®
Chromalox
SERVICE REFERENCE
Installation, Operation
DIVISION
SALES
4
SECTION CHPES
(Supersedes PQ436)
and
REFERENCE
PQ436-1
RENEWAL PARTS IDENTIFICATION
161-562802-002
DATE
MAY, 1999
Type CHPES-6A through CHPES-180A
High Pressure Electric Steam Boiler
Standard Trim is 250 PSI — 0-225 PSI 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
Quantity/Rating
of Contactors
Elec
at
No./kW
Heating
Elements
Rating Cap. Vol. 212˚F
(BHP) (kW) (Gals.) (Lbs./Hr.)
Model
208
240
480†
Type CHPES — 20-250 PSIG
CHPES-6A
CHPES-9A
CHPES-12A 1.22
CHPES-18A 1.73
CHPES-24A 2.45
0.6
0.9
6
6
6
6
18
27
36.2
51.2
30
30
40
50
30
30
30
30
30
30
1-6
1-9
1-12
1-17
2-12
9
12
17
24
6
50
30
14.3
72.3 2-40
2-30
2-30
1-40
87.4
1-40
1-30
1-12
1-17
CHPES-30A 2.95
CHPES-36A 3.47
CHPES-48A 4.69
29
34
46
14.3
40
50
1-50
14.3 102.5 2-50
2-50
2-17
1-40
14.3 138.7
2-50
1-30
2-50
1-40
1-30
1-12
2-17
2-50
14.3 174.8
2-40
2-30
2-50
4-50
6-50
8-50
2-12
2-17
4-17
6-17
8-17
CHPES-60A 5.91
CHPES-72A 6.93
58
68
2-40
14.3
205
307
410
4-50
6-50
—
2-50
3-50
4-50
CHPES-100A 10.40 102 27.8
CHPES-135A 13.9 136 30.5
1-30
CHPES-160A 16.1 157.5 30.5
CHPES-180A 18.4 180 30.5
475
543
—
—
7-60
8-60
7-22.5
3-60
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.
DIMENSIONS
Type CHPES — Dimensions (In.)
Type CHPES — Dimensions (In.)
Model
CHPES-6A
CHPES-9A
A
B*
C
D
E
F
G
H
I
J
1
1
1
1
1
K
L
Model
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
1/2 1/2
1/2 1/2
1/2 1/2
1/2 1/2
CHPES-48A 43-1/2 26
CHPES-60A 43-1/2 26
CHPES-72A 43-1/2 26
CHPES-100A 63-1/2 30
CHPES-135A 63-1/2 32
CHPES-160A 63-1/2 32
CHPES-180A 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
37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2
CHPES-12A 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2
CHPES-18A 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2
55
21
27
36 16-3/4 37-1/2 1-1/2 1-1/4
CHPES-24A 43-1/2 26
CHPES-30A 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
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
CHPES-36A 43-1/2 26
*Add two inches for transformer.
INSTALLATION
water line valves open at all times except during blowdown.
WARNING: To avoid electrical shock hazard, boilers
must be suitably grounded to earth.
1. The boiler should be mounted on a solid level foundation. Note:
When installing boiler, allow sufficient room (21” minimum) to
facilitate removal of elements if and when necessary.
2. WARNING: A minimum distance of 18” between boil-
er and any combustible material must be maintained.
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
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
WIRING
damage. Industrial type lightning protectors should be installed per
manufacturer’s recommendations at your service entrance. Check
your contractor or electrical dealer for recommended type for your
system.
WARNING: Hazard of Shock. Disconnect all power
before working on boiler. Boilers must be effectively
grounded in accordance with the National Electrical
Code to eliminate shock hazard.
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.
WARNING: Use 90˚copper conductors only.
1. Select proper wire gauge and type for supply conductors in accor-
dance with the National Electrical Code and local wiring codes fol-
lowing wiring diagram supplied (See recommendations for dis-
connect switches and fusing).
2. The unit is completely wired and pre-tested before shipment. No
internal wiring is required. Check all electrical connections for
tightness and retighten if necessary before energizing.
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).
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.
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
TYPICAL WIRING DIAGRAMS
Use Applicable wiring diagrams based on model number and power voltage.
