Sussman ES Installation, Operation And Maintenance Manual - page 22
Element Replacement
22
Installation, Operation & Maintenance Manual
READ INSTRUCTIONS COMPLETELY BEFORE STARTING WORK
Before Installing your new elements be sure the
McDonnell Miller low water cut-off and aux. low water cutoff (if sup-
plied) is operating properly. The float chamber and lower equalizer col-
umn of the MM control must be completely clear of sludge or other for-
eign matter. Failure to do this may cause the immediate burn-out of the
new elements. If the unit is probe equipped, check condition of the
probes and isolator.
All elements are thoroughly checked before shipment The manufacturer
cannot be responsible for burn-outs 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 piping with
your finger or probes to see if it is clear and clean.
1.
Disconnect boiler from electric power supply at main safety switch or fuse panel.
Then turn boiler switch to “OFF" position.
2.
Close water supply valve on incoming water supply line. Drain boiler completely of water.
3.
Open boiler door to access heating element.
4.
Disconnect wire (electric) leads connecting element to main power system of boiler.
Again, note wire connections to facilitate re-assembly. Proceed to remove and discard
(6) bolts from flange.
IMPORTANT:
Note the wire connections to facilitate re-assembly (see wiring schematic).
Remove and discard six (5/16"-18) bolts from flange. Do not reuse these bolts.
5.
Thoroughly clean boiler flange of all foreign material. Be certain no part of old gasket
remains on flange.
6.
Apply "Slic-Tite" Gasket Compound (or equal) 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
so element wire connection terminals on element assembly are in line with previously
disconnected wire leads to facilitate easy connections.
NOTE:
Observe markings on element flange. Install element marking “TOP” on top.
7.
Use only new element flange bolts. Tighten all (6) element flange bolts to a torque value
of 22 lb-ft each (see illustration).
8.
Connect all wires to the terminals. Tighten all element terminals to a torque value of
20 lb-in each (see illustration). Make sure all wires are clean and bright to assure good
electrical contact.
9.
Check that the wires are correctly connected to the contactor terminals and are tightened
to a torque value of 45 lb-in. (see illustration). Make sure all wires are clean and bright to
assure good electrical contact.
10.
Open water valve to allow water supply to reach boiler feed mechanism.
11.
As boiler automatically refills, observe the new flange assembly for possible leaks. If water
is noticed, the bolts must be re-tightened. Before doing this, turn the boiler off at the
main fuse safety switch.
12.
When boiler reaches working pressure, check flange assembly again for leaks.
Follow maintenance instructions provided with the boiler.
Torque Values:
Element Flange Bolts: 22 lb-ft
Element Terminals: 20 lb-in
Contactor Terminals: see Torque chart
For Illustrative Purposes Only.
Power wiring shown in approximate
factory-installed location
Torque
Wrench
Torque
Wrench
Torque
Wrench
Boiler with
McDonnell Miller
1
1
⁄
2
”
1”Steam Equalizing Pipe
Pump and LowWater Control
Normal Boiler Water Line
Cut-Off Level is ArrowMark
Blowdown Valve
1”Water Equalizing Pipe
TORQUE VALUES
Element Flange Bolts
22 lb-ft
Element Terminals
20 lb-in
Contactor Terminals
50 amp
25 lb-in
60 amp
45 lb-in
75 amp
75 lb-in
!
C A U T I O N
!
C A U T I O N