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Chromalox CES-6 manual

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Table of contents for the manual

  • Page 1

    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-[...]

  • Page 2

    MODEL CES-24 through CES-180 MODEL CES-6 through CES-18 DIMENSIONS Drain Blowdown Valve K A C H B D E F G Check Valve L Optional T ransformer Safety Valve Outlet J Manual Reset High Limit Control Optional Vacuum Breaker McDonnell & Miller Low Water Cutoff Pump Control Drain Blowdown Valve Operating Pressure Control Control Circuit On-Off Switch[...]

  • Page 3

    T ypical Plumbing Installation of a Steam Boiler with Condensate Return System CES — Dimensions (In.) DIMENSIONS INST ALLA TION 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-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-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 2[...]

  • Page 4

    Diagram 1 3 Phase Voltage 3 Phase Voltage 3 Phase Voltage Boiler 208 240 480 Boiler 208 240 480 Boiler 208 240 480 WIRING TYPICAL WIRING DIAGRAMS WARNING: Hazard of Electric Shock. Boiler must be suitably grounded according to N.E.C. standard. 1. Be sure to use the proper wire. Electric wiring to boiler should be in accordance with National Electri[...]

  • Page 5

    Diagram 2 TYPICAL WIRING DIAGRAMS 2PS BR Heater Contactors Feed Water Boiler On 3 GND B FU9 B 1PB Off 2 GND 1 GND 1 HTR C1 FU1 FU2 FU3 FU8 FU7 H1 H2 X1 X3 L3 1L1 1L3 1L2 L2 L1 X2 X4 Optional T ransformer 1 1 C1 2 2 C2 R 1L T Y On IFS O 1PS O O W Feed Water Electrical Connection 2 1 2TB 2 GND 1 HTR FU9 1PB Cabinet Exterior Left Side Cabinet Exterior[...]

  • Page 6

    Diagram 4 TYPICAL WIRING DIAGRAMS 2PS BR Heater Contactor Feed Water Boiler On 3 GND B FU12 B 1PB Off 2 GND 1 GND 1 HTR C1 FU1 FU2 FU3 FU11 FU10 H1 H2 X1 X3 L3 1L1 1L3 1L2 L2 L1 X2 X4 Optional T ransformer 1 1 C1 2 2 C2 R 1L T Y On IFS O 1PS O O W Feed Water Electrical Connection 2 1 2TB 2 GND 1 GND 2 GND 1 HTR FU12 1PB Cabinet Exterior Left Side C[...]

  • Page 7

    Diagram 6 TYPICAL WIRING DIAGRAMS 2PS BR Heater Contactors Feed Water Boiler On 3 GND B FU15 B 1PB Off 2 GND 1 GND 1 HTR C1 FU1 FU2 FU3 FU14 FU13 H1 H2 X1 X3 L3 1L1 1L3 1L2 L2 L1 X2 X4 Optional T ransformer 1 1 C1 2 2 C2 R 1L T Y On IFS O 1PS O O W Feed Water Electrical Connection 2 1 2TB 1 GND 2 GND 1 HTR FU15 1PB Cabinet Exterior Left Side Cabine[...]

  • Page 8

    Diagram 8 TYPICAL WIRING DIAGRAMS FU 1 2 3 FU 4 5 6 FU 7 8 9 C1 C3 C2 C4 FU 10 11 12 C5 FU 13 14 15 C6 FU 16 17 18 5 HTR 4 HTR 3 HTR 6 HTR 2 HTR 1 HTR 1 2 2TB 1TB 3 GND 2 GND 1 GND FU21 1PB 3 GND C1 C2 C6 C5 C4 C3 2PS 3PS 1PS On Off FU21 IFS O O O Y BR B B 1PB 1 1 2 2 W R Boiler On Feed Water Heater Contactor Heater Contactor Heater Contactor Heate[...]

