure (psig) Capacity (Gals.) Pump (hp) Motor (Volts/Phase)
Ret. Conn (NPT)
L
H
W
ES38083V
ES38084V
CES 12 - 72
CES 100 - 180
100
100
26
33
1/3
1/2
120
120
1
1
1
1
1
1
23
23
46
52
18
18
16
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WATER FEED SYSTEMS
Installation
D. Be sure to use the proper wire. Electrical wiring to boiler
should be in accordance with National Electrical Code or local
wiring code following wiring diagram supplied.
Wiring
A. Check the voltage of the motor before making the wiring connec-
tion. Some Chromalox boilers are supplied with dual voltage sys-
tems. The motor should always match the voltage of the control
circuit.
B. The motor circuit should be wired into the pump control located
on the boiler. See boiler instruction sheet for wiring diagram.C.
All electrical wiring should be done by licensed electrician.
Plumbing
A. Connect water line to tagged fitting on the motor and pump assem-
bly control feeder.
B. Interconnecting piping between boiler and condensate return sys-
tem should be installed with a minimum of 90˚ bends or other
restrictions.
MAINTENANCE
elements in the boiler. If heavy solids build-up is evident or ele-
ments are distorted, replace all elements effected.
7. Examine heater element bolts. If these are corroded, replace with
ASME grade B-7 bolt of equivalent size.
WARNING: Hazard of Electric Shock. Disconnect all
power before working on boiler.
Chromalox Electric Steam Boilers are designed for years of trou-
ble-free performance. To establish a good preventative maintenance
program, we suggest the building maintenance man or engineer famil-
iarize himself with these simple rules:
8. Clean flange face on boiler carefully so as to maintain smooth gas-
ket surface.
9. Install gasket over heater element and insert element into boiler.
When installing heating element gasket do not use any liquid seal-
er, etc. Install dry.
10. Shown below is the bolt tightening sequence required when
replacing heating elements. All bolts, finger tight, should be
sequentially tightened (Fig.1, Fig.2 & Fig.3 on the following page)
in two (2) stages. First to 100 In/lb then to a final torque of 200
In/lb.
1. The use of specific boiler cleaning compounds cannot be rec-
ommended. We do recommend that a reputable firm of water
treatment engineers be consulted regarding conditioning boiler
water. Proper selection must be made of a compound to prevent
damage to copper sheath heating elements.
2. The sight glass should be checked daily to ensure the boiler has
adequate water.
3. A monthly inspection should be made of internal wiring. All elec-
trical connections should be checked for tightness.
Sequence
A check for water or steam leaks should also be made and any
loose fittings immediately tightened.
4. If boiler is equipped with Solid State Auxiliary Low Water Cutoff,
every four months the probe should be checked for deposits and
cleaned, if necessary. This is accomplished by removing inspec-
tion plate, removing the probe (with a standard sparkplug wrench)
cleaning and replacing.
Fig.1-Eight (8) bolt flange (5-3/4 Sq.)
Fig.2-Six (6) bolt flange (4-1/2 Sq.)
Fig.3-Four (4) bolt flange (2 1/2 Sq.)
1-5-3-7-2-4-6-8
1-3-5-6-2-4
1-3-2-4
11. Reconnect wiring to heater element and follow boiler startup pro-
cedures. Check that required electrical clearance between termi-
nals is maintained.
Note: The system will not operate if the boiler is using distilled,
demineralized or deionized water. At the same time, one of the
bottom heating elements should be removed. If scale has
begun to form, all elements should be cleaned and boiler
drained and flushed.
Note: Heater element bolts should be retorqued after generator has
been operating several hours at working pressure.
WARNING: Retorquing should be done when unit is
cold and with power disconnected at source.
5. IMPORTANT: The Manufacturers’ Data Report enclosed
within the instruction sheet is very important and must be put
in a safe place. You may be called upon to produce it by a state
agency.
