Steam Boilers Optional Equipment
Packaged Systems
Steam Boilers
Optional Equipment
ES38038V Condensate
Return System
CSB-1 Blow Down Separator —
Dimensions (Inches)
Condensate Return
Water Inlet
Vent
Sight Glass
B
A
Condensate Return Systems
H
CAUTION — When a condensate system is
used, a vacuum breaker must always be
installed on the boiler to prevent the boiler
from flooding during shut down.
Low and Medium Pressure Condensate
Return Systems (150 psig maximum).
Chromalox condensate return systems (except
model HPCS 3003) are designed for use with
steam boilers operating up to 150 psig steam
pressures. The condensate systems consist of
an 11 gauge steel tank, motor, pump, float
valve, sight glass and associated plumbing. A
1/2” inlet is located on the tank for connection
to a local water supply for make up water. A
“vent” is located on the top of the tank and is
open to the atmosphere. The “return”
connection is plumbed to the trapped
condensate return line from the process.
The condensate tank has an internal ball check
valve, a float and float arm which mechanically
opens a valve, allowing make up water to enter
the tank as the original supply is depleted. The
outlet of the pump is plumbed to the boiler
water inlet check valve. The pump motor is
wired to the boiler feed water control or motor
starter. No further adjustments and/or
plumbing are required other than plumbing the
condensate tank drain and drain valve to a
proper waste connection.
High Pressure Condensate Return Systems
(250 psig maximum). The Chromalox
HPCS3003 high pressure (250 psig maximum) condensate return system is specifically
designed for use with the CHPES-6 through
180 kW boilers whenever condensate is to be
returned for reuse.
The high pressure condensate return system
consists of a 30 gallon tank with an internal
make up water float valve, a 3 Hp three phase
motor (motor voltage will match the boiler’s
voltage), a special high-pressure pump and a
sight glass. A motor starter and fuses can be
supplied as an option. Installation requires
wiring and field plumbing to the boiler with
minimum 1/2" NPT piping rated at 250 psig.
Drain
Strainer
Pump
18
W
Condensate Return System Selection
Storage
Tank Max.
Motor
Dimensions (In.)
Wt.
Hp
L
W
H
Model
Stock PCN
(Lbs.)
1/3 14-1/2 14-1/2 48 ES38083V NS 109372 125
1/2 14-1/2 14-1/2 54 ES38084V NS 109399 240
3/4 14-1/2 14-1/2 54 HS38019V NS —
260
3
14-1/2 14-1/2 66 HS38031V NS —
310
5
20
50
40 HS38039H NS —
365
Contact Factory for Recommendations
30 235 230/460 3 3
34-1/4 41-1/2 21 HPCS3003H NS 109428 310
Stainless steel boilers require de-ionized water. Contact your Local
Chromalox Sales office.
Stock Status: S = stock AS = assembly stock NS = non-stock
To Order— Specify model number of condensate system, boiler model number, volts,
phase, kW, PCN if applicable, and quantity.
Note —
A. Connections (NPT): Pump Out = 1", Tank Return = 1-1/4"
B. All motors can operate on 208V. Systems for boilers larger than 810 kW
have horizontal tanks. Use ES38084V for all CES boilers with 135 psig trim.
For Use On
CES 6 -100
CES 135 -180
CHS 150 - 300
CHS 360 - 810
CHS 945 -1215
CHS 1320 -1620
CHPES 6 -180
CSSB 6 -180
Gal.
26
33
33
46
50
psig
110
130
150
150
150
Volts
115/230
115/230
115/230
230/460
230/460
Ph
1
1
1
3
3
Blow Down Separator Selection
Blow Down Separators
Many state and municipal boiler codes do not
permit discharge of boiler blow down directly
into city sewers. Chromalox blow down
separators separate liquid from vapor during
blow down and prevent the dangerous
discharge of live steam down city drains. The
separator accepts water and flash steam from
the boiler blow down, reducing temperatures
and pressures to safe levels for subsequent
discharge to the sewer.
