Chromalox Boiler CAS 20CM User Manual

Installation, Operation  
and  
4
cas  
(Supersedes PQ435)  
PQ435-1  
RENEWAL PARTS IDENTIFICATION  
161-562795-001  
JUNE, 1994  
Type CAS-20CM Electric Steam Boiler  
(Standard Trim is 100 PSI — 0-90 PSI Operating Pressure Range)  
Boiler Serial No. ______________________________________________ Power Circuit Voltage __________________________  
Model No. ___________________________________________________ Control Circuit Voltage__________________________  
National Board No. ____________________________________________ Amps ___________Phase __________Cy __________  
IMPORTANT – This data file contains the National Board Registration Certificate approving your boiler. It must be kept near the boiler at all  
times.  
Model  
Electric Capacity  
BHP Rating  
Voltage  
Phase  
Amperes Drawn  
Contactor  
20 kW  
16/20 kW  
20 kW  
2.0  
1.6/2.0  
2.0  
208  
208/230  
240  
1
3
1
3
1
3
96  
45/51  
84  
50A, 4 Pole  
60A, 3 Pole  
50A, 4 Pole  
40A, 3 Pole  
60A, 2 Pole  
30A, 3 Pole  
CAS-20CM  
20 kW  
2.0  
346  
34  
20 kW  
2.0  
380  
53  
20 kW  
2.0  
480  
24  
Note: Control circuit 120V  
© 2010 Chromalox, Inc.  
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SCHEMATIC WIRING DIAGRAM  
Wire Color Code —  
B
= Black  
= White  
= Red  
W
R
O
Y
= Orange  
= Yellow  
GR = Green  
BL = Blue  
HTR  
O
OPERATION  
once a day. In soft water areas, once each week. If water is known  
to be corrosive, consult water treating specialists to recommend  
water treatment needed to insure corrosion free boiler operation. If  
there is a particular problem which applies to your own local water  
condition other than mineral content, take this into consideration  
in determining what schedule is to be followed.  
SOLID STATE FLOATLESS LIQUID LEVEL  
CONTROL SYSTEM  
This boiler is equipped with a solid state, floatless liquid level  
control which operates by sensing the electrical resistance of  
water. Note: Control will not work with de-ionized or demineral-  
ized water. Two probes are provided. The HI probe activates and  
controls the feed water relay. The LOW probe is a safety back-up  
probe that turns off the power to the element in the event of low  
water. A 12 volt potential is established between each probe and  
ground. The presence or absence of water generates a small signal  
that is amplified and fed to a SCR. The SCR, in turn, activates a  
relay, depending on the function and the water level.  
1. At the end of the working day turn switch to the OFF position  
and close water supply valve. De-energize wall mounted safe-  
ty switch (main power supply).  
2. If blowing down into a receptacle, cover receptacle to prevent  
splash of scalding water.  
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. However, check local codes and suitability  
of drainage system before connecting.  
ADJUSTING PRESSURE CONTROLS  
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.  
MANUAL BLOWDOWN INSTRUCTIONS  
4. When blowdown 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.  
Blowdown is an essential part of boiler operation. It is the best  
preventive 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.  
5. When refilling is complete, turn off the boiler switch unless  
further operation is desired.  
Blowdown will remove accumulated hard water scale and dis-  
lodge scale from water heating surface thereby insuring efficient  
heating. In extremely hard water areas blowdown is necessary  
The use of chemical boiler cleaning compounds in these boilers  
voids all warranties unless approved by Chromalox, Inc.  
-3-  
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MAINTENANCE  
Normal Operation Sequence.  
WARNING: Hazard of Electric Shock. Disconnect all  
1. Water drops below HI probe. After 10 second delay, water feed  
energizes refilling boiler.  
power before working on boiler.  
1. A monthly inspection should be made to ensure that all electri-  
cal connections are tight.  
2. Water reaches HI probe and turns off water feed.  
3. Sight glass should be 1/  
3
to 1/  
full. Heater contactor will cycle at  
2
2. When steam or water leaks are observed, fittings should be  
operating pressure depending on load. Heater contactor should  
not chatter on short cycle. In the event of contactor chatter,  
check for low water condition and check for damaged or short-  
ed probes.  
tightened immediately.  
