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PQ444-1 CHX.Qxd Chromalox ® Installation, Operation SERVICE REFERENCE DIVISION 4 SECTION CES and SALES REFERENCE (Supersedes PQ444) 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 Quantity and Rating No./kW Elec at of Contactors of Rating Cap. Vol. 212˚F Heating Model (BHP) (kW) (Gals.) (Lbs./Hr.) 208 240 480† Elements Type CES — 0-100 PSIG CES-6 .6 6 6 18 30 30 30 1-6 CES-9 .9 9 6 27 30 30 30 1-9 CES-12 1.22 12 6 36.2 40 30 30 1-12 CES-18 1.73 17 6 51.2 50 50 30 1-17 CES-24 2.45 24 14.3 72.3 2-40 2-30 2-30 2-12 CES-30 2.95 29 14.3 87.4 1-40 1-4040 1-12 1-50 1-30 1-17 CES-36 3.47 34 14.3 102.5 2-50 2-50 50 2-17 CES-48 4.69 46 14.3 138.7 1-40 1-30 1-40 1-12 2-50 2-50 1-30 2-17 CES-60 5.91 58 14.3 174.8 2-50 2-302-40 2-12 2-40 2-50 2-17 CES-72 6.93 68 14.3 205 4-50 4-50 2-50 4-17 CES-100 10.40 102 27.8 307 6-50 6-50 3-50 6-17 CES-135 13.9 136 30.5 410 — 8-50 4-50 8-17 CES-160 16.1 157.5 30.5 475 — 7-60 1-30 7-22.5 3-60 CES-180 18.4 180 30.5 543 — 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. DIMENSIONS MODEL CES-6 through CES-18 B Check Valve A L C Optional Transformer Drain H Blowdown G Valve K D E F Safety Valve Operating J Outlet I Steam Outlet Pressure Manual Reset Control High Limit Control Pump/Solenoid Connection Control Circuit Optional Vacuum Conduit Box On-Off Switch Breaker 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-24 through CES-180 B A C L Check Valve Drain H Blowdown G Valve K E D F Safety Valve Operating Outlet I Steam Outlet Pressure Manual Reset High Limit Control Pump/Solenoid Control Optional Vacuum Connection Control Circuit Breaker Conduit Box On-Off Switch with Pilot Light McDonnell & Miller Sight Glass Low Water Cutoff Pump Control Element Control Panel Access Door Standard when Three (3) Element or more Contactors are used Optional Transformer Drain Blowdown Valve 5/8" 1-1/4" 7/16" Bolt Hole (typical) 7/16" Bolt Hole (typical) 2 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-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-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-18 37 22-1/2 30 15-1/4 20 30-1/2 9-1/2 16 1/2 1 1/2 1/2 CES-100 63-1/2 30 55 21 27 36 16-3/4 37-1/2 1-1/2 1-1/4 1 3/4 CES-24 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4 CES-135 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4 CES-30 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4 CES-160 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4 CES-36 43-1/2 26 46 17-1/2 23 34-1/2 16-1/2 24-1/2 1 1 1 3/4 CES-180 63-1/2 32 55 20-1/2 26 37-1/2 16 37-1/2 2 1-1/4 1 3/4 *Add two inches for transformer. INSTALLATION Note: When installing boiler, allow sufficient room (21” minimum) to 5. All water feed systems are connected to water inlet check valve. facilitate removal of elements if and when necessary. 6. Connect steam line (with Globe valve) to boiler steam outlet. 1. The boiler should be mounted on a solid level foundation. Valve should be placed as close as possible to boiler outlet and 2. WARNING: A minimum distance of 18” between sized per label on boiler. boiler and any combustible material must be main- 7. To insure maximum efficiency of supplied kW, all piping from tained. outlet should be insulated. 3. Complete all piping to boiler. Connect water line to tagged fitting 8. Drain and relief valve piping should be in accordance with state on the motor and pump assembly, if used, or to tagged fitting on and local codes. Floor drain to be provided directly below unit. water control feeder. 9. All electrical wiring should be done by licensed electrician in 4. When any type of feed other than a pump feed is used — the exist- accordance with national and local electrical codes. ing water supply must be 10 pounds greater than the boiler operat- 10. If pump is located less than 30 feet from boiler, a second ing pressure to assure water supply maintains proper water level in check valve is required. boiler. Otherwise, lack of water can cause heater failure. Keep feed water line valves open at all times except during blowdown. Typical Plumbing Installation of a Steam Boiler with Condensate Return System Insulated Steam Lines (Pitch Down 5˚) Heat Exchanger Safety Water/Steam Gate Valve Globe Separator Valve Valve (Typical Load) Trap Trap Vacuum Breaker Check Check Check Valve Valve Valve Return Pitch Down 5˚ Vent Cold Water Boiler Make-Up Drain Condensate Return Steam Drain Water Strainer Gate Condensate Valve Vapor Centrifugal Turbine Pump 3 WIRING WARNING: Hazard of Electric Shock. Boiler must be your contractor or electrical dealer for recommended type for your suitably grounded according to N.E.C. standard. system. 