The separator is kept half full of cold water
before each blow down. The design utilizes a
water seal at the outlet which permits the
system to introduce cold water from the
bottom to mix with the hot water and boiler
steam blow down inside the separator. Flash
steam is absorbed by the cold water and
allowed to pass to the outside through a vent.
Chromalox blow down separators, CSB-1, 2, 3
and 4 are built and stamped to Section VIII of
the ASME Code.
Blow down separators require only plumbing
from the boiler blow down, hook-up to a cold
water supply line and connection to a drain.
No electrical connections are required. Order
options include a 0 - 30 psig pressure gauge,
0 - 200°F temperature gauge and a water sight
glass gauge assembly.
DIM.
Boiler
Boiler
kW
CSB-1 6 - 200
CSB-2 201 - 500
CSB-3 501 - 1000
CSB-4 1001 - 1620
A
NPT
B Inlet Outlet PCN
24 16 1
36 24 1
48 36 1-1/4
72 42 1-1/2
Wt.
(Lbs.)
1-1/2 109250 230
2-1/2
— 260
3
— 290
3-1/2
— 320
Vacuum Breaker Systems
After boiler shut down, the steam inside the
vessel condenses as the shell cools. This
creates a vacuum which will siphon water into
the boiler from the water feed or condensate
return system, flooding the boiler. A vacuum
breaker permits outside air to enter into the
shell to relieve the vacuum, thus preventing
excess water from being drawn into the
vessel. The vacuum breaker consists of a valve
with a spring loaded disc and associated
piping, factory plumbed to the boiler. They can
be used on all Chromalox boilers.
Vacuum Breaker Selection
Use
With
Model
Boiler
ES89369
CES
ES89369SS CSSB
HPES 89369 CHPES
Max.
Pressure
(psig)
150
150
300
PCN
109479
—
109760
D-39
D-039
1
9/18/02, 1:25 PM
BOILERS
Chromalox condensate return systems are
used wherever condensed steam can be
collected for reuse in the boiler. Significant
energy can be saved by returning hot
condensate to the boiler for feed water. The
condensed water is free from corroding
minerals and contains a substantial amount of
heat energy which does not have to be
replenished.
Packaged Systems
Steam Boilers
Optional Equipment
HS99117 — Low
Pressure Water Feed
ES38002 — High
Pressure Water Feed
81025 — Blow Down
Kit for CHPES
(cont’d.)
Cold Water Feed Systems
Automatic water feed is required on all CES,
CHPES, CHS and CSSB steam boilers. Water
feed systems are available for low pressure
and high pressure applications. Low pressure
or solenoid feed systems may be used when
the incoming water line pressure is at least 10
psig greater than the boiler operating
pressure. High pressure or pump and motor
feed must be used when the boiler operating
pressure is greater than 10 psig less than
incoming water line pressure.
A selection of different models is available
depending on the size and pressure rating of
the boiler. The correct water feed system may
be determined from the following chart:
Water Feed System Selection
Pressure
Boiler
CES 6-72
CES 100-180
CSSB 6-72
CSSB 100-180
CHPES 6-180
CHS 150
CHS 180-300
CHS 360-1620
Low
ES99117
ES99117
ES99117SS
ES99117SS
—
HS99117
HS99117
Note 1
High
ES38002/ES38020
ES38020/ES99157
ES38002SS
ES38020SS
ES38020HP
ES38020/ES99157
ES38021
Note 1
Low-Pressure Water Feed Systems
Low pressure cold water feed systems supply
makeup water to the boiler where incoming
water line pressure is 10 psig or greater than
the operating pressure of the boiler.
ES99117 — Low-Pressure Water Feed
System 0 to 90 psig. ES99117 piping is 1/2"
NPT and is completely factory plumbed and
wired. The systems consists of strainer,
solenoid valve and check valve. The solenoid
valve is 120V/1/50 - 60 Hz. For CSSB boilers
specify ES99117-SS with all stainless steel
construction.
HS99117 — Low-Pressure Water Feed
System for larger boilers 0 to 150 psig. The
HS99117 is similar to ES99117 except piping
is 1” NPT and a bypass system with a manual
valve is provided for initial fill of larger boilers.