3 Phase Voltage
3 Phase Voltage
3 Phase Voltage
Boiler
208
1
1
1
1
240
1
1
1
1
480
1
1
1
1
Boiler
208
2
2
4
6
240
2
2
4
6
480
3
3
5
7
Boiler
208
8
240
8
10
12
10
480
9
11
12
10
CHPES-6A
CHPES-9A
CHPES-12A
CHPES-18A
CHPES-24A
CHPES-30A
CHPES-36A
CHPES-48A
CHPES-60A
CHPES-72A
CHPES-100A
CHPES-135A
CHPES-160A
CHPES-180A
Export
2
2
3
6
6
7
14
Diagram 1
L1 L2
L3
1
GND
C1
1 HTR
1L1
1L2
1L3
FU1
FU2
1
GND
FU3
CR
IT1
IT2
IT3
10L
20L
30L
Feed Water
Motor
2L1
2L2
2L3
FU4
FU5
FU6
1
Mtr
Customer
Connect
FU9
FU8
H2
FU7
H1
1PB
FU
2
Feed Water
Electrical
Connection
Optional Transformer
1
3
3
GND
X1
X2 X4
X3
3
GND
2
1
2
1
B
W
2
1
FU9
1PB
GND
GND
1LT
R
BR
Y
On
Off
B
Boiler On
IFS
Feed Water
CR
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
Black
B
=
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
* Boilers under 40 Amps total (not fused)
Y
G
BL
W
White
4
TYPICAL WIRING DIAGRAMS
Diagram 2
L1 L2
L3
1
GND
C1
1 HTR
2 HTR
1L1
1L2
1L3
FU1
FU2
2
GND
FU3
C2
2L1
2L2
2L3
FU4
FU5
FU6
CR
IT1
IT2
IT3
10L
20L
30L
Feed Water
Motor
3L1
3L2
3L3
FU7
FU8
1
Mtr
FU9
Customer
Connect
FU11
H4
FU10
H3
H1
H2
FU12
1TB
1PB
Optional Transformer
X1
X2 X4
X3
3
2
1
Feed Water
Electrical
Connection
2 GND
GND
C1
FU
C2
FU
2
1
B
FU12
1PB
W
4 5 6
1 2 3
1LT
R
BR
Y
On
Off
B
Boiler On
IFS
CR
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
Diagram 3
L3
L1 L2
1
C1
GND
1 HTR
2 HTR
1L1
1L2
1L3
FU1
FU2
2
GND
FU3
2L1
2L2
2L3
CR
IT1
IT2
IT3
10L
20L
30L
Feed Water
Motor
3L1
FU4
FU5
3L2
3L3
1
Mtr
FU6
Customer
Connect
FU7
FU8
H4
H1
H3
X3
H2
FU9
1PB
Optional Transformer
X1
2 GND
X2 X4
3
2
1
Feed Water
Electrical
Connection
GND
C1
FU
2
1
B
1 2 3
W
FU9
1PB
1LT
R
BR
Y
On
Off
B
Boiler On
IFS
Feed Water
CR
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
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
CR
IT1
IT2
IT3
10L
Feed Water
Motor
4L1
4L2
4L3
FU10
20L
30L
FU11
FU12
1
Mtr
Customer
Connect
FU13
H1
FU14
H4
H3 H2
Optional Transformer
1PB
X1
X2 X4
X3
FU15
1TB
2
3
1
GND
Feed Water
Electrical
Connection
2
1
2 GND
B
W
FU15
1PB
1LT
R
1 GND
BR
Y
On
Off
B
Boiler On
IFS
C1
C2
C3
FU
CR
C1
Feed Water
3
1PS
2PS
FU
1 2 3
Htr
O
FU
4 5 6
O
O
Heater
7 8 9
Contactor
C2
C3
1
2
Heater
Contactor
HTR
HTR
Wire Color Code
Black
B
=
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
Diagram 5
L1 L2 L3
1
GND
C1
C2
1 HTR
2 HTR
1L1
1L2
1L3
FU1
FU2
2
GND
FU3
2L1
2L2
2L3
FU4
FU5
FU6
CR
3 HTR
3L1
3L2
3L3
IT1
10L
FU7
Feed Water
Motor
4L1
4L2
4L3
IT2
IT3
20L
30L
FU8
FU9
1
Mtr
Customer
Connect
FU10
H1
FU11
H4
H2
H3
Optional Transformer
FU12
1TB
1PB
X3
X4
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
W
FU12
1PB
1LT
R
BR
On
Off
B
Boiler On
IFS
Y
CR
C1
C2
Feed Water
1PS
2PS
O
O
O
3
HTR
Heater
Contactors
1
2
HTR
HTR
Wire Color Code
Black
B
=
BR = Brown
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
6
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
CR
IT1
IT2
IT3
10L
Feed Water
Motor
5L1
5L2
5L3
FU13
20L
30L
FU14
FU15
1
Mtr
Customer
