Atlantic Boilers MULTI-ELEC STANDARD Series User manual

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TECHNICAL MANUAL
MULTI-ELEC STANDARD BOILER
09/2011 CODE: 560955
CE Directive 2006/95/CEE
British Standard EN 60335-1 (C 73800)

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CONTENTS Page
1) INTRODUCTION
1.1) Description 3
1.2) Dimensions &connections 4
1.3) Electrical power requirements 4
1.4) Dimensions 5
2) INSTALLATION
2.1) Procedure 6
2.2) Arrangement 6
2.3) Essential accessories 7
2.4) Precautions 7
2.5) Boiler room arrangements 7
2.6) Commissioning 7
3) ELECTRICAL ARRANGEMENTS
3.1) Control panel arrangement 8
3.2) Control circuitry 9
3.3) Electrical power circuitry 10
3.4) Fuse and overload protection 11-12
3.5) Operation of the digital controller 13
3.6) Alarm arrangements 13
4) DELIVERY and OFF-LOADING 14
5) MAINTENANCE 15
6) GUARANTEE 16
7) IDENTIFICATION OF SPARE PARTS 17
8) FAULT DETECTION 17

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1) INTRODUCTION
1.1) Description
The STANDARD electric boiler is suitable for avariety of types of space heating and indirect
domestic hot water –covering sealed circuits from 0.5BARS to 7.0BARS working pressure.
The STANDARD electric boiler always requires earthing, under protection index IP21/1K 08.
The STANDARD electric boiler is designed and manufactured according to the following :-
EN Decree 95-1081 –control of boiler materials and electrical supply voltage used in
order to conserve the safety of persons and animals which might be in the vicinity
European Directive 2006/95/CEE covering low voltage system application
BS EN 60335-1 class C73800, part 1, general rules
THE STANDARD ELECTRIC BOILER
Outputs from 90kW to 630kW
Outputs above 630kW to 980kW by special order
Maximum working pressure 4BARS, test pressure 6BARS
Maximum working temperature 100degC, limit 110degC
50mm thick glass silk insulation with MO fire classification cladding
Hand reset limit thermostat at 110degC
Resistance to earthing shock not less than 1megohm
INCOLLOY IMMERSION HEATERS –90kW to 180kW boilers
Individual heater elements 80-200mm diameter
Individual elements –30kW, 415V, 3phase &earth
Vertical access requirement –2010mm
INCOLLOY IMMERSION HEATERS –210kW to 630kW
Individual heater elements 80-200mm diameter
Individual elements –35kW, 415V, 3phase &earth
Vertical access requirement –2050mm
CONTROL PANEL
Control cabinet fixed to the boiler
Enabling from remote electronic or hand operation
Three cartridge fuses per each step control
Three contactors, one per step
One transformer for the control circuit
One main isolator with manual lock
One ‘alive’ lamp indicating power on
One ‘lock-out’ lamp indicating boiler stopped
One digital controller
One set of terminal connections
The control panel can
(i) be located in any of three positions on the boiler
(ii) have the panel door in either of two hinge positions
(iii) be provided with variable control &output

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1.2) Performance
M
ODEL
210
245
280
315
350
385
420
Output kW
210
245
280
315
350
385
420
No of Immersion heaters
6
7
8
9
10
11
12
Minimum flow rate l/sec
1.7
1.7
1.7
1.7
2.2
2.2
2.2
Maximum flow rate l/sec
11.7
11.7
11.7
11.7
11.7
11.7
11.7
Maximum pressure d
rop kPA
16
16
16
16
16
16
16
Flow/return connections
100
100
100
100
100
100
100
Dry weight kgs
233
238
243
248
253
258
263
Water content
283
283
283
283
283
283
283
M
ODEL
455
490
525
560
595
630
Output kW
455
490
525
560
595
630
No of Immersion he
aters
13
14
15
16
17
18
Minimum flow rate l/sec
2.8
2.8
2.8
2.8
3.6
3.6
Maximum flow rate l/sec
26.0
26.0
26.0
26.0
26.0
26.0
Maximum pressure drop kPA
16
16
16
16
16
16
Flow/return connections
150
150
150
150
150
150
Dry weight kgs
367
372
377
382
38
7
392
Water content
395
395
395
395
395
395
MODEL
90
120
150
180
Output kW
90
120
150
180
No of Immersion heaters
3
4
5
6
Minimum flow rate l/sec
0.6
0.8
0.8
1.1
Maximum flow rate l/sec
5.0
5.0
10.0
10.0
Maximum pressure drop kPA
8
8
28
28
Flow/return connections
80
80
80
80
Dry weight kgs
117
121
125
129
Water content
128
128
128
1
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OUTPUT
STEP ONE
STEP TWO
STEP THREE
Power
kW
fuse
A
Power
kW
fuse
A
Power
kW
fuse
A
90kW
30
63
30
63
30
63
120
60
125
30
63
30
63
150
60
125
60
125
30
63
180
60
12
5
60
125
60
125
210
70
125
70
125
70
125
245
105
160
70
125
70
125
280
105
160
105
160
70
125
315
105
160
105
160
105
160
350
140
250
105
160
105
160
385
140
250
140
250
105
160
420
140
250
140
250
140
250
455
175
315
175
315
140
250
490
175
315
1
75
315
140
250
525
175
315
175
315
175
315
560
210
400
175
315
175
315
630
210
400
210
400
210
400
1.3 Electrical power required