Notes —
1. For larger systems, use a condensate
return system.
2. System equipped with two motorized ball
valves for pressures above 100 psig.
3. High pressure feed systems ES38002
(SS), ES38020 (SS) and ES99157 can be
mounted on CES & CSSB boiler enclosures.
High-Pressure Water Feed Systems
Automatic Blow Down Systems
High pressure cold water feed systems are
used to maintain constant water level in the
boiler when boiler operating pressure is equal
to or greater than the incoming water line
pressure.
Chromalox engineering recommends a
factory-installed automatic blow down unit.
Automatic blow down systems can:
ES38002 — System 0 - 90 psig — This water
feed system is a separate pump and motor
assembly requiring field plumbing and wiring
to the boiler.3 The piping is 1/2" NPT and the
assembly includes a 1/4 Hp 120V/1/60 motor
and pump piping, a strainer and a solenoid
valve. The assembly is mounted on rubber
shocks, secured on a steel base mounting
plate. A flexible 18” high pressure hose with
fittings is included for connection to boiler and
a cable for electrical connection. For CSSB
boilers 6 to 72 kW (stainless steel) and deionized water, specify ES38002-SS3.
• Extend Life of Boiler
• Save Labor Costs
ES38020 — System 0 - 135 psig — This
system is similar to ES38002 except it has
1/2" NPT piping and a 1/3 Hp 120V/1/60
motor and pump.3 For CSSB boilers 72 to 180
kW (stainless steel) and de-ionized water,
specify ES38020-SS3.
ES99157 — System 0 - 135 psig — This
system is similar to ES38002 except it has
1/2" NPT piping and a more powerful 1/2 Hp
120V/1/60 motor and pump.3 Recommended
for all CES boilers rated for 135 psig and
heavy duty pumping applications.
HS38021 — System 0 - 135 psig — This
system is similar to ES38002 except it has 1”
NPT piping and a 3/4 Hp 120V/1/60 motor for
greater capacity.
ES38020HP System 0 - 235 psig — This high
pressure cold water feed system can be used
with all CHPES boilers where the condensate
is not returned. Installation requires plumbing
and wiring between the pump assembly and
the boiler. The system consists of a 3/4 Hp
208/230/460V, 3ø motor, a positive displacement type pump, 1/2” NPT piping, strainer
and solenoid valve.
• Automatically Start the Boiler in the Morning
• Automatically Shut the Boiler Down at Night
• Automatically Blow it Down Each Working
Day
• Be Programmed to Skip Days and Weekends.
The heart of the Chromalox automatic blow
down unit is a motor-driven, straight-through,
self-cleaning ball valve with Teflon® seats and
stainless steel trim. It handles dirty fluids and
particles without a strainer or other cleaning
device. The ball valve and boiler are controlled
by an electronic unit with a time clock and
pilot lights which indicate when the drain valve
is open or closed and when the boiler is on or
off. Blow down can also be done manually, at
any time, by means of a push button switch
which momentarily de-energizes the boiler and
opens the drain valve. The blow down system
may be installed on any steam boiler regardless of size or operating duty cycle. Select
from the following chart:
Automatic Blow Down System
Selection
Model
81015A
81015B
81015B
81015SS
81115
81215
810252
D-40
D-040
1
9/18/02, 1:27 PM
Pipe
Use With Boiler
NPT
CES 6-18, CHS-150 1/2
CES 24-180
1
CHS 150-420
1
All CSSB
1
CHS 495-630
1-1/2
CHS 720-1,620
2
All CHPES
1
Press.
psig
150
150
150
150
150
150
250
Wt.
(Lbs.)
46
46
46
46
46
50
50
Packaged Systems
Optional Equipment
(cont’d.)
Circular sequencer operation and staging can
be visualized by the referring to following
illustration. The “O” represents an element
bundle in the de-energized position. The “ ”
represents an element bundle which has been
energized by the sequencer.
•
Electric Element Sequencers
Sequencers are designed to apply power to
large kW boilers in progressive stages.