12. Open water valve so water supply can reach boiler feed mech-
anism.
13. Put Main safety switch to “on” position.
14. Turn boiler switch to “on” position.
INSTRUCTIONS FOR ELEMENT REPLACEMENT
READ COMPLETELY BEFORE STARTING WORK
15. As boiler automatically refills, observe the new flange assembly
for possible leaks. If water is noticed, the bolts must be retight-
ened. Before doing this, turn the boiler off at the main fuse safety
switch.
1. Disconnect boiler from electric power supply at main safety
switch or fuse panel. Then, turn boiler switch to “off” position.
16. As boiler is heated to working pressure, check flange assembly
WARNING: Hazard of Electric Shock, can cause severe
personal injury or death. Disconnect power at source
before servicing.
again for leaks.
WARNING: Avoid use of chemical cleaning com-
pounds. Follow maintenance instruction.
WARNING: Hazard of severe personal injury. Allow
boiler to cool and pressure to drop to zero before ser-
vicing.
WARNING: Before installing your new elements, be
sure the McDonnell-Miller low-water cut-off is operat-
ing perfectly and the float chamber and lower equal-
izer column are completely clear of sludge or other
foreign matter.
Failure to do this may cause the immediate burnout of the new ele-
ments.
All elements are thoroughly checked before shipment. The manu-
facturer cannot be responsible for burnouts caused by a faulty low-
water cut-off.
The lower equalizer column can best be examined by breaking the
unions on either side and then visually and manually examining the
piping with your fingers or probes to see if it is clear and clean.
WARNING: Provision should be made to prevent water
damage from any eventual leaking of boiler or com-
ponents. Install near a floor drain.
2. On automatic feed units, close valve on incoming water line. Drain
boiler completely of water.
3. Open boiler door to expose heating element.
4. Before proceeding with heating element replacement, review
causes of element failure on the following page to determine if
items other than element replacement need to be serviced.
5. Check that boiler is properly drained. Note wire locations, discon-
nect wires, and remove failed heating element from the boiler.
6. Boilers with multiple heater elements examine condition of other
17
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MAINTENANCE
1
Boiler
1" Steam Equalizing Pipe
8
2
Pump and Low
Water Control
1-1/2"
1
Normal Boiler
2
Water Level
3
Cutoff Level
is Arrow Mark
6
7
Blowdown
Valve
3
1" Water Equalizing Pipe
5
4
6
5
4
2
3
1
5-3/4
REF.
4-1/2
REF.
FIG. 2
FIG. 1
4
2-1/2
F
R
IG
E
.
F.
3
IMMERSION HEATER FAILURE CAUSES
HEATER ELEMENT CONDITION
PROBABLE CAUSE
1. Water leakage at heater flange
1. Heater bolts improperly tightened. Refer to flange tightening instructions.
2. Debris on heater flange or generator flange surface. Clean prior to installation.
3. Heater bolts not retorqued after initial operation. Refer to flange tightening
instructions.
1. Faulty weld or braze on element to flange connection or corrosion.
2. Verify water is not exiting through heater terminal. Normally seen in condition #5.
2. Water leakage at heater element
to flange junction.
1. Loose wire connections. Tighten properly after inspection.
3. Burned wiring connections
2. High resistance in wire connection due to oxidation. Clean wires before
reconnecting to element. Replace if necessary.
1. Element has open circuit due to normal wear and tear to end life.
4. Heater element has open circuit.
(Element looks OK but Ohmmeter
check shows infinite resistance).
2. If generator is undersized for its application, heaters will be over worked and
reach end of life sooner.
3. Element has been overheated due to excessive scale build up. The scale acts as an
insulator retarding heat transfer to the water. Short life will result. If significant
scale is observed on element, this would indicate need for more frequent blowdown
or descaling.