Connect
FU17
H2
X2
FU16
H1
1PB
Optional Transformer
FU18
X1
X3
X4
Feed Water
Electrical
Connection
1TB
2
3
1
GND
2
1
2 GND
B
W
FU18
1PB
1LT
R
1 GND
BR
Y
On
Off
B
Boiler On
IFS
C1
C2
C4
C3
CR
C1
Feed Water
3
Htr
4
Htr
FU
10
FU
7 8 9
FU
1PS
FU
2PS
O
O
O
Heater
4 5 6
1 2 3
11 12
Contactors
C2
C3
1
2
HTR
HTR
Wire Color Code
Black
B
=
C4
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
1
GND
Diagram 7
L3
L1 L2
C1
C2
2 HTR
4 HTR
1 HTR
3 HTR
FU4
FU5
FU6
1L1
FU1
2L1
FU2
FU3
1L2
1L3
2L2
2L3
2
GND
4L1
4L2
4L3
3L1
3L2
3L3
CR
IT1
IT2
IT3
10L
FU7
Feed Water
Motor
5L1
5L2
5L3
20L
FU8
FU9
1
Mtr
30L
Customer
Connect
FU11
H4
FU10
H1
H3
H2
3
GND
FU12
1TB
Optional Transformer
1PB
X1 X3
X2 X4
2
3
1
Feed Water
Electrical
Connection
2 GND
C2
GND
C1
2
1
FU
FU
B
1 2 3
4 5 6
W
FU12
1PB
1LT
R
BR
Y
On
Off
B
Boiler On
3
4
IFS
HTR
HTR
Feed Water
CR
1PS
O
2PS
O
O
Heater
Contactors
C1
C2
1
2
HTR
HTR
Wire Color Code
Black
B
=
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
7
TYPICAL WIRING DIAGRAMS
Diagram 8
L2
L1
L3
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
CR
IT1
4L1
4L2
4L3
7L1
7L2
7L3
Feed Water
Motor
FU10
FU11
FU12
FU19
FU20
10L
20L
30L
1
Mtr
IT2
IT3
FU21
FU22
FU23
Customer
Connect
Feed Water
Electrical
1PB
1TB
Connection
FU24
Optional Transformer
X1
X2 X4
X3
3
GND
1
2
3 GND
C1
C3
C2
2
1
2
GND
FU
4 5 6
FU
1 2 3
FU
7 8 9
B
W
FU24
1PB
1LT
R
On
BR
B
Boiler
On
Off
IFS
Y
C4
C5
C6
Feed Water
5
6
CR
C1
C2
C3
HTR
HTR
3PS
2PS
1PS
FU
10
FU
13
FU
16
O
O
O
Heater Contactor
Heater Contactor
11 12
14 15
17 18
3
HTR
4
HTR
1
HTR
2
HTR
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
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
FU1
FU2
FU3
1
GND
C1
1 HTR
C3
5 HTR
5L1
1L1
1L2
FU7
FU8
FU9
2
GND
5L2
5L3
1L3
2 HTR
3 HTR
4 HTR
2L1
2L2
6 HTR
6L1
6L2
6L3
2L3
C2
3L1
3L2
FU4
FU5
FU6
3L3
CR
4L1
4L2
4L3
IT1
IT2
IT3
10L
Feed Water
Motor
7L1
7L2
7L3
FU10
20L
30L
FU11
FU12
1
Mtr
Customer
Connect
FU15
FU13
FU14
H2 H4
1 GND
Feed Water
Electrical
1PB
1TB
Connection
H1 H3
3 GND
Optional Transformer
C1
C3
C2
3
1
2
2
GND
X1 X3
X2 X4
FU
4 5 6
FU
1 2 3
FU
7 8 9
GND
1
2
B
W
FU15
1PB
1LT
R
On
BR
Y
B
Boiler
On
5
6
Off
IFS
HTR
HTR
Feed Water
CR
3PS
2PS
1PS
O
3
4
O
O
Heater Contactor
Heater Contactor
Heater Contactor
C1
C2
C3
HTR
HTR
1
HTR
2
HTR
Wire Color Code
Black
BR = Brown
B
=
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
8
TYPICAL WIRING DIAGRAMS
L2
L1
L3
1
GND
Diagram 10
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
7L1
7L2
5L3
FU7
FU8
FU9
FU13
FU20
FU21
4L1
4L2
4L3
FU10
FU11
FU12
6 HTR
8L1
FU22
8L2
8L3
FU23
FU24
CR
IT1
Feed Water
Motor
9L1
9L2
9L3
FU25
FU26
10L
20L
30L
1
Mtr
IT2
IT3
FU27
Customer
Connect
FU28
H1 H3
FU29
H4
Feed Water
Electrical
H2
1PB
1TB
Connection
FU30
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
FU30
1PB
1LT
R
23 24
On
BR
Y
B
Boiler
On
8
7
HTR
HTR
Off
IFS
Feed Water
CR
C1
C2
C3
C1
C4
C2
C3
5
HTR
6
3PS
1PS
O
O
O
HTR
10
1
2
3
4
5
6
7
8
9
11 12
3
HTR
4
Heater Contactor