1. Be sure to use the proper wire. Electric wiring to boiler should be 5. Be sure all electrical connections are sufficiently tightened. in accordance with National Electrical Code or local wiring code 6. WARNING: Substitution of components or modifica- following wiring diagram supplied. (See recommendations on tion of wiring system voids the warranty and may safety switches and fusing.) lead to dangerous operating conditions. 2. The unit is completely wired and pre-tested before shipment. No 7. SPECIAL INSTRUCTIONS FOR CUSTOMERS SUPPLY- internal wiring is required. ING THEIR OWN CONDENSATE OR PUMP SYSTEMS. If a separate control circuit is used, the control circuit should be A. Check the voltage of the motor before making the wiring con- connected to the control terminal block, inside access door (not nection. Some Chromalox boilers are supplied with dual volt- required with transformer). age systems. The motor should always match the voltage of the 3. Safety Switches — WARNING: Purchaser should use a control circuit. safety switch employing circuit breakers or fuses B. The motor circuit should be wired into the pump control as between his main power source and the boiler. shown in wiring diagram (float type pump control). If boiler is 4. Because of their water lines, boilers are susceptible to lightning equipped with solid state pump control, refer to wiring diagram damage. Industrial type lightning protectors should be installed per and use terminals 5 and 2. manufacturer’s recommendations at your service entrance. Check TYPICAL WIRING DIAGRAMS Use Applicable wiring diagrams based on model number and power voltage. 3 Phase Voltage 3 Phase Voltage 3 Phase Voltage Boiler 208 240 480 Boiler 208 240 480 Boiler 208 240 480 CES-6 1 1 1 CES-30 2 2 3 CES-100 8 8 9 CES-9 1 1 1 CES-36 2 2 3 CES-135 10 11 CES-12 1 1 1 CES-48 4 4 5 CES-160 12 13 CES-18 1 1 1 CES-60 6 6 7 CES-180 10 11 CES-24 2 2 3 CES-72 6 6 7 Export 14 Diagram 1 L1 L2 L3 1 1 HTR C1 GND 1L1 FU1 1 1L2 FU2 GND 1L3 FU3 FU6 FU4 FU5 1PB 2 1TB Feed Water 1 FU H1 H2 Electrical 3 1 2 3 Optional Transformer Connection GND X1 X3 X2 X4 3 1 2 GND 1 2 B 1 2 W GND GND FU6 1LT B 1PB On BR R Boiler On Off IFS Y Feed Water O 1PS O 2PS O Heater 1 C1 Contactors HTR C2 Cabinet Exterior Left SidePanel Layout Cabinet Exterior Right Side C3 C4 Wire Color Code B = Black BR = Brown R = Red O = Orange Y = Yellow * Boilers under 40 Amps total (not fused) G = Green BL = Blue W = White 4 TYPICAL WIRING DIAGRAMS L1 L2 L3 1 Diagram 2 C1 GND 1 HTR 1L1 FU1 1L2 FU2 2 GND 1L3 FU3 C2 2 HTR 2L1 FU4 2L2 FU5 2L3 FU6 FU7 FU8 H1 H3 H2 H4 3 FU9 1TB GND 2 1PB 2TB Optional Transformer 1 X1 X3 X2 X4 Feed Water 3 1 2 2 GND GND Electrical 1 GND C1 C2 1 2 Connection FU FU 1 2 3 4 2 6 B W FU9 1LT B 1PB On BR R Boiler On Off IFS Y Feed Water O 1PS O 2PS O C1 1 2 Heater HTR HTR Contactors C2 Wire Color Code Cabinet Exterior Left SidePanel Layout Cabinet Exterior Right Side B = Black BR = Brown R = Red O = Orange Y = Yellow G = Green BL = Blue W = White Diagram 3 L1 L2 L3 C1 1 1 HTR 1L1 FU1 GND FU2 2 1L2 GND 1L3 FU3 2 HTR 2L1 2L2 2L3 FU4 FU5 H1 H3 H2 H4 FU6 2 3 GND 1PB 2TB Optional Transformer 1 2 GND X1 X3 X2 X4 Feed Water 3 1 2 GND Electrical C1 2 Connection FU 1 1 2 3 B W 1 GND FU6 1LT B 1PB On BR R Boiler On Off IFS Y Feed Water O 1PS O 2PS O Heater C1 1 2 Contactor HTR HTR Cabinet Exterior Left SidePanel Layout Cabinet Exterior Right Side Wire Color Code B = Black BR = Brown R = Red O = Orange Y = Yellow G = Green BL = Blue W = White * Boilers under 40 Amps total (not fused) 5 TYPICAL WIRING DIAGRAMS Diagram 4 1 L1 L2 L3 GND C1 C3 1 HTR 1L1 FU1 FU7 3L1 3 HTR 1L2 FU2 FU8 3L2 2 GND 1L3 FU3 FU9 1L3 2 HTR 2L1 C2 FU4 2L2 FU5 2L3 FU6 FU10 FU11 2 GND H3 H2 H1 H4 1PB Optional Transformer 3 FU12 X1 X3 X2 X4 GND 2 1TB 3 1 2 2TB Feed Water 1 GND Electrical 1 2 2 GND Connection B W FU12 1LT 1 GND B 1PB On BR R Boiler On C1 C2 C3 Off IFS Y Feed Water 3 FU FU FU Htr O
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