4. Wrong voltage supplied to element.
5. Element not totally immersed in water. This causes a localized hot spot which
melts the wire inside the element. Cause of problem is fault in water level control
system. Elements damaged in this manner may be distorted. Repair and verify oper-
ation of the level control prior to restarting the heater.
1. Corrosion of heater element sheath-use of corrosive descaler compounds will etch
5. Heater element has developed a
ground fault. When this occurs, a
hole may be formed in the sheath
material, allowing water to enter the
element.
sheath. Use only approved descaler to remove scale.
2. Element has overheated due to excessive scale build up. This can cause localized
hot spot which sometimes arcs thru insulation and the ground metal sheath. More
frequent blowdown and/or descaling is needed.
3. Element not totally immersed in water. This causes a localized hot spot which pro-
duces a hole in sheath. Cause of problem is fault in water level control system.
Elements damaged in this manner may be distorted.
4. Excess vibration. Vibration could cause rubbing of elements wearing a hole in the
sheath. Vibration could be caused by large machinery nearby.
5. Wrong voltage supplied to element.
18
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RENEWAL PARTS IDENTIFICATION
Part Description
Part Number
Part Description
Part Number
GAUGE GLASS ASSEMBLIES, CHECK VALVES & SIGHT GLASSES
COLD WATER INJECTION PUMPS (0-100 PSIG)
Motor and Pump used in ES-38002 . . . . . . . . . . . . . . . . . . . . . .
Motor and Pump used in ES-38020 . . . . . . . . . . . . . . . . . . . . . .
Pump only used in ES-38002 . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump only used in ES-38020 . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor only used in ES-38002 115V 60Hz . . . . . . . . . . . . . . . . .
Motor only used in ES-38002 230V 50Hz . . . . . . . . . . . . . . . . .
Motor only used in ES-38020 115V 60Hz . . . . . . . . . . . . . . . . .
Strainer used in ES-38020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V-Band Mount used in ES-38002 & ES-38020 . . . . . . . . . . . . .
Solenoid Valve used in ES-38002 & ES-38020 . . . . . . . . . . . . .
Hose Assembly 18” Long used in ES-38002 & ES-38020 . . . . . . .
Pump Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter for Hose used in ES-38002 . . . . . . . . . . . . . . . . . . . . . .
226-300177-001
226-300177-004
226-300173-001
226-300173-004
193-300175-001
193-300175-002
193-300175-004
351-118664-001
355-300174-001
344-121780-002
349-300181-002
015-300125-001
001-300180-001
Check Valve 1/2” CES-6 through CES-18 . . . . . . . . . . . . . . . . . .
Check Valve 3/4” CES-24 through CES-180 . . . . . . . . . . . . . . . .
Gauge Glass Assembly Valves (O-ring gaskets included) . . . . . . .
Protector Rods (2 required) CES-6 through CES-18 . . . . . . . . .
Protector Rods (2 required) CES-24 through CES-72 . . . . . . . .
Protector Rods (2 required) CES-100 through CES-180 . . . . . . . .
O-Ring Gaskets (2 Required) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pyrex Glass 2 “O” Ring Gaskets 7 3/4”
CES-6 through CES-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pyrex Glass 2 “O” Ring Gaskets 9 3/4”
CES-24 through CES-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pyrex Glass 2 “O” Ring Gaskets 11 3/4”
344-118536-053
344-118536-054
344-120970-002
242-121047-008
242-121047-001
242-121047-009
132-073284-001
374-121046-011
374-121046-012
SAFETY VALVE
CONDENSATE RETURN SYSTEMS
Adapter for Hose used in ES-38020 . . . . . . . . . . . . . . . . . . . . . .
Pump and Motor Assembly used in ES-38083V 26 Gal. . . . . . .
Pump and Motor Assembly used in ES-38084V 33 Gal. . . . . . .
Condensate Tank only used in ES-38083V 26 Gal. . . . . . . . . . .