Heater Contactor
HTR
1
2
Wire Color Code
Black
HTR
HTR
C4
C5
B
=
BR = Brown
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
R
=
=
=
=
=
=
Red
C6
C7
C8
2PS
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
L1 L2 L3
FU1
FU2
FU3
1
Diagram 11
GND
C1
1 HTR
C3
5 HTR
5L1
1L1
1L2
FU7
FU8
FU9
2
5L2
5L3
GND
1L3
2 HTR
3 HTR
4 HTR
2L1
2L2
6 HTR
7 HTR
6L1
6L2
6L3
2L3
C2
C4
FU4
5L1
3L1
3L2
FU10
FU11
FU12
7L2
5L3
FU5
FU6
3L3
4L1
4L2
4L3
8 HTR
8L1
8L2
8L3
CR
IT1
Feed Water
Motor
9L1
9L2
9L3
FU13
FU14
10L
20L
30L
1
Mtr
IT2
IT3
FU15
Customer
Connect
FU17
H4
FU16
FU18
Feed Water
Electrical
1 GND
1PB
1TB
H1 H3
H2
Connection
Optional Transformer
3 GND
C1
C3
C4
C2
X1 X3
X2 X4
3
2
1
2
GND
FU
10
GND
FU
4 5 6
FU
1 2 3
FU
7 8 9
1
2
11 12
B
W
7HTR
8
FU18
1PB
HTR
1LT
On
BR
Y
B
Boiler
On
R
5
HTR
6
HTR
Off
IFS
Feed Water
CR
C1
C2
C3
C4
3PS
1PS
O
3
HTR
4
HTR
O
O
Heater Contactor
Heater Contactor
1
HTR
2
HTR
Wire Color Code
Black
B
=
2PS
BR = Brown
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
9
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
CR
4L1
4L2
4L3
FU10
FU11
FU12
IT1
Feed Water
Motor
8L1
8L2
8L3
FU22
FU23
10L
20L
30L
1
Mtr
IT2
IT3
FU24
Customer
Connect
Feed Water
Electrical
FU25
H1
FU26
H4
1PB
H2
H3
1TB
Connection
FU27
Optional Transformer
X3
X1
X4
X2
3 GND
C5
C7
3
C6
1
2
GND
2
FU
13
FU
16
FU
19
1
2
GND
B
W
14 15 17 18 20 21
FU27
1PB
7
HTR
1LT
R
On
BR
Y
B
Boiler
On
C1
C2
C3
FU
8
Off
C4
IFS
5
HTR
6
Feed Water
CR
C1
C2
C3
HTR
FU
2
FU
10
FU
5
3PS
1PS
O
O
O
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
1
3
4
6
7
9
11 12
3
HTR
4
HTR
1
2
HTR
HTR
C4
C5
Wire Color Code
Black
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
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
C2
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
3L1
3L2
3L3
FU4
FU5
FU6
7L1
7L2
5L3
FU10
FU11
FU12
4L1
4L2
4L3
CR
IT1
Feed Water
Motor
8L1
8L2
8L3
FU13
FU14
10L
20L
30L
1
Mtr
IT2
IT3
FU15
Customer
Connect
Feed Water
Electrical
1PB
1TB
Connection
FU16
H1
FU17
H4
FU18
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
FU18
1PB
1LT
R
On
BR
Y
B
Boiler
On
5
HTR
6
HTR
Off
IFS
Feed Water
CR
C1
C2
C3
3PS
2PS
3
HTR
4
HTR
1PS
O
O
O
Heater Contactor
Heater Contactor
Heater Contactor
Heater Contactor
1
HTR
2
HTR
Wire Color Code
Black
B
=
Cabinet Exterior Left Side
Panel Layout
Cabinet Exterior Right Side
C4
BR = Brown
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Y
G
BL
W
White
10
TYPICAL WIRING DIAGRAMS
Diagram 14
346V 3Ø 50 HZ
L2
1
L1
L3
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
CR
IT1
Feed Water
Motor
5L1
5L2
5L3
FU13
FU14
10L
20L
30L
3
1PB
Connection
1
Mtr
GND
FU16
IT2
IT3
1TB
FU15
1CR
Customer
Connect
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
FU16
1PB
1LT
R
1
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
OPERATION
B. ADJUSTING OPERATING PRESSURE CONTROLS
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)
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.
