Atlantic Boilers A-YO Series Installation and operation manual

ATLANTIC 2000 - boilerplant sales ACM ATLANTIC - commissioning and maintenance ATLANTIC 4422 – spares
Atlanc 2000 Registered in England Company No: 1477687 Vat Reg No: 306 0653 89
PO BOX 11, ASHTON UNDER LYNE, OL6 7TR T: 0161 621 5960 E: technical@atlancboilers.com www.atlancboilers.com
A-YO SERIES
ELECTRIC STEAM BOILER
OPERATING & MAINTENANCE MANUAL
ALL MODELS

Index
Performance ………………….. 2
Boiler drawings ………….. 3
Installation …………………… 8
Operation …………………….. 10
Setting the time control … 15
Daily maintenance ………….. 16
Fault finding ……………………. 18
Typical installation …………. 20
Typical electrical wiring … 21

BARSg
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
7 to 10
8 to 10
8 to 10
8 to 10
8 to 10
415/240
415/240
415/240
415
415
415
415
415
415
415
415
415
415
415
415
415
Boiler front elevation
1. Boiler pressure guage
2. System controller (pp 12 – 15)
3. Brake wheels

1 Safety valve
2. Output steam control valve
3. Feed water tank overflow
4. Feed water tank ball valve
5. Feed water tank drain
6. Housing cover plate
7. Boiler drain valve
8. Power supply inlet
9. Water supply inlet
10. Feed water tank
11. Frost protection water drain
Boiler rear elevation
Boiler front inner elevation
1. Electric control panel
2. Live, neutral & earth terminals
3. Electric leakage protection
4. Feed water pump fuse
5. Heating elements contactor
6. Feed water pump air bleed
7. Feed water pump
8. Heating elements fuse
9. Steam heating elements
10. Check valve stops reverse flow
11. Feed water pump motor

Right side boiler elevation
Boiler view from above
1. Product rating plate
2. Feed water level sensor
3. Glass level tube with valves
4. Glass tube with flushing valve
5. Feed water levelling pipe
1. High/low levelling of feed water
2. Low level limit stops heating
3. On/off pressure control
4. Pressure gauge
5. Pressure sensing pipe
6. Robust earth connection

Connect water supply, insert an
isolating valve; ensure feed water is blow 50°C
We recommend the installation of
a water-softening plant.
Connect the steam boiler output through
a non-return valve to a distribution system
Connect
3 x L’s to three live supply wires
1 x N to neutral supply
1 x PE to robust earth
Connect safety valve outlet and
frost valve outlet to sump.
Avoid scalding of installer and operators
on these pipe runs

Check that the feed water tank is clean
and free of all debris.
Open valve and allow water into the
Feed Water tank. Flow will stop when the
tank is full and the ball valve is satisfied.
Open the steam valve and close the drain
outlet valve.
Purge all air from the steam drum
Open air screw on the feed water pump
and check all air is removed.
Switch on pump for 60 seconds and repeat
air test until only water appears
Switch on the power supply and the
controller lights up.
Check all terminals

Press the ‘POWER’ button
Full screen lights up
Boiler indicates ‘lack of water’
Press ‘ON/OFF’ button
Feed water added automatically
And the high water mark reached and the
feed water pump stopped plus the pump
symbol disappears.
Water is entering the steam drum
If the feed water tank remains full, the
Pump may be jammed – press ‘+’ for more
than 5 seconds otherwise repeat the
exercise of step three.
Press ‘ON/OFF’ on controller
Boiler is in ‘RUN’ condition and everything will operate.
Display ‘P-L’, boiler will commence heating – turn on
steam valve and
cycle of heat/water feed will proceed
IMPORTANT NOTICE
Boilers (3kW-15kW) have only one heating tube
The remainder have two tubes, used in alternative
lead order
Symbols on the controller
‘M’ water level between ‘H’ and ‘L’
‘L’ feed water pump on
‘H’ feed water pump off