Condensate Tank only used in ES-38084V 33 Gal. . . . . . . . . . .
Parts Common to both 26 & 33 Gal. Systems
Impeller Raceway for Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seal for Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“O” Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Float Valve Assembly (Float Valve & Stem) . . . . . . . . . . . . . . . .
Disc Cover Assembly (Less Float Valve) . . . . . . . . . . . . . . . . . .
Gasket for Disc Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Assembly (Less Tank) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainer 1” NPT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge Glass Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gauge Glass Protector Rods (2 Required) . . . . . . . . . . . . . . . . .
Manual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sight Glass Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
001-300180-002
226-300172-003
226-300172-006
226-300218-001
226-300218-002
CES-120 through CES-100 . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 psig 1/2” CES-6 through CES-36 . . . . . . . . . . . . . . . . . . . . .
15 psig 3/4” CES-48 through CES-72 . . . . . . . . . . . . . . . . . . . .
15 psig 1 1/2” CES-100 through CES-180 . . . . . . . . . . . . . . . . .
30 psig 1/2” CES-6 through CES-60 . . . . . . . . . . . . . . . . . . . . .
30 psig 3/4” CES-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 psig 1” CES-100 through CES-180 . . . . . . . . . . . . . . . . . . . .
50 psig 1/2” CES-6 through CES-72 . . . . . . . . . . . . . . . . . . . . .
50 psig 1” CES-100 through CES-180 . . . . . . . . . . . . . . . . . . . .
374-121046-014
344-300032-001
344-300032-017
344-300032-040
344-300032-002
344-300032-018
344-300032-035
344-300032-003
344-300032-036
226-118671-001
251-118657-002
251-118657-003
344-300223-006
101-300220-001
132-300224-001
126-300221-001
351-118664-019
344-120970-002
374-121046-011
242-121047-008
344-121194-002
130-073287-004
344-121194-006
PRESSURE CONTROLS & SEQUENCES
100 psig 1/2” CES-6 through CES-72 . . . . . . . . . . . . . . . . . . . .
100 psig 3/4” CES-160 through CES-180 . . . . . . . . . . . . . . . . .
Operating Pressure Controls 10-100 psi . . . . . . . . . . . . . . . . . .
Hi-Limit Control Manual Reset 90 psi . . . . . . . . . . . . . . . . . . . .
344-300032-004
344-300032-020
292-300031-001
292-300031-002
LOW WATER CUTOFF & PUMP CONTROLS
5-Step Solid State Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . .
10-Step Solid State Sequencer . . . . . . . . . . . . . . . . . . . . . . . . .
Siphon Tube for Pressure Controls . . . . . . . . . . . . . . . . . . . . . .
MM-150 Control Complete (Auto Reset) . . . . . . . . . . . . . . . . . .
MM-150M Control Complete (Manual Reset) . . . . . . . . . . . . . .
Float and Rod for MM-150 & MM-150M . . . . . . . . . . . . . . . . . .
Complete Head Mechanism (Auto Reset) . . . . . . . . . . . . . . . . .
Complete Head Mechanism (Manual Reset) . . . . . . . . . . . . . . .
Head Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Wire Cut-off & Alarm Switch (Auto Reset) . . . . . . . . . . . . . . .
3 Wire Cut-off & Alarm Switch (Manual Reset) . . . . . . . . . . . . .
2 Wire Pump Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bellows Base Clamp & Bellows Assembly (Auto Reset) . . . . . . . .
Bellows Base Clamp & Bellows Assembly (Manual Reset) . . . . . .
323-300107-015
323-300107-015
215-300026-002
292-300065-001
292-300065-002
292-300065-102
292-300065-100
292-300065-101
292-300065-103
292-300065-104
292-300065-105
292-300065-106
292-300065-108
292-300065-109
AUX LOW WATER CUT-OFF (OPTIONAL EQUIPMENT)
Probe Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aux Low Water Cut-off Board with Relay . . . . . . . . . . . . . . . . . .