Automatic sequencing provides accurate and
cost effective control, saving energy and
minimizing wear and tear on electrical
components. Sequencing extends the life of
the individual heating elements by rotating the
load evenly across all element bundles.
Reacting to an input signal from a factory
installed proportional pressure control, the
sequencer energizes and de-energizes each
heating element circuit through individual
power contactors. The sequencer programs a
delay before start up and between each
subsequent step to eliminate power surges.
Once up to power and pressure, the load is
“fine-tuned” for close pressure control, with a
minimum of over-shoot or droop. Each
sequencer is pre-set to match the specific
boiler and system requirements. In case of
power interruption, the sequencer restarts
with all steps de-energized. Electronic solid
state sequencers are available with up to 20
steps or stages for efficient operation of any
size Chromalox boiler.
Electronic Sequencer Operation — Solid
state progressive sequencers provide accurate
electronic control of multistage loads of the
type used in Chromalox steam boilers. They
feature progressive circular sequencing
(first-on, first-off) which equalizes the
operating time of each load and contactor. The
control gives visual indication of each
energized stage by means of integral solid
state light emitting diodes. In the event of
power interruption, all heating elements are
immediately de-energized for safety. When
power resumes, the control will restage the
loads one at a time.
Electronic Solid State Sequencer
(Control Board)
Visualization of Progressive Circular
Sequencing
Progression —> —> —>
+1 +1 +1 +1 +1 -1 -1 +1 -1 -1
O = Stage “OFF”
• = Stage “ON”
Electronic Auxiliary
Low Water Cutoff
Transformers
Transformers for control circuits and pump
motors can be supplied to eliminate the need
for separate 120 Vac power for control
circuits. Transformer primary voltage will
match boiler power voltage. Transformer
secondary voltage will be 120 Vac unless
otherwise specified.
Transformer Selection — To select transformer size, simply find the sum of all
component kVA requirements to be powered
by the transformer. A CES-72A with ES38083V
condensate return system and 81015B
automatic blow down system would require:
Basic Boiler
ES38083V
81015B
Total Required
1/4 kVA
3/4 kVA
1/2 kVA
1-1/2 kVA
Factory Mounted & Wired
Transformer
An auxiliary low water cutoff can be used as a
safe and reliable backup to the primary low
water cutoff control and is required by some
state and local boiler codes. Auxiliary low
water cutoff is provided by an electronic
device with a solid state amplifier and a solid
state switch for operating the mechanical
control relay. Operation is accomplished by
sensing a minute current flow between
submerged contact probe and the boiler shell.
When water level falls below safe operating
level, the boiler is shut down. Auxiliary low
water cutoffs are standard on all CHS type
steam boilers.
Electronic Level Control
BOILERS
Steam Boilers
Transformer Sizing — Basic Boiler
Min.
Basic Boiler
kVA Required
CMB 6, 15
1/4
CES, CHPES, CSSB 6-72
1/4
CES 100-180, CHPES 100
1/2
CHS 150-420
1/2
CHS 495-630
3/4
CHS 720-1620
1
Minimum size transformer offered
is 1.0 kVA.
Transformer Sizing-Option Loading
Note — For single probe auxiliary low water
cutoff (shown with plug-in control relay).
Note — Electronic auxiliary low water cutoffs
are not appropriate for use with CSSB or other
boilers using demineralized, de-ionized or
distilled water. Contact your Local Chromalox
Sales office for information on available
stainless steel low water float switches for use
with electronic auxiliary low water cutoffs.
Additional
Option
kVA Required
Water Feed Systems
ES99117 (SS), HS991117
1/4
ES38002 (SS), ES38020 (SS)
3/4
ES99157
1
HS38021, ES38020HP
1-1/2
Automatic Blow Down Systems
81015A, B, SS
1/2
81115, 81215
1/2
81025
1
Condensate Return Systems
ES38083V
3/4
ES38084V
1
All 3-phase Condensate
Return Systems (3 pole
1/4
motor starter required)
D-41
D-041
1
9/18/02, 1:33 PM
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement