BT SERIES ELECTRIC BOILER
Contents
1. 5 1 SERVICE HINTS This boiler has been designed to provide years of trouble free performance under normal operating conditions However the owner should conduct a general external examination at the beginning of each heating season and at mid heating season to assure good working performance is continued In addition a qualified service technician should examine the boiler at least once every year b Do not store anything against the boiler or allow dirt or debris to accumulate in the area immediately surrounding the boiler c Elements will burn out if the boiler is not filled with water when electrical power is turned on Do not connect thermostat wires until system has been filled with water Water should be drained out from system only when absolutely necessary to make repairs or prevent freeze up during extended cold weather shutdown d The pressure 8 temperature gauge on the system should be checked frequently During normal operating conditions pressure should be relatively stable throughout the heating season If pressure under normal operating conditions consistently rises and falls over a period of time this can indicate a fill valve leak system leak or expansion tank malfunction Leaks anywhere in the system must be repaired without delay If any leaks or significant pressure fluctuations are observed call for service immediately Controller Information Section 6 6 1 BiTRONIC CONTROLLER INFORMATION BiTronic Control Board2. INSTALLATION AND SERVICE MANUAL BT SERIES ELECTRIC BOILER FOR HYDRONIC HEATING APPLICATIONS 6 kW to 54 kW 208 Vac to 600 Vac Single or Three Phase WARNING Risk of electric shock This unit may be connected to more than one electrical circuit Disconnect all electrical circuits before servicing IMPORTANT The boiler must be installed in accordance with all applicable national provincial state and local codes laws regulations and ordinances This manual must be left with owner and should be located adjacent to the boiler for reference Ensure boiler is full of water before turning on electricity Elements will burn out immediately without water in the boiler A boiler installed above radiation level or as required by an Authority having jurisdiction must be provided with a low water cut off device at the time of boiler installation Overcurrent protection between the power supply and the boiler must be provided in accordance with the related national and or local codes Always ensure power is turned off before servicing Electrical wiring or internal controls must be serviced by a qualified electrician Any adjustment of the internal controls must be performed by a qualified service technician Post these instructions in a visible place DATE OF INSTALLATION INSTALLED BY PHONE Featuring our newest BiTronic Control System Manufactured by Allied Engineering Company S Re Division of E Z Rect Manufa
3. e Pressure reducing valve set too high e Reduce setting of pressure reducing valve Water leaking from electric boiler e Element or sensor threads leaking e Turn off all electricity to the boiler Remove wires from element terminals and tighten elements with correct socket wrench Turn off water drain remove and apply sealant if necessary e Plumbing connections leaking e Tighten incoming pipes and pressure relief valve Turn off water drain and remove and apply sealant if necessary Be sure to turn off electricity before draining or elements will burn out 12 BT Series Electric Boilers Installation Operating and Maintenance Instructions 7 2 SENSOR CHECK 1 SHUTOFF MAIN POWER TO THE ELEMENT HEATING CIRCUIT BEFORE TROUBLESHOOTING Also be careful of 120 Vac power while troubleshooting near Line in terminals L18L2 Pump terminals P1 amp P2 and other areas of the Controller 2 Control Board should be powered with green power LED on Confirm 120 Vac power at L1 amp L2 using an AC voltmeter Confirm correct sensor wiring red wire to HL black wire to CL and white wire to OL Test hi limit sensor by using a DC voltmeter to measure voltage across HL amp CL and record voltage Test operator sensor by using a DC voltmeter to measure voltage across OL amp CL and record voltage DOV O A sensor at room temperature 68 F should measure approximately 2 93 Vdc If the sensor is not at room temperat
4. screws from the sides a Wiring on Controller Line Voltage Connect if not pre wired only 120 Vac 60 Hz single phase power to terminals L1 and L2 on the controller Strip wire ends before inserting into terminal block Tighten terminal screw clamps Pump Connect only 120 Vac 1 6 HP maximum pump to terminals P1 and P2 on the controller Strip wire ends before inserting into terminal block Tighten terminal screw clamps If a pump horsepower larger than 1 6 HP is used change the pump fuse on the controller based on the pump rating Do not use a pump requiring greater than 5A or 600 VA Thermostat Connect thermostat or zone valve end switch to terminals T1 and T2 DO NOT apply any power to these terminals Strip wire ends before inserting into terminal block Tighten terminal screw clamps Water Temperature Control Sensors Pre wired factory wiring high limit temperature sensor to terminals HL and CL common Strip wire ends before inserting into terminal block Tighten terminal screw clamps Pre wired factory wiring operating temperature sensor to terminals OL and CL common Strip wire ends before inserting into terminal block Tighten terminal screw clamps b Power Supply to Heaters The supply cable has to be sized based on the amperage in Table 1 and the cables used Connect only specified line voltage and phase power to main terminal block on the control panel Strip wire ends before inserting into terminal bl
5. 1 Three 24 Vac 3 AMP relays drive stage 1 stage 2 and stage 3 Maximum load of the individual drive or the total load of three relays should not exceed 1 33 A or 32 VA 2 One 120 Vac pump output is switched by using a 10A relay The load current of this output is also limited by the pump fuse selected controller supplied with 3 A fuse and must not exceed 5 A or 600 VA Power Consumption Controller internal 4 watts maximum 24 Vac contactor drive depends on the contactors LED Displays A total of seven indicator lights display the following information 1 Hi limit red High limit or high limit sensor error LED is lit when either the boiler water temperature reaches the high limit of 230 F or the high limit sensor is faulty disconnected or misconnected 2 Sensor red Operating sensor error LED is lit when operating sensor is faulty disconnected or misconnected Power green Power on off Pump yellow Pump relay on off Stage 1 yellow Boiler first stage on off low heat Stage 2 yellow Boiler second stage on off medium heat Stage 3 yellow Boiler third stage on off high heat IV OV BO Signal Control Input T1 and T2 Thermostat or zone valve end switch switching input closed is activation HL High limit temperature sensor CL Common return of the high limit and the operating temperature sensors OL Operating temperature sensor Temperature Control Ranges Temperature notation degrees F
6. Specifications BiTronic Controller Layout see figure 3 Dimensions 8 1 2 L x 3 1 4 W x 1 3 4 H High Limit Control Outlet Water Temperature 230 F fixed Operating Control Outlet Water Temperature 100 210 F adjustable Controller Input Voltage 120 Vac Controller Output Voltage 24 Vac stage relays 120 Vac pump terminal POWER STATUS PUMP STATUS SENSOR MISCONNECT ALERT HEAT OUTPUT LEVELS HIGH LIMIT ALERT ALLIED ENGINEERING CO BITRONIC CONTROLLER y HELIMIT SENSOR POWER PUMP STAGE1 STAGE2 STAGES j Y DIAGNOSTIC LED INDICATOR LIGHTS MADE IN CANADA CONTROL SIGNAL FIELD WIRED INPUT TERMINAL 24 Vac THERMOSTAT TRANSFORMER FACTORY WIRED HIGH LIMIT amp OPERATING LIMIT SENSORS tao 159 160 479 SL 1303 _ 180 sia 120 Vac BOER 120 190 Ta 109 200 l Mole 7 100 210 3AI250 TEMPERATURE STAGE 1 STAGE2 STAGE3 PUMP FUSE 1A 250 CONTROLLER FUSE SERIAL