Aux Low Water Cut-off Board Without Relay . . . . . . . . . . . . . . .
Relay for Aux Low Cut-off Board . . . . . . . . . . . . . . . . . . . . . . . .
Probe 7 15/16” CES 6-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Probe 9 1/2” CES 24-72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
346-300035-001
323-300033-016
323-300033-017
072-300047-003
242-300036-019
242-300036-002
MISCELLANEOUS PARTS
Probe 10 15/16” CES-100 through CES-180 . . . . . . . . . . . . . . .
ON-OFF Switch with Pilot Light . . . . . . . . . . . . . . . . . . . . . . . . .
Control Circuit Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Circuit Terminal Block 4 Pole 250V 20AMP . . . . . . . . .
Control Circuit Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blank Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Element Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
242-300036-017
292-053223-002
128-072576-027
303-075443-003
129-300029-001
121-300199-001
132-146012-011
CONTROL VOLTAGE TRANSFORMERS (120V SECONDARY)
Bellows Base Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bellows Base Clamp Assembly (Auto Reset) . . . . . . . . . . . . . . .
Bellows Base Clamp Assembly (Manual Reset) . . . . . . . . . . . . .
292-300065-110
292-300065-111
292-300065-112
AUTO BLOWDOWN PARTS
Stainless Steel Bolts (6 required) for Element . . . . . . . . . . . . . .
Vacuum Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motorized Valve 1/2” CES-6 through CES-18 . . . . . . . . . . . . . .
Motorized Valve 1” CES-24 through CES-180 . . . . . . . . . . . . . .
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay SPST No. 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay Interval Delay .6-60 Sec. 3 . . . . . . . . . . . . . . . . . . . . . . . .
Switch Momentary Contact DPDT 4 . . . . . . . . . . . . . . . . . . . . . .
Switch Rocker SPDT 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pilot Light Red 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Block 4 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminal Block 5 Pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Block 30A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse 15A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motorized Ball Valve (Size 1/2) . . . . . . . . . . . . . . . . . . . . . . . . .
Motorized Ball Valve (Size 1/2) . . . . . . . . . . . . . . . . . . . . . . . . .
Motorized Ball Valve (Size 1/2) . . . . . . . . . . . . . . . . . . . . . . . . .
Motorized Ball Valve (Size 1) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motorized Ball Valve (Size 1) . . . . . . . . . . . . . . . . . . . . . . . . . . .
345-072565-428
344-300149-001
344-300089-002
344-300089-005
292-300101-002
072-300072-002
072-300148-003
292-300146-001
272-300147-001
213-300145-001
303-075444-003
303-075444-004
129-024494-001
128-121133-072
344-300089-001
344-300089-002
344-300089-003
344-300089-004
344-300089-005
LOW PRESSURE WATER FEED (ES-99117)
Bellows Base Assembly with Gasket . . . . . . . . . . . . . . . . . . . . .
292-300065-113
CORROSION RESISTANT ELEMENTS & GASKETS
1KVA 208V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1KVA 240/480V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1/2 KVA 208V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 1/2 KVA 240/480V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THREE PHASE
12kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
315-300088-020
315-300088-021
315-300088-025
315-300088-026
344-121780-002
351-118664-001
155-554735-044
155-554735-032
155-554735-015
155-554735-048
155-554735-028
155-554735-016
132-146012-011
HONEYWELL PRESSURE CONTROLS
Motorized Ball Valve (Size 1) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Pressure Control 2-15 psi . . . . . . . . . . . . . . . . . . . . .
Hi-Limit Control (Manual Reset) 15 psi . . . . . . . . . . . . . . . . . . .
Proportional Pressure Control 2-15 psi . . . . . . . . . . . . . . . . . . .
Operating Pressure Control 5-50 psi . . . . . . . . . . . . . . . . . . . . .
