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®
Chromalox
SERVICE REFERENCE
Installation, Operation
DIVISION 4 SECTION CES
and
SALES
(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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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DIMENSIONS MODEL CES-6 through CES-18 B Check Valve L A C Optional Transformer Drain H Blowdown G Valve K E D F Safety Valve J Operating Outlet Manual Reset I Steam Outlet Pressure High Limit Control Control Pump/Solenoid Optional Vacuum Connection Control Circuit Breaker Conduit Box On-Off Switch with Pilot Light McDonnell & Miller Sight Glass Low Water Cutoff Pump Control Element Access Door Element Drain Blowdown Valve 5/8" 1-1/4" 7/16" Bolt Hole (typical) 7/16" Bolt Hole (typical) MODEL CES-
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DIMENSIONS CES — Dimensions (In.) CES — Dimensions (In.) Model A B* C D E F G H I J K L Model A B* C D E F G H I J K L CES-6 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2 CES-48 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4 CES-9 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2 CES-60 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4 CES-72 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4 CES-12 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2 CES-18 37 22-1/2 30
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WIRING your contractor or electrical dealer for recommended type for your WARNING: Hazard of Electric Shock. Boiler must be system. suitably grounded according to N.E.C. standard. 5. Be sure all electrical connections are sufficiently tightened. 1. Be sure to use the proper wire. Electric wiring to boiler should be 6. WARNING: Substitution of components or modifica- in accordance with National Electrical Code or local wiring code tion of wiring system voids the warranty and may following wiring
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TYPICAL WIRING DIAGRAMS L1 L2 L3 1 Diagram 2 C1 GND 1 HTR 1L1 FU1 FU2 1L2 2 GND 1L3 FU3 C2 2 HTR 2L1 FU4 FU5 2L2 2L3 FU6 FU8 FU7 H1 H3 H2 H4 FU9 1TB 1PB Optional Transformer X1 X3 X2 X4 2 Feed Water 3 1 2 GND GND Electrical C1 C2 2 1 Connection FU FU B 1 2 3 4 2 6 W FU9 1LT 1PB BR B On R Boiler On Off IFS Y Feed Water 1PS O O 2PS O C1 1 Heater 2 HTR HTR Contactors C2 Wire Color Code Cabinet Exterior Left Side Panel Layout Cabinet Exterior Right Side B = Black BR = Brown R = Red O = Orange Y = Ye
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TYPICAL WIRING DIAGRAMS Diagram 4 1 L1 L2 L3 GND C1 C3 3 HTR 1 HTR 1L1 FU1 FU7 3L1 1L2 FU2 FU8 3L2 2 GND FU3 1L3 FU9 1L3 C2 2 HTR FU4 2L1 2L2 FU5 FU6 2L3 FU10 FU11 2 GND H3 H2 H1 H4 Optional Transformer 1PB X1 X2 X4 X3 FU12 1TB 3 1 2 Feed Water GND 2 Electrical 1 2 GND B Connection W FU12 1LT 1 GND 1PB On BR B R Boiler On Off IFS C1 C2 C3 Y Feed Water 3 Htr 1PS 2PS FU FU FU O O O Heater C1 1 2 3 4 5 6 7 8 9 Contactor C2 1 2 Heater HTR HTR C3 Contactor Cabinet Exterior Left Side Panel Layou
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TYPICAL WIRING DIAGRAMS Diagram 6 1 L1 L2 L3 GND C1 C3 3 HTR 1 HTR 1L1 FU1 FU7 3L1 FU2 1L2 FU8 3L2 2 GND 1L3 FU3 FU9 1L3 C4 C2 4 HTR 2 HTR 2L1 FU4 FU10 4L1 FU5 FU11 2L2 4L2 2L3 FU6 FU12 4L3 FU14 FU13 H2 H1 H2 1PB Optional Transformer FU15 X1 X3 X2 X4 Feed Water 1TB 3 1 2 Electrical GND Connection 2 1 2 GND B W FU15 1LT 1 GND 1PB On BR B R Boiler On Off IFS C1 C2 C3 C4 Y 3 Feed Water 4 Htr FU FU Htr FU FU 1PS 2PS O O O Heater 10 C1 7 8 9 1 2 3 4 5 6 11 12 Contactors 1 C2 2 HTR HTR C3 C4 Cab