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.
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.
Pressure
Adjusting
Screw
Pressure
Manual
Adjusting
Reset
Differential
Adjusting Screw
Mercury
Switch
Screw
Mercury
Switch
Lever
Scaleplates
Scaleplates
Differential
Setting
Indicator
Pressure
Setting
Indicator
Pressure
Setting
Indicator
Operating
Lever
Index
Mark
Index
Mark
Pointer
Operating
Lever
Diaphragm
Assembly
Pointer
Leveling
Indicator
Leveling
Indicator
Diaphragm
Assembly
Figure 2 — Pressure Control
To check operation of the controls, close steam outlet valve and adjust
operating pressure control to a low pressure setting. Also, set high limit
control at 10 psig above operating pressure control. Turn on boiler, and
Figure 3 — Hi Limit Control
OPERATION
RECOMMENDED START-UP PROCEDURES
than mineral content, take this into consideration in determining
which schedule is to be followed.
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.
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.
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
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. Tzhe 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
13
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.
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
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.
Specifications
Input Supply — 120 vac/50-60 hz
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.
Detectable Range — 100,000 ohms
Probe Voltage — 24 Vac
Probe Current — 10 milliamps
Control Relay — Single pole double throw
WARNING: Control will not work with de-ionized or
THROTTLING RANGE SETTING L91B
demineralized water.
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.
Typical Wiring for
Auxiliary Low Water Cutoff
Electronic Resistance Sensing
Amplifier for Auxiliary
Low Water Cutoff
PRESSURE
SCALE RATING
0-15 psi
VALUE EACH
DIVISION ON SCALE
2.2 psi
20-300 psi
16.4 psi
480V
3
1
60 HZ
L2
Pressure scale rating will vary depending on pressure control supplied.
CHECKOUT
GND
L1
L3
C1
FU
FU
FU
1 HTR
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.
2
GND
Fuses Supplied
on Boilers Rated
Over 40 Amps.
FU2
FU1
H1 H3 H2 H4
480V/120V
1.5 KVA
1
2
3
X3
X2 X4
X1
GND
2
1
B
FU3
W
1LT
R
1PB On
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
O
W
L1 L2
O
2PS
BL
Heater
Contactor
BL
C1
H
NO
C
C1
Adjusting Screw
R
Differential Adjusting Screw
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.
R
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.
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
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
(L91B) Proportioning Pressure Control used with Sequencer Control
14
OPTIONAL EQUIPMENT FOR STEAM BOILERS
IF A CONTROLLER SEEMS TO OPERATE IMPROPERLY
If the controller is suspected of operating improperly, it may be
further checked as follows:
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.
Sequencer (5-Step)
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.
TESTING OPERATION OF SEQUENCER
1. With boiler off, remove wiring from pressure control on
sequencer low voltage terminal board.
2. Turn on boiler to supply the voltage to the sequencer. Short ter-
minal R and B for counterclockwise rotation and terminal R and
W for clockwise rotation.
9. Reconnect power to the controlled motor.
3. If sequencer operates under this test procedure, but when rewired
to pressure controller and does not function, check pressure con-
trol. Note that wiring is W-B and B-W-R-R between sequencer
and pressure controller
Main Scale
Adjusting
Screw
Proportioning Range
Adjusting Screw
BOILER SEQUENCE — SOLID STATE
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 interruption, all
heating elements are immediately de-energized for safety. When
power resumes, the control will restage the loads one at a time.
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 sensi-
tivity control which is adjustable from min. to max. This sensitivity
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.
R
W
B
Main Scale
Setting
Indicator
Set Point
Increase
Ohmmeter
B
R
W
Increases to
135 Ohms
Terminals are not Labeled, but Screw-Heads are
Color Coded Red (R), White (W) and Blue (B).
