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First and foremost, an user manual of Chromalox PQ404-6 should contain:
- informations concerning technical data of Chromalox PQ404-6
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- safety signs and mark certificates which confirm compatibility with appropriate standards
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Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Chromalox PQ404-6 alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Chromalox PQ404-6, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Chromalox service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Chromalox PQ404-6.
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Table of contents for the manual
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Page 1
(Supersedes PQ404-5) PQ404-6 CHS 161-048642-001 OCTOBER, 1983 4 and Installation, Operation RENEWAL PARTS IDENTIFICATION Horizontal Electric Steam Boiler Model Number CHS 0 – 150 PSI © 2010 Chromalox, Inc. Power CC Size of Output Nominal 90˚C Amps Standard Lbs. per Model B.H.P . Fuse Delta Size Wire per Elements Control Hr . at Number Rating kW[...]
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Page 2
2 High Pressure Control Pressure Gauge Manual Reset Pressure Conrol Electric Control Box Blow Down Drain Valve (L) Return Inlet (J) Heating Elements Step Sequencer (Optional) Wall 30” C B A Wall D I H E Blow Down Drain Valve (L) Check Valve Water Inlet (K) Water Level Control G 60” Safety Valve (G) Steam Outlet (F) INST ALLA TION (cont’d.) Fi[...]
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Page 3
3 INST ALLA TION (cont’d.) SPECIAL INSTRUCTIONS FOR CUSTOMERS SUPPL YING THEIR OWN CONDENSA TE OR PUMP SYSTEMS. 1. 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. 2. The motor circuit should be w[...]
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Page 4
4 WIRING (cont’d.) Figure 8 – T ypical Wiring Diagram Power Circuit T erminal Block T o Other Heater Groups To Other Heater Groups T ypical 3 Phase Heater Group To Power Curcuit Relay Step Sequencer Figure 9 – Power Circuit Detail Low Water Probe 120 Volt Control Voltage Hi Limit Control Electronic Resistance Sensing Amplifier for Auxiliary L[...]
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Page 5
NOTES 1. Motor , Solenoid V alve and Dotted Control W iring are included if Motor and Pump package is supplied. Solenoid V alve only is sup- plied with 991 17 W ater feed. 2. 1/3 HP Motor is controlled directly without use of Motor Starter . After proper wiring and piping of boiler system is complete, testing of controls can start. Before testing c[...]
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Page 6
6 RECOMMENDED ST ART -UP PROCEDURES 1. Close globe valve on outlet side of boiler . (Customer Supplied) 2. T urn on boiler and allow pressure to build up to operating pressure. 3. Only open globe valve by quarter turns at first, introducing small- er amounts of steam into process. A void opening globe valve all at once. This will eliminate the poss[...]
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Page 7
7 OPERA TION (cont’d.) Figure 16 – T ypical Wiring for Automatic Blowdown System Now turn the wheel on the large timer until the “of f” tab passes the “time now” arrow . The “boiler normal” light should go out and the valve should begin to open. Once the “valve open” light goes on, the valve should remain open for a few seconds [...]
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Page 8
8 AUXILIAR Y LOW W A TER CUT -OFF (See page 4 for Wiring Diagram) 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 100,000 ohms or less, a signal of sufficient mag- ni[...]
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Page 9
9 5. Connect the ohmmeter between controller terminals W and R and raise the set point of the controller above the actual pressure being measured. The ohmmeter should read the full value of the poten- tiometer measured in step 4 (135 ohms for an L91B). 6. Slowly lower the set point of the controller while observing the ohmmeter reading. The resista[...]
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Page 10
10 The Sequence Reverser accomplishes its tasks and shows the rela- tive use of each of ten beat stages during the first four days of the cycle. This is how the work load would be distributed on a boiler with- out Sequence Reverser . It can be seen the early stages are ON most of the time and the later stages are OFF most of the time, since they ar[...]
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Page 11
11 MAINTENANCE RENEW AL P ARTS IDENTIFICA TION INSTRUCTIONS FOR ELEMENT REPLACEMENT CAUTION: Before installing your new elements, be sure the McDonnell-Miller low-water cut-off is operating perfectly and the float chamber and lower equalizer column are completely clear of sludge or other foreign matter . (See Figure 23) Failure to do this may cause[...]
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Page 12
2150 N. RULON WHITE BLVD., OGDEN, UT 84404 Phone: 1-800-368-2493 www.chromalox.com RENEW AL P ARTS IDENTIFICA TION (cont’d.) Low Water Cutoff and Water Feed Controls Description Part Number Complete Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-118538-013 Complete Assembly (Manual Reset) . . . . . . . . . [...]