Hi-Limit Control (Manual Reset) 50 psi . . . . . . . . . . . . . . . . . . .
Proportional Pressure Control 2-50 psi . . . . . . . . . . . . . . . . . . .
Operating Pressure Control 10-150 psi . . . . . . . . . . . . . . . . . . .
Hi-Limit Control (Manual Reset) 90 psi . . . . . . . . . . . . . . . . . . .
Proportional Pressure Control 5-150 psi . . . . . . . . . . . . . . . . . .
344-300089-006
292-300038-001
292-300038-005
292-300039-001
292-300038-002
292-300038-006
292-300039-002
292-300038-003
292-300038-007
292-300039-003
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RENEWAL PARTS IDENTIFICATION
Part Description
VALVES & GAUGES
Part Number
1/4” Ball Valve (Pressure Gauge) . . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 1/2” CES-6 through CES-18 . . . . . . . . . . . . . .
Blowdown Valve 1” CES-24 through CES-180 . . . . . . . . . . . . . .
Pressure Gauge 2” 0-160 psi CES-6 through
CES-72 (50 and 100 psi trim) . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gauge 3 1/2” 0-160 psi CES-100 through
CES-180 (50 and 100 psi trim) . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gauge 2 1/2” 0-60 psi CES-6 through
CES-72 (30 psi trim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gauge 3 1/2” 0-60 psi CES-100 through
CES-180 (30 psi trim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gauge 2 1/2” 0-30 psi CES-6 through
CES-72 (15 psi trim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gauge 3 1/2” 0-30 psi CES-100 through
CES-180 (15 psi trim) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
344-300323-002
344-121194-006
344-121194-002
130-118661-001
130-118661-009
130-118661-003
130-118661-007
130-118661-013
130-118661-006
CONTACTORS
Manual Reset High Limit Control
Steam Pressure Gauge
Safety Valve
Steam Outlet
Fusable Contactors
30 amps with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . .
40 amps with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . .
50 amps with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . .
Non-fusable Contactors
60 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
072-122686-003
072-122686-006
072-122686-009
Operating
Pressure
Control
072-047913-016
072-047913-019
072-047913-012
Automatic
Blowdown
Control
Vacuum Breaker
POWER FUSES AND TERMINAL BLOCKS
30 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
072-047913-020
35 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60 amp 600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuse Block 35-60 amp 60 amp 600V . . . . . . . . . . . . . . . . . . . . .
Power Terminal Blocks
3 pole 115 amp 1 line circuit 1 load circuits . . . . . . . . . . . . . . .
3 pole 175 amp 1 line circuit 4 load circuits . . . . . . . . . . . . . . .
3 pole 335 amp 1 line circuit 4 load circuits . . . . . . . . . . . . . . .
3 pole 335 amp 1 line circuit 8 load circuits . . . . . . . . . . . . . . .
128-121138-033
128-121133-064
128-121133-065
128-121133-066
128-121133-067
129-047445-002
McDowell & Miller
Low Water Cutoff
and Pump Control
Sight Glass
Heating
Elements
303-071809-032
303-071809-012
303-071809-014
303-071809-016
Fuses, Terminal
Blocks and
Contactors
Insulation
Automatic
Blowdown
Valve
HEATING ELEMENTS — SPECIFY VOLTAGE
Check Valve
Water Feed
SINGLE PHASE
12kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THREE PHASE
155-554735-004
155-554735-009
155-554735-006
155-554735-011
Strainer
Gate Valves
12kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 346V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 380V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 346V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 380V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22.5kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22.5kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22.5kW 550V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
155-554735-003
155-554735-001
155-554735-012
155-554735-017
155-554735-008
155-554735-005
155-554735-002
155-554735-013
155-554735-018
155-554735-010
155-554735-021
155-554735-022
155-554735-019
Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
2150 N. RULON WHITE BLVD., OGDEN, UT 84404
Phone: 1-800-368-2493
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