BOILER SEQUENCER (5 STEP) MOTOR DRIVEN
RECYCLE FEATURE
The step control is designed to drop out all contactors when con-
trol circuit is interrupted. On resumption of power, the camshaft
rotates to the counterclockwise (ccw) limit, opening all the load
switches. The recycle relay then energizes, pulling in the load con-
tact, and finally the camshaft rotates clockwise (cw) to the position
called for by the pressure controller energizing, in sequence, the
required load stages.
Solid State Sequencer
15
OPTIONAL EQUIPMENT FOR STEAM BOILERS
480V 3Ø 60 HZ
L1 L2 L3
Feed Water
Motor
CR
IT1
IT2
IT3
10L
20L
30L
1
Mtr
Optional Transformer
Customer
Connect
W
Boiler
On
Auto
Blowdown
System
Feed Water
CR
Sequencer
Solenoid Valve
Wire Color Code
Black
B
=
BR = Brown
Pressure
Control
Heater Contactor
R
=
=
=
=
=
=
Red
O
Orange
Yellow
Green
Blue
Heater Contactor
Heater Contactor
Heater Contactor
Y
480/120V
G
BL
W
5 Step
Control
White
Typical wiring for boilers equipped with Auto Blowdown System and/or Solid State Sequencer
WATER FEED SYSTEMS
HIGH PRESSURE FEED
1. Locate feed on level floor or platform.
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.
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.
Installation
WARNING: Hazard of Electric Shock. Water feed system
must be effectively grounded in accordance with the
National Electrical Codes to eliminate shock hazard.
5. If pump is located less than 30 feet from boiler, a second check
valve is required.
Automatic High Pressure Water Feed Pump/Motor Assembly
Pump Motor Dimensions
Pipe
Pressure Size
Range (NPT)
Dimensions (In.)
Assembly
Model
HP
A
B
C
D
E
F
ES-38020
3/4
0-200
1/2 16-1/4
3
7-3/16 4-7/8 6-1/2 6-1/8
16
WATER FEED SYSTEMS
CONDENSATE RETURN SYSTEMS
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.
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.
Chromalox condensate return systems are used wherever condensed
steam can be collected for reuse in the boiler. Significant energy 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.
IMPORTANT: Vacuum breaker is required whenever using a conden-
Plumbing
sate return system.
A. Connect water line to tagged fitting on the motor and pump assem-
Installation — Wiring
bly control feeder.
B. Interconnecting piping between boiler and condensate return system
should be installed with a minimum of 90˚ bends or other restrictions.
A. Check the voltage of the motor before making the wiring connection.
Some Chromalox boilers are supplied with dual voltage systems. The
motor should always match the voltage of the control circuit.
1-1/4” NPT Vent
L
30 Gal.
Condensate
Return Inlet
Return System
Make-Up Valve
Inlet
1-1/4” NPT
3” NPT
Discharge
H
1” NPT
Drain
W
Dimensions (In.)
Condensate
Model
Storage Tank
Capacity (Gals.)
Pump Discharge
Conn. (NPT)
Condensate
Ref. Conn. (NPT)
For Boiler Model
Max. Pressure (psig)
Pump (Hp) Motor (Volts/Phase)
240 / 480 1
L
H
W
HPCS-
3003
All CHPES
250
30
3
1-1/4
2
36
42-3/16 24
MAINTENANCE
INSTRUCTIONS FOR ELEMENT REPLACEMENT
WARNING:Before installing your new elements, be sure
the McDonnell-Miller low-water cut-off is operating
perfectly and the float chamber and lower equalizer
column are completely clear of sludge or other foreign
matter.
WARNING: Hazard of Shock. Disconnect all power
before working on boiler.
Chromalox Electric Steam Boilers are designed for years of trouble-free
performance. To establish a good preventative maintenance program,
we suggest the building maintenance man or engineer familiarize him-
self with these simple rules:
1. The use of specific boiler cleaning compounds cannot be rec-
ommended. We do recommend that a reputable firm of water treat-
ment engineers be consulted regarding conditioning boiler water.
Proper selection must be made of a compound to prevent damage to
copper sheath heating elements.
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 pip-
ing with your fingers or probes to see if it is clear and clean.
2. The sight glass should be checked daily to ensure the boiler has ade-
quate water.
3. A monthly inspection should be made of internal wiring. All elec-
trical connections should be checked for tightness.
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 inspection
plate, removing the probe (with a standard sparkplug wrench) clean-
ing and replacing.
Boiler
1-1/2"
1" Steam Equalizing Pipe
Pump and Low
Water Control
Normal Boiler
Water Level
Note: The system will not operate if the boiler is using distilled,
demineralized or deionized water. At the same time, one of the bot-
tom heating elements should be removed. If scale has begun to form,
all elements should be cleaned and boiler drained and flushed.
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.
Cutoff Level
is Arrow Mark
Blowdown
Valve
1" Water Equalizing Pipe
17
MAINTENANCE
READ COMPLETELY BEFORE STARTING WORK
7. When all (6) flange bolts are tight, connect all wires to terminals.
Make certain wires are clean and bright to assure good electrical
contact and nuts on screws are firmly secured.
WARNING: Avoid use of chemical cleaning com-
pounds. Follow maintenance instructions.
8. Open water valve so water supply can reach boiler feed mecha-
nism.
1. Disconnect boiler from electric power supply at main safety
switch or fuse panel. Then, turn boiler switch to “off” position.
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. Disconnect wire (electric) leads connecting element to main power
system of boiler. Again note wire connections to facilitate
reassembly. Proceed to remove (6) 5/16-18 bolts from flange.
5. Thoroughly clean boiler flange of all foreign material. Be certain
no part of old gasket remains on boiler flange.
9. Put main safety switch to “on” position.
10. Turn boiler to “on” position.
11. As boiler automatically refills, observe the new flange assemble
for possible leaks. If water is noticed, to bolts must be retightened.
Before doing this, turn the boiler off at the main fuse safety switch.
12. As boiler is heated to working pressure, check flange assembly
again for leaks.
6. Apply “Slic-Tite” Gasket Compound or equal to both surfaces of
new gasket with supplied replacement element. Proceed to install
element flange assembly with gasket between boiler flange and
element flange. In doing this, be careful to align flange holes so
wire connection terminals on element assembly are in line with
previously disconnected wire leads to facilitate easy connections.
WARNING: Avoid the use of chemical cleaning com-
pounds. Follow maintenance instructions
RENEWAL PARTS IDENTIFICATION
Safety Valve
Operating Pressure Control
Range 10-300 Psi
Manual Reset High
Limit Control
Steam Outlet
Pressure Gauge, 0-600 Psi
On/Off Switch and
Pilot Light
Water Level Sight Glass
McDonnell & Miller #194
Low Water Cutoff/Pump
Check Valve/Water Inlet
(not shown)
Drain Blowdown Valve
Drain Blowdown Valve
18
RENEWAL PARTS IDENTIFICATION
Part Description
VALVES & GAUGES
Part Number
Part Description
Part Number
PRESSURE CONTROLS & SEQUENCES
1/4” Ball Valve (Pressure Gauge) . . . . . . . . . . . . . . . . . . . . . . . .
Blowdown Valve 1” CHPES-24A
through 180A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Gauge 3-1/2” 0-600 psi CHPES-100A
344-121194-007
344-121194-042
Operating Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hi-Limit Control (Manual Reset) 15 psi . . . . . . . . . . . . . . . . . . .
Proportional Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . .
5-Step Motor-Driven Sequencer . . . . . . . . . . . . . . . . . . . . . . . .
10-Step Motor-Driven Sequencer . . . . . . . . . . . . . . . . . . . . . . .
6-Step Solid State Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . .
10-Step Solid State Sequencer . . . . . . . . . . . . . . . . . . . . . . . . .
Siphon Tube for Pressure Controls . . . . . . . . . . . . . . . . . . . . . .
429-300038-009
429-300038-008
429-300039-004
323-121505-001
323-121505-002
323-300107-015
323-300107-015
215-300026-002
CONTACTORS
through 180A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fusible Contactors
30 amp with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . . .
40 amp with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . . .
50 amp with 35-60 amp 600V block . . . . . . . . . . . . . . . . . . . . .
Non Fusible Contactors
130-118661-012
LOW WATER CUTOFF & PUMP CONTROLS
072-122686-003
072-122686-006
072-122686-009
MM-94 Control Complete (Auto Reset) . . . . . . . . . . . . . . . . . . .
MM-94M Control Complete (Manual Reset) . . . . . . . . . . . . . . .
292-300065-007
292-300065-008
CONTROL VOLTAGE TRANSFORMERS (120V SECONDARY)
60 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
072-047913-016
072-047913-019
1KVA 208V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1KVA 240/480V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1/2 KVA 208V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1/2 KVA 240/480V Primary . . . . . . . . . . . . . . . . . . . . . . . . . . .