3. Every four months, the Solid State Liquid Control probes  
should be checked for deposits and cleaned if necessary.  
Remove deposits from probe and teflon sleeve. This is accom-  
plished by removing the inspection plate and with the use of a  
standard spark plug wrench, removing the probes. Care should  
be taken during the removal and reinstallation of the probes so  
the porcelain insulator is not damaged.  
Inconsistent water level causing low water cutoff.  
1. Test feed solenoid control circuit by energizing control circuit.  
Remove cover plate from probes.  
2. Check for shorted or failed water feed probes.  
3. Check water feed lines, valves and circuits.  
The feed water probe is mounted in a surge isolator tube. This  
isolator tube should be removed and cleaned at the same time  
as the probes.  
INSTRUCTIONS FOR ELEMENT REPLACEMENT  
Note: Element failure is usually caused by excessive scale build  
up or low water operating conditions. Before replacing element, be  
sure boiler tank is clean and free of scale. Check control board,  
water feed system and control probes for proper operation.  
Failure to perform the above maintenance checks may result in  
immediate burn-out of new elements.  
1. A monthly inspection of the boilers, boiler installation and  
electrical wiring should be made to insure proper operation.  
These inspections should include:  
Note: Make sure that probe does not touch the insulator tube,  
as grounding will occur. This will cause boiler to run dry.  
4. At the same time, remove the heating element and inspect for  
scale formation. If scale has begun to form, clean element and  
also flush boiler.  
TROUBLE SHOOTING HINTS  
1. Boiler does not energize when main switch is turned on (noth-  
ing happens).  
A. Electrical connections. Look for overheated or discolored  
power terminals. Check and tighten all terminals that may  
work loose from expansion and contraction.  
B. Check for steam or water leaks and tighten all pipe fittings.  
C. Check safety relief valve.  
A. Check to see if main power is turned on.  
B. Check to see if control circuit voltage is turned on. (ON-  
OFF switch has a pilot light)  
C. Check power and control circuit fuses or breakers.  
D. Check control circuit fuse on boiler.  
E. Check all electrical connection for tightness.  
2. Boiler power control circuit pilot light is on. Boiler will not fill  
or heat.  
D. Check water feed line, strainers and check valves.  
E. Blow down boiler and make sure drain lines are clear.  
Read completely before starting work.  
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.  
1
1
A. No water in boiler. Check sight glass, it should be /  
8
to /  
2
full. Check water feed lines, valves, pumps, strainer, etc. for  
proper operation.  
B. Solid state water feed probe inoperative. Check solid state  
liquid controls probes. Water feed solenoid should activate  
10 seconds after control circuit is turned on. Clean probe  
and isolator tube as required. Make sure probe is straight  
and does not touch wall.  
3. Remove wiring compartment end panel to expose heating ele-  
ment.  
4. Disconnect wire (electric) leads connecting element to main  
power system of boiler. Again note wire connections to facili-  
5
tate re-assembly. Proceed to remove (6) /16-18 bolts from  
flange.  
C. Water feed relay bad – replace plug-in relay.  
D. Solenoid valve bad — replace solenoid valve.  
3. Boiler has power and water in sight glass. Boiler will not heat.  
A. Bad heating contactor. Check for open coil or frozen contacts.  
B. Bad relay on control Board. Replace control board.  
C. Burned out element. Replace heating element.  
D. Loose power connection. Tighten electrical connections.  
4. Boiler floods.  
5. Thoroughly clean boiler flange of all foreign material. Be cer-  
tain no part of old gasket remains on boiler flange.  
6. Apply “Slic-Tite” Gasket Compound (or equivalent) to both  
surfaces of new gasket supplied with 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; element flange is marked “TOP”  
so wire connection terminals on top element assembly will be  
in line with previously disconnected wire leads to facilitate  
easy connections.  
7. When all (6) flange bolts are tight, connect all wires to termi-  
nals. Make certain wires are clean and bright to assure good  
electrical contact and nuts on screws are firmly secured.  
Note: Bolts should be tightened to a torque of 22 ft. lbs.  
8. Open water valve so water supply can reach boiler feed mech-  
anism.  
A. Check high water probe and isolator tube for deposits.  
B. Check water feed relay for frozen contacts.  
C. Check solenoid valve, may be stuck or damaged.  
5. Element repeatedly burns out.  
A. Low water cutoff probe damaged or shorted to ground.  
Remove and check low probe.  