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1.4 Dimensions
Model
Depth
mm
Width
mm
Height
mm
Access Front
mm
Access Rear
mm
Access Side
mm
Access Other
Side
90
820
520
1380
1000
750
500
100
120
820
520
1380
1000
750
500
100
15
0
820
520
1380
1000
750
500
100
180
820
520
1380
1000
750
500
100
210
970
670
1570
1000
750
500
100
245
970
670
1570
1000
750
500
100
280
970
670
1570
1000
750
500
100
315
970
670
1570
1000
750
500
100
350
1070
670
1600
1000
750
500
100
385
1070
670
1600
1000
750
500
100
420
1070
670
1600
1000
750
500
100
455
1170
770
1800
1000
750
500
100
490
1170
770
1800
1000
750
500
100
525
1170
770
1800
1000
750
500
100
560
1170
770
1800
1000
750
500
100
595
1170
770
1800
1000
750
500
100
630
1170
770
180
0
1000
750
500
100

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2) INSTALLATION
2.1) Procedure
*Position the boiler squarely on the prepared base
*Fit the correct accessories to the boiler connections
*Connect the boiler to the pipework system
*Connect the boiler to the isolated electrical supply
*Fill the boiler with fresh, clean water
*Check that the immersion heaters are electrically isolated from the
boiler. If the isolation is less than 2mega-ohms, the bridge must be
found and rectified.
*Check the operation of the main control panel isolator, and of the
overloads serving the immersion heaters
*Check the operation and the correct direction of rotation of the
circulating pump
*Check, with the circulation pump stopped, that the water flow switch
over-rides the immersion heaters through their relays and also brings
on the relevant alarm light
*Check the setting and operation of the immersion heater step controls
*Switch off the immersion heaters using the main control panel isolator
*Check that all the cartridge fuses are sound
*Double check that all the immersion heaters receive the common
voltage. Repeat the check after several hours run. Any defect in
voltage can destroy the heaters and invalidate the guarantee.
2.2) Typical heating arrangement
Balancing Vessel
Xpresso
Radiators
DHW
Expansion
vessel
Pressure &
temperature
relief valve
Auto air
vent
Pump
Non return
valve
Pressure relief
valve
Isolating ball
valve
Fill Loop
3 Port valve

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2.3) Essential accessories
The following items are required :-
A. One 4-bar safety valve and one 7-bar temperature and pressure relief valve
B. One shunt pump –protected by overloads (1A to 1.6A adjustable) and run/fault lamps
C. One water flow switch
-Recommended water flow settings in litres per second
Pipeline sizes 32mm 40mm 50mm 65mm
Minimum range 0.35-0.47 0.53-0.72 0.61-0.83 1.0-1.4
Maximum setting 1.0 1.6 1.9 3.2
D. One automatic air vent with isolating valve
E. One drain ball valve
2.4) Precautions
The Multi-elec Standard requires an installation conforming to
89.336/EEC Directive (electromagnetic compatibility)
73/23/EEC Directive (low voltage)
92/42/EEC Directive (performance)
The ATLANTIC Guarantee conditions
2.5) Boiler room arrangements
The Multi-elec Standard must be installed
In an adequately-ventilated boiler room with ambient temperature below 30degC
And relative humidity maintained between 30% and 80% and where condensation
does not occur
In anon-corrosive atmosphere
In anon-explosive atmosphere
Where there is good access to the boiler position for installation and maintenance
Where there is good access for delivery, off-loading and positioning
Using similar materials in the pipework, and avoiding materials leading to electrolytic
action and system deterioration
The Multi-elec Standard is not suitable for external installation
2.6) Commissioning
The boiler must be completely full of water before the heating elements are switched
on. To ensure 100% filling, manual and automatic vents must be in effective positions
where complete air clearance can be guaranteed.
The boiler can be filled with water by connecting afill hose to the boiler drain valve
and partly opening the valve.
The boiler safety valve can also be used firstly to vent the boiler at filling and,
secondly, ensuring the blow-down facility of the valve is clear in case of emergency.
For full guarantee, the boiler should be commissioning by Atlantic 2000 or an
authorised engineer

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3) ELECTRICAL ARRANGEMENTS
3.1) Control panel arrangement
Photograph of control panel with identification of components

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3.2) Control circuitry
EXTERNAL CONTROLS

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3.3) Electrical power circuitry

