Sussman MBA - User Manual

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MBA Electric

Steam Generator

Installation, Operation and Maintenance Manual

A Division of Sussman-Automatic Corporation

PN 101141 Rev 2/06

43-20 34th Street, Long Island City, NY 11101

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(718) 937-4500

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1-800 238- 3535

Fax: (718) 937-4676

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www.sussmanboilers.com

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Email: seb@sussmancorp.com

Model No. ___________________________ Power Circuit Voltage ___________________

Generator Serial No. __________________ Control Circuit Voltage __________________

National Board No____________________ Amps ________ Phase ________ Cy ________

IMPORTANT:

This data file contains the National Board Registration Certificate

approving your generator. It must be kept near the generator at all times.

KW Design Max. Work

Model Range Steam Rate BHP Pressure Pressure*

__________________________________________________________________________________________

MBA3 3 9 lbs./hr 0.3 100 PSIG 85 PSIG

__________________________________________________________________________________________

MBA6 6 18 lbs./hr 0.6 100 PSIG 85 PSIG

__________________________________________________________________________________________

MBA9 9 27 lbs./hr 0.9 100 PSIG 85 PSIG

__________________________________________________________________________________________

MBA12 12 36 lbs./hr 1.2 100 PSIG 85 PSIG

__________________________________________________________________________________________

MBA18 18 54 lbs./hr 1.8 100 PSIG 85 PSIG

__________________________________________________________________________________________

MBA20 20 60 lbs./hr 2.0 100 PSIG 85 PSIG

__________________________________________________________________________________________

*Line water pressure must be a minimum of 10 PSIG higher than generator operating pressure or you will require high pressure water feed

w/motor and pump.

Products Covered by this Manual

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The Sussman MBA Electric Steam Generator is an industrial-grade electric boiler designed for generating steam. It is covered by an installation, operation, and maintenance manual, which provides comprehensive guidance for its setup, use, and upkeep.

Function Description:

The MBA Electric Steam Generator produces steam using electric heating elements. It is equipped with an electronic controller that automatically maintains the proper water level within the boiler. If the water supply drops below a safe operating level, the generator automatically shuts off to prevent damage. Steam pressure is maintained automatically by an operating pressure control, and a high-limit pressure control provides an additional safety cut-out with a manual reset. A steam safety valve, compliant with ASME Code, automatically opens to release pressure if it builds up excessively. The generator is designed for various industrial applications, providing a reliable source of steam.

Important Technical Specifications:

The MBA series covers a range of models with varying capacities:

KW Range: From 3 KW (MBA3) to 20 KW (MBA20).
Steam Rate: From 9 lbs./hr (MBA3) to 60 lbs./hr (MBA20).
BHP (Boiler Horsepower): From 0.3 (MBA3) to 2.0 (MBA20).
Design Pressure: All models are rated for 100 PSIG.
Max. Work Pressure: All models operate at 85 PSIG.
Voltage and Phase Options: Available in single-phase (120V, 208V, 240V) and three-phase (208V, 240V, 480V) configurations, depending on the model and KW rating. For example, MBA3 is available in 120V, 208V, 240V single-phase, while MBA20 is available in 208V, 240V, 480V three-phase.
Amperage: Ranges from 13 Amps (MBA3, 240V, 1PH) to 56 Amps (MBA20, 208V, 3PH).
Physical Dimensions: All units are physically identical, with a packed shipping weight of 125 lbs.
Connections: Water connection is 1/4 NPT, and steam outlet is 1/2 NPT.
Pressure Vessel: Rated at 100 PSIG to ASME Section I, Code M, and National Board registered.
Certifications: UL listed, CSA certified, and built to NEC standards.

Usage Features:

Liquid Level / LWCO Controller: An electronic controller ensures proper water levels and automatically shuts off the generator if water drops below a safe operating level.
Water Level Sight Glass: Allows for continuous visual monitoring of the water level during operation.
On-Off Switch: Features a pilot light for easy power control.
Integral Electrical Control: Includes a magnetic contactor that energizes the heating elements, integrated within the control unit.
Blowdown/Drain Valve: Facilitates easy emptying of the pressure vessel for blowdown and draining.
J-Box: Provided for motor/pump connections.
Long Life Heating Elements: Industrial-grade, heavy-duty stainless steel elements with one-piece resistance welded terminations for enhanced strength and safety.
Operating Pressure Control: Automatically maintains desired steam pressure.
Manual Reset Pressure Control: Offers a high-limit pressure cut-out with a manual reset for added safety.
Steam Safety Valve: An ASME Code valve that automatically opens to relieve excessive steam pressure.
Steam Pressure Gauge: Allows visual observation of steam pressure across its full range.
Energy Saving and Minimum Maintenance: The fully insulated pressure vessel minimizes heat loss, contributing to energy savings.
Easy Control Maintenance: All controls and components are easily accessible through fully-louvered openings, which also prevent component heat build-up.
Water Feed System: Requires incoming water line pressure to be at least 10 PSIG higher than the generator's operating pressure. If not, a motor/pump system (Sussman MBA38002A high pressure water feed motor/pump system) is required.
Installation Requirements: The boiler should be mounted on a solid, level foundation. All piping must be installed by a licensed plumber. A minimum clearance of 21 inches is suggested for heating element removal.
Wiring: Requires grounding according to National Electric Code. Proper sized, 90°C copper wire must be used, following the supplied wiring diagram. A disconnect switch with circuit breakers or fuses is recommended between the main power source and the boiler.
Safety Precautions: Boilers are susceptible to lightning damage; industrial-type lightning/surge protectors should be installed at the service entrance. Substitution of components or modification of wiring systems voids the warranty and can lead to dangerous operating conditions.

Maintenance Features:

Blowdown Schedule: Essential for preventative maintenance. Daily blowdown is recommended in hard water areas, and weekly in soft water areas. The blowdown valve can be connected directly to a drainage system if local codes permit.
Chemical Cleaning Compounds: Use of chemical boiler cleaning compounds voids all warranties unless approved by the manufacturer, as some compounds can damage heating elements. Consultation with water treatment engineers is recommended for conditioning boiler water.
Daily Checks: The sight glass should be checked daily to ensure adequate water.
Monthly Inspection: Internal wiring should be inspected for tightness, and checks for water leaks and loose fittings should be performed.
Quarterly Checks (Every Four Months):
- The low water cut-off and pump control should be checked for proper functioning.
- The probe and isolator should be checked for deposits, cleaned if necessary, by removing the inspection plate and the probe.
- Heating elements should be removed and cleaned if scale has begun to form. The boiler should also be drained and flushed. New bolts and gaskets should be used when re-installing elements to ensure proper sealing.
Water Quality: The system will not operate if distilled, demineralized, deionized water, or water from reverse osmosis is used.
Gauge Glass Maintenance: Regular examination for clouding, scratching, erosion, or corrosion is recommended. Commercial non-abrasive glass cleaners or diluted acids (like Hydrochloric acid) can be used for cleaning. A bright concentrated light should be used to inspect for scratches, corrosion, chips, cracks, or surface flaws. Defective glass should be replaced. Gauge glass should be stored in original packaging until installation.
Safety during Maintenance: Always disconnect all power before working on the boiler. Safety glasses and gloves must be worn when working with or examining the water gauge glass and connections. Pressure in the generator must be at zero before proceeding with any work on the gauge glass.

The manual also includes a detailed wiring control circuit diagram and a comprehensive list of replacement heating elements and spare parts, ensuring that users can easily identify and order necessary components for maintenance and repair.