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TYPICAL WIRING DIAGRAMS L2 L1 L3 Diagram 8 1 GND 1 HTR C1 C5 5 HTR 1L1 FU1 FU13 5L1 2 1L2 FU14 5L2 FU2 GND 1L3 FU3 FU15 5L3 C2 C6 2 HTR 2L1 FU16 6L1 6 HTR FU4 2L2 6L2 FU5 FU17 2L3 FU18 6L3 FU6 3 HTR C3 3L1 FU7 3L2 FU8 3L3 FU9 4 HTR C4 4L1 FU10 4L2 FU11 4L3 FU12 FU20 FU19 Feed Water Electrical 1PB 1TB Connection FU21 Optional Transformer X1 X3 X2 X4 3 1 3 GND 2 C1 C2 C3 GND 2 1 2 GND FU FU FU B W FU21 1 2 3 4 5 6 7 8 9 1LT 1PB On BR B Boiler R On Off IFS C4 Y C5 C6 Feed Water 5 6 HTR HTR 3P
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TYPICAL WIRING DIAGRAMS L2 L1 L3 Diagram 10 1 GND 1 HTR C1 C5 5 HTR 1L1 FU1 FU13 5L1 2 1L2 FU2 FU14 5L2 GND 1L3 FU3 FU15 5L3 C2 C6 2 HTR 2L1 FU4 FU16 6L1 6 HTR 2L2 6L2 FU5 FU17 2L3 FU6 FU18 6L3 3 HTR C3 C7 7 HTR 3L1 FU7 FU13 7L1 3L2 FU8 FU20 7L2 3L3 FU9 FU21 5L3 4 HTR C4 C8 4L1 FU10 FU22 8L1 6 HTR 4L2 FU11 8L2 FU23 4L3 FU12 FU24 8L3 FU25 FU26 Feed Water Electrical H1 H3 H2 H4 1TB 1PB Connection FU27 Optional Transformer 3 1 2 GND X1 X3 X2 X4 3 GND C5 C6 C7 C8 1 2 2 B W GND 13 16 19 22 FU27 1PB 1
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TYPICAL WIRING DIAGRAMS Diagram 12 L1 L2 L3 1 GND C1 1 HTR C5 5 HTR 1L1 5L1 FU1 FU13 2 1L2 FU2 FU14 5L2 GND 1L3 FU3 FU15 5L3 2 HTR C2 C6 2L1 FU4 FU16 6 HTR 6L1 2L2 FU5 FU17 6L2 FU6 FU18 6L3 2L3 C3 C7 7 HTR 3 HTR 3L1 7L1 FU7 FU19 3L2 FU8 FU20 7L2 FU9 3L3 FU21 5L3 4 HTR C4 4L1 FU10 4L2 FU11 4L3 FU12 Feed Water FU22 FU23 Electrical 1PB H2 1TB H3 Connection H1 H4 FU24 Optional Transformer X1 X3 X2 X4 3 GND C5 C6 C7 3 1 2 GND 2 1 2 16 GND 13 19 B 17 18 14 15 20 21 W FU24 7 1PB 1LT HTR On B BR Boil
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TYPICAL WIRING DIAGRAMS Diagram 14 Typical Export Boiler 346V 3Ø 50 HZ L2 L1 L3 1 GND 1 HTR C1 C3 3 HTR 1L1 FU1 FU7 3L1 2 1L2 FU2 FU8 3L2 GND 1L3 FU3 FU9 3L3 2 HTR C2 C4 4 HTR 2L1 FU4 FU10 4L1 2L2 FU5 FU11 4L2 2L3 FU6 FU12 4L3 Feed Water Electrical 3 1PB Connection GND FU13 1TB 1CR C1 C2 C3 C4 2 GND 1 FU FU FU GND FU 10 1 2 3 4 5 6 7 8 9 11 12 220 VAC Single Phase Control Circuit 3 3 4 GND 1 2 HTR HTR B W FU13 1PB 1LT 1 2 On B BR Boiler R HTR HTR On Off 1 IFS Y 9.9 CR 2PS Cabinet Exter
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OPERATION ADJUSTING OPERATING PRESSURE CONTROLS To check operation of the controls, close steam outlet valve and adjust 1. Chromalox boilers are supplied with operating and high limit pres- operating pressure control to a low pressure setting. Also, set high limit sure controls. One is used for controlling the operating pressure of control at 10 psig above operating pressure control. Turn on boiler, and the boiler while the other is used as a high limit control. To deter- allow pressure to build
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OPERATION AUTOMATIC BLOWDOWN INSTRUCTIONS OPERATION— Set the “BOILER PROGRAMMEDDUTY” (IF FURNISHED) switch to “BOILER ON” if the boiler is to be shut down each night. The Automatic Blowdown is a device which automatically starts Set it to “24-HOUR DUTY” if the boiler is to remain on continuous- up your boiler in the morning; shuts it down at night and blows down ly 24-hours per day (except during blowdown). (partially drains) the main boiler drain and the low water cut-off col- Set the tabs on