315-300088-020
315-300088-021
315-300088-025
315-300088-026
POWER FUSES AND TERMINAL BLOCKS
40 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30 amp without fuse block . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
072-047913-012
072-047913-020
128-123459-012
128-123459-013
128-123459-014
128-123459-015
128-123459-016
129-047445-002
COLD WATER INJECTION PUMPS (0-100 PSIG)
Motor and Pump used in ES-38020 HP . . . . . . . . . . . . . . . . . . .
Pump only used in ES-38020 HP . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Pump used in ES-38020 HP . . . . . . . . . . . . . . . . . . .
Strainer used in ES-38020 HP . . . . . . . . . . . . . . . . . . . . . . . . . .
V-Band Mount used in ES-38020 HP . . . . . . . . . . . . . . . . . . . . .
Solenoid Valve used in ES-38020 HP . . . . . . . . . . . . . . . . . . . .
226-300177-009
226-300173-011
193-121843-020
351-118664-001
355-300174-001
344-121780-002
3 Pole 115 amp 1 line circuit 1 load circuits . . . . . . . . . . . . . . .
3 Pole 175 amp 1 line circuit 4 load circuits . . . . . . . . . . . . . . .
303-071809-032
303-071809-012
CONDENSATE RETURN SYSTEMS
Hose Assembly 18” Long used in EES-38020 HP . . . . . . . . . . . . .
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Return System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
349-300181-002
128-121133-053
359-122688-031
296-300222-026
HEATING ELEMENTS — SPECIFY VOLTAGE
3 Pole 335 amp 1 line circuit 4 load circuits . . . . . . . . . . . . . . .
3 Pole 335 amp 1 line circuit 8 load circuits . . . . . . . . . . . . . . .
SINGLE PHASE
12kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THREE PHASE
12kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 346V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 380V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 208V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 346V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 380V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22.5kW 240V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
303-071809-014
303-071809-016
AUX LOW WATER CUT-OFF (OPTIONAL EQUIPMENT)
155-554735-004
155-554735-009
155-554735-006
155-554735-011
Pump/Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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” CHPES 6A through 18A . . . . . . . . . . . . . . . . . .
Contact Factory
346-300035-001
323-300033-016
323-300033-017
072-300047-003
242-300036-019
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
MISCELLANEOUS PARTS
Probe 9-1/2” CHPES 24A through 72A . . . . . . . . . . . . . . . . . . .
Probe 10-15/16” CHPES-100A through CHPES-180A . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
242-300036-002
242-300036-017
292-053223-002
128-072576-027
303-075443-003
129-300029-001
121-300199-001
132-146012-001
GAUGE GLASS ASSEMBLIES, CHECK VALVES & SIGHT GLASSES
22.5kW 480V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22.5kW 550V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Valve 1/2” CHPES-6A through 18A . . . . . . . . . . . . . . . . .
Check Valve 3/4” CHPES-24A through 180A . . . . . . . . . . . . . . .
Gauge Glass Assemble Valves
(O-ring gaskets included) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protector Rods (2 Required) CHPES-6A
through 18A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protector Rods (2 required) CHPES-24A
through 180A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
O-ring gaskets (2 required) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sight Glass Tubing, 7” CHPES-6A
155-554735-022
AUTO BLOWDOWN PARTS
155-554735-019
344-114590-013
344-114590-014
Stainless Steel Bolts (6 required) for Element . . . . . . . . . . . . . .
Vacuum Breaker Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motorized Valve 1/2” CHPES-6A through CHPES-18A . . . . . . . .
Motorized Valve 1” CHPES-24A through CHPES-180A . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
345-072565-428
344-300149-003
344-300089-009
344-300089-010
292-300101-002
072-300072-002
072-300148-001
292-300146-001
272-300147-001
213-300145-001
303-075444-003
303-075444-004
129-024494-001
128-121133-072
344-120970-004
242-121047-008
242-121047-001
132-073284-003
through 18A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sight Glass Tubing, 9” CHPES-24A through 72A . . . . . . . . . . .
Sight Glass Tubing, 11” CHPES-100A through 180A . . . . . . . .
374-121046-006
374-121046-038
374-121046-015
SAFETY VALVE
250 psig 1/2” CHPES-6A through 180A . . . . . . . . . . . . . . . . . . .
344-300032-006
19
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
|