  • Page 9

    Diagram 10 TYPICAL WIRING DIAGRAMS 13 14 15 16 17 18 19 20 21 C5 C7 C6 C1 1 2 3 C2 4 5 6 C3 7 8 9 5 HTR 4 HTR 3 HTR 6 HTR 2 HTR 1 HTR 1 2 2TB 1TB 3 GND 2 GND 1 GND FU27 1PB 3 GND C1 C2 C6 C3 2PS 3PS 1PS On Off FU27 IFS O O O Y BR B B 1PB 1 1 2 2 W R Boiler On Feed Water Heater Contactor 1L T Optional T ransformer X1 X4 X2 X3 FU25 FU26 2 HTR 3 HTR 1[...]

  • Page 10

    Diagram 12 TYPICAL WIRING DIAGRAMS 13 14 15 16 17 18 19 20 21 C5 C7 C6 C1 1 2 3 C2 4 5 6 C3 7 8 9 5 HTR 4 HTR 3 HTR 6 HTR 2 HTR 1 HTR 1 2 2TB 1TB 3 GND 2 GND 1 GND FU24 1PB 3 GND C1 C2 C5 C3 2PS 3PS 1PS On Off FU24 IFS O O O Y BR B B 1PB 1 1 2 2 W R Boiler On Feed Water Heater Contactor 1L T Optional T ransformer X1 X4 X2 X3 FU22 FU23 2 HTR 3 HTR 1[...]

  • Page 11

    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 incom[...]

  • Page 12

    ADJUSTING OPERATING PRESSURE CONTROLS 1. Chromalox boilers are supplied with operating and high limit pres- sure controls. One is used for controlling the operating pressure of the boiler while the other is used as a high limit control. To deter- mine the difference in the controls, the high limit has a manual reset lever on top of the case. Also, [...]

  • Page 13

    OPERA TION AUTOMATIC BLOWDOWN INSTRUCTIONS (IF FURNISHED) 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 elect[...]

  • Page 14

    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- tud[...]

  • Page 15

    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 [...]

  • Page 16

    Automatic water feed is required on all CES Boilers: LOW PRESSURE FEED Note: Water Pressure feeds must be at least 10 psi greater than steam pressure. Low pressure water feed systems are used to supply make up water to the boiler where incoming water line pressure is 10 psig or greater than the operating pressure of the boiler. It consists of strai[...]

  • Page 17

    W A TER FEED SYSTEMS Installation Wiring A. Check the voltage of the motor before making the wiring connec- tion. Some Chromalox boilers are supplied with dual voltage sys- tems. The motor should always match the voltage of the control circuit. B. The motor circuit should be wired into the pump control located on the boiler. See boiler instruction [...]

  • Page 18

    Boiler 1" Steam Equalizing Pipe Pump and Low Water Control Normal Boiler Water Level Cutoff Level is Arrow Mark Blowdown Valve 1" Water Equalizing Pipe 1-1/2" 18 1 2 8 7 3 4 6 5 1 6 5 4 3 2 5-3/4 REF. 4-1/2 REF. FIG. 1 FIG. 2 MAINTENANCE 1 2 3 4 2-1/2 REF. HEATER ELEMENT CONDITION PROBABLE CAUSE 1. Water leakage at heater flange 2. W[...]

  • Page 19

    19 RENEW AL P ARTS IDENTIFICA TION Part Description Part Number Check Valve 1/2” CES-6 through CES-18 . . . . . . . . . . . . . . . . . . 344-118536-053 Check Valve 3/4” CES-24 through CES-180 . . . . . . . . . . . . . . . . 344-118536-054 Gauge Glass Assembly Valves (O-ring gaskets included) . . . . . . . 344-120970-002 Protector Rods (2 requi[...]

  • Page 20

    2150 N. RULON WHITE BLVD., OGDEN, UT 84404 Phone: 1-800-368-2493 www.chromalox.com RENEW AL P ARTS IDENTIFICA TION Part Description Part Number 1/4” Ball Valve (Pressure Gauge) . . . . . . . . . . . . . . . . . . . . . . . . 344-300323-002 Blowdown Valve 1/2” CES-6 through CES-18 . . . . . . . . . . . . . . 344-121194-006 Blowdown Valve 1” CE[...]