Open the steam valve slowly to encourage
dry steam at stable pressure
To stop the boiler
1. Press ‘POWER’ button
– controller display disappears
2. Turn of main electrical power
3. After 15seconds and pressure drops to 1BARg,
open drain outlet
WARNING
Do not open the drain immediately
after stopping the boiler
1. Boiler can be damaged
2. Potential scalding of people close by
Setting the time control
The steam boiler must be under the control
of a qualified operator
The operator must be in attendance during
time setting

Regular Maintenace
After boiler is switched off, allowed to cool for
15minutes, and pressure falls to 1BARg
Then drain valve is opened to release condensate
do not open drain valve too soon
– there will be damage to the boiler
Daily Maintenance
Monthly Safety Valve Test
Under pressure conditions, manually test the
safety valve handle for blow-down conditions
If there is no blow-down, replace or service
the safety valve
Monthly Electrical Terminals Check
Turn off the main power supply –
check all terminal screws and bolts
Three Monthly check heating tubes and boiler for
scale
The heating tubes need to be withdrawn and,
together with the boiler shell, cleaned of scale
The amount of water treatment can be adjusted a
s the amount of scale is recorded

Fault Finding
ERROR POSSIBLE FAULT LIKELY REPAIR
LCD controller – no display Fuse failure Change fuse
Low voltage Check voltage
Wire(s) loose Check circuits
LCD faulty Replace LCD
LCD lights up – button F no go High or low voltage Check voltage
Button F faulty Replace LCD
Feed water pump not operating Pump seized Press ‘+’ to rotate pump
at low water boiler conditions No LCD message Replace LCD
Fuse burnt out Replace fuse
Wiring loose Check connections
Pump burnt out Replace pump
Pump rotating, no water flow Air in the pump Release the air
Check valve blocked Clean check valve
Water pump jammed Switch off boiler/open
housing/release jamming
Water pump impeller worn Replace pump
Feed water full, pump continues Scale on high level water probe Check the HL water probe
& clean if possible
HL probe connection loose Check the HL probe circuit
Water level control not correct Check the HL/LL control levels
Heat Contactor operates Circuit breaker not operating Open the circuit breaker
reduced or no output Circuit breaker has failed Replace the circuit breaker
AC contactor has failed Replace the AC contactor
Heating tube has failed Replace the heating tube
Power circuit has failed Fit new power wiring
Water level sensor failure Build-up of scale on sensor Clean or replace sensor
Sensor wire is faulty Check the circuit
Sensor housing is scaled up Clean the housing

ERROR POSSIBLE FAULT LIKELY REPAIR
Pressure gauge mis-reading Pressure gauge broken Replace gauge
Brass housing blocked Clean or replace housing
Water overspill from boiler Ball valve blocked in open tank Open tank lid and repair
Ball valve broken Replace ball valve
Open tank filled with hot water Back-feed from check valve Clean or replace check valve
Circuit breaker fails in OFF position Reset button in ‘OFF’ position Press re-set button
Heating tube has failed Replace heating tube
Circuit breaker has failed Replace circuit breaker
Circuit breaker circuit is faulty Check the circuit
Boiler over-rides working pressure Pressure controller faulty Replace pressure controller
Pressure control circuit faulty Check the circuit
Safety valve exhausts at low setting Safety valve is at faulty setting Test for behaviour
or safety valve has alternate faulty
steam/water cycle Safety valve has failed Replace with certificated safety valve
Safety valve exhausts too much water Incorrect action of feed water pump Drain boiler of water & re-start
cycle
Water level sensor over-cycling Clean & wash the water level sensor
LCD Panel displays – contactor inert LCD controller is faulty Replace LCD controller
AC contactor is faulty Replace AC contactor
AC contactor circuit faulty Check the circuit
AC contactor vibrates in circuit Dust in the contactor Air pressure clean or replace
Voltage unstable Check voltage
Air leak in sight glass Lock ring faulty Replace lock ring
Fault Finding

Feed Water
Feed water to boiler
Water Treatment Samples
Drain
Trapped Steam Header
Steam Trap
A-YO
100kW electric steam boilers & typical circuit diagram
voltage 240V/50Hz
A-YO 3-9kW

voltage 415V/50Hz
A-YO 3 – 15kW
voltage 415V/50Hz
A-YO 18 – 50kW

voltage 415V/50Hz
A-YO 60 – 100kW