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3.4) Fuse and overload protection
Fuse ratings and type –industrial cylindrical cartridge
90 to 280kW
F1 –1A type aM, F2 –1A type gG, F3 –0.5A type gG
315 to 630kW
F1 –1A type aM, F2 –1A type gG, F3 –0.5A type gG
F4 –F6 type 22 x58 : 63A type gG
Type 0: 125A type gG
Type 1: 160A type gG
Type 2: 250, 315 &400A type gG
Amperage requirement –insert table from earlier
ELECTRICAL CIRCUIT
The Standard electric boiler must be provided with 415volts and
without neutral wiring
The electrical wiring cables must be sized by aqualified electrician in
order to conform
to BS C15100 and satisfying load, length of run and prevention of short
circuit.
The installation must be tested for automatic power failure in the
event of emergency
power cut, heater lock-out or error in the neutral layout.
All electrical equipment shall satisfy IP21/IK08 Class 1
The immersion heaters shall only receive electrical power if they are
fully immersed in water; otherwise the guarantee on the heaters will
not apply
ALL ELECTRICAL WIRING MUST BE CORRECTLY EARTHED

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3.5) Operation of the digital controller
Factory settings (primary heating circuit)
Flow temperature –80degC
Maximum flow temperature setting –95degC
Minimum flow temperature setting -20degC
Time delay T1 –30 seconds
Time delay T2 -1minute
Time delay T3 -2minutes
digital controller has numbers or message, touch settings
+–touch raise settings, –touch lower settings
3.6) ALARM SIGNAL
On Alarm, light (7) shows and the following messages appear on (1)
<PFO >Lock-out or power cut
<HA >High temperature lock-out
<LA >Low temperature alarm
3.6 Information on the Control Panel
1. The Panel has aregistration label
2. The wiring is capable of amaximum current of 23kA
3. Neutral panel wiring is not required
4. The Panel is protected by isolators, circuit breakers and fuses.
5. Earth wiring is essential
6. One week after commissioning, all connectors –on immersion
heaters and incoming electrical supplies –need to be checked.
This should be repeated annually.
7. Manufacturing tests include heat output and control circuitry
8. The boilers should not be installed or operated in corrosive,
explosive or humid atmosphere
9. Adequate natural ventilation is required. 550mm2 x kW free
area at high and low level is recommended

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4) DELIVERY and OFF-LOADING
It is recommended that the STANDARD electric boiler is transported and, if necessary,
stored on the pallet on which it is delivered from the factory.
If temporarily stored, the surroundings should be maintained at temperatures below
80degC, and without condensation at relative humidities between 30% and 80%
Manhandling the STANDARD electric boiler into position requires :-
(a) Qualified, skilled manpower
(b) Use of apallet trolley or afork lift truck
(c) Use of the lifting eyes provided on the boiler and tested of lifting beams

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5) MAINTENANCE
Effective maintenance must aim at preventing :-
a). areduction in the influx of fresh water through the boiler
-this can result in the formation of sediment or limescale on the
boiler immersion heater elements
b). pockets of high temperature water across the boiler immersion heater
elements –resulting in their destruction by overheating
c). accumulation of sediment or limescale within the boiler, particularly on
or around the boiler immersion heater elements –overcoming these
developments by the introduction of small amounts of fresh, clean water
without any inhibitor or de-scaling agent
Minimum maintenance periods
A). Monthly maintenance
i). Check operation of the automatic air vent
ii). Check operation of the water flow switch
iii). Check operation of the safety valve
B). Annual maintenance
i). Carry out the monthly checks
ii). Check all electrical connections
iii). Check all the electric control functions
iv). Check all pipework joints are water-tight
v). Drain off small amount of boiler water content and check for condition
C). 3-yearly maintenance
i). Carry out the annual maintenance
ii). Isolate the boiler safely from all services
iii). Drain the boiler of water and open up for inspection
iv). Check for all maintenance requirements and remedy as necessary
v). Close and seal the boiler, fill with fresh clear water through drain outlet
vi). Pressure test, then repeat annual maintenance procedure

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6). GUARANTEE
7). IDENTIFICATION OF SPARE PARTS

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7). IDENTIFICATION OF SPARE PARTS
Controller 790220
Flow sensor 583027
30kW immersion heater 2534
35kW immersion heater 2536
Limit thermostat 581104
Water flow switch 480230
8). FAULT DETECTION
Before making any physical check, switch off the power
FAULT CHECK
The ‘live’ light is out Check for incoming power
Check fuses F1 and F2
Check the ‘alive’ bulb
………………………………………………………………………………………………………………………..
The controller screen is out Check fuse F3
………………………………………………………………………………………………………………………….
Step 1or Step 2light is out Change the bulb
………………………………………………………………………………………………………………………….
The ‘red’ light is lit Check the limit thermostat
Check the water flow switch action
Check the circulating pump overload
…………………………………………………………………………………………………………………………..
If the fault remains Call in aqualified service engineer