B. Boiler not supplied with water. Check water feed lines,  
valves and circuits. Check water feed probe.  
C. Control board defective. Check operation of board and  
component. Replace board if necessary.  
9. Put main safety switch to “ON” position.  
10. Turn boiler switch to “ON” position.  
6. Control board trouble shooting. Start-up sequence.  
The two probe board has the following sequence of operation  
when the boiler is initially energized.  
11. As boiler automatically refills, observe the new flange assem-  
bly for possible leaks. If water is noticed, the bolts must be  
retightened. Before doing this, turn the boiler off at the main  
fuse safety switch.  
A. Turn on control circuit power.  
B. Approximately 10 second delay before water feed solenoid  
or pump starts.  
12. As boiler is heated to working pressure, check flange assembly  
C. Water rises in boiler and contacts low probe which closes  
relay contacts, turning on heater.  
again for leaks.  
WARNING: Avoid use of chemical cleaning com-  
pounds. Follow maintenance instructions.  
D. Water continues to rise to HI probe. Turns off water feed.  
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RENEWAL PARTS IDENTIFICATION  
HEATING ELEMENTS  
Description  
PRESSURE CONTROLS  
Description  
Part Number  
Part Number  
20kW 240V 1PH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
20kW 208V 1-3PH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
155-300121-006  
155-554735-023  
Operating Pressure Control Auto Reset . . . . . . . . . . . . . . . . .  
High Limit Pressure Control – Auto Reset . . . . . . . . . . . . . . .  
292-300031-001  
292-300031-001  
16/20kW 208/230V 3PH . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
20kW 346V 1-3PH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
155-554735-024  
155-554735-051  
20kW 380V 1PH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
20kW 480V 3PH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
155-554735-042  
155-554735-030  
VALVES AND GAUGES  
Description  
Part Number  
Element Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Element Bolt (6 Req’d.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
132-146012-001  
345-072565-428  
Safety Valve 1/2”, 100 PSIG . . . . . . . . . . . . . . . . . . . . . . . . . . .  
334-300032-004  
344-118536-005  
Check Valve 3/  
8
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Drain Valve 1/2” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
344-121194-006  
344-121780-012  
Solenoid Valve, 120V, 1/4” NPT . . . . . . . . . . . . . . . . . . . . . . . .  
ELECTRICAL COMPONENTS  
Description  
Strainer 1/4” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Pressure Gauge, 1/4”, 0-160 PSIG . . . . . . . . . . . . . . . . . . . . .  
351-118664-003  
130-118661-001  
Part Number  
Rocker Switch with Pilot (ON/OFF) . . . . . . . . . . . . . . . . . . . .  
Contactor 30A, 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
292-053223-002  
072-047913-020  
Contactor 40A, 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Contactor 50A, 4 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
072-047913-012  
072-047913-021  
SOLID STATE LEVEL CONTROL PARTS  
Description  
Part Number  
Contactor 60A, 2 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Contactor 60A, 3 pole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
072-047913-026  
072-047913-016  
Probe Level Control, 53/8” . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
242-300036-010  
242-300036-011  
Probe, Cutoff, 57/8” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Fuse Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Terminal Block, Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
129-300029-001  
303-075444-001  
Control Board with Relay (2 probe) . . . . . . . . . . . . . . . . . . . .  
Control Board* (1 probe) . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Control Board* (3 probe) . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
323-300033-001  
323-300033-011  
323-300033-006  
Terminal Block, Power (1 PH only) . . . . . . . . . . . . . . . . . . . .  
Fuse 15A, 250V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
303-047468-003  
128-072576-027  
Relay for Control Board, Plug-in . . . . . . . . . . . . . . . . . . . . . .  
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
072-300047-001  
346-300035-001  
Probe Isolator (For Level Control) . . . . . . . . . . . . . . . . . . . . .  
332-300009-002  
GAUGE GLASS PARTS  
Description  
*Used on older models.  
Part Number  
Sight Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
374-121046-021  
Sight Glass O-Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Valve Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
132-073284-001  
344-120970-003  
Sight Glass Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Nipple, Conduit 1” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
334-056360-002  
198-300084-004  
-5-  
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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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