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OPTIONAL EQUIPMENT FOR STEAM BOILERS AUXILIARY LOW WATER CUTOFF flows through one side of the balancing relay. The “close” contacts in Operation the relay make, causing the motor to drive toward its closed position. As Operation of this control is accomplished by sensing a minute AC the motor runs, the wiper on the feedback potentiometer moves in a current flowing between submerged contact probe in the boiler shell. direction to balance the circuit. When the circuit is again in balance, the When
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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 Solid State Progressive Sequencer further checked as follows: The solid state progressive sequencer provides accurate elec- 1. Leave the controller installed where it is, but disconnect all power tronic control of multi-stage loads of the type used in Chromalox to the boiler. steam boilers. It features progressive sequenc
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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 2. Connect water line to tagged fitting on feed. pressure. 3. Connect piping from discharge to water inlet check valve on boil- er with minimum of 90˚ bends or other restrictions. Low Pressure Pressure 4. All electrical wiring should be done by licensed electricians in Boiler (Soleno
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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 wiring code following wiring diagram supplied. A. Check the voltage of the motor before making the wiring connec- tion. Some Chromalox boilers are supplied with dual voltage sys- Plumbing tems. The motor should always match the voltage of the control A. Connect water line to tagged fitting on the motor and pump assem- circuit. bly co
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MAINTENANCE 1 Boiler 1" Steam Equalizing Pipe 8 2 Pump and Low 1-1/2" Water Control 1 Normal Boiler 2 Water Level 3 Cutoff Level 6 is Arrow Mark 7 Blowdown Valve 3 1" Water Equalizing Pipe 5 4 6 5 4 2 1 5-3/4 4-1/2 FIG. 2 FIG. 1 REF. REF. 3 4 2-1/2 FIG. 3 REF. IMMERSION HEATER FAILURE CAUSES HEATER ELEMENT CONDITION PROBABLE CAUSE 1. Water leakage at heater flange 1. Heater bolts improperly tightened. Refer to flange tightening instr
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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 . . . . . . . . . . . . . . . . . . . . . . 226-300177-001 Check Valve 1/2” CES-6 through CES-18 . . . . . . . . . . . . . . . . . . 344-118536-053 Motor and Pump used in ES-38020 . . . . . . . . . . . . . . . . . . . . . . 226-300177-004 Check Valve 3/4” CES-24 through CES-180 . . . . .
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RENEWAL PARTS IDENTIFICATION Part Description Part Number VALVES & GAUGES 1/4” Ball Valve (Pressure Gauge) . . . . . . . . . . . . . . . . . . . . . . . . 344-300323-002 Blowdown Valve 1/2” CES-6 through CES-18 . . . . . . . . . . . . . . 344-121194-006 Blowdown Valve 1” CES-24 through CES-180 . . . . . . . . . . . . . . 344-121194-002 Pressure Gauge 2” 0-160 psi CES-6 through CES-72 (50 and 100 psi trim) . . . . . . . . . . . . . . . . . . . . . . . . 130-118661-001 Pressure Gauge 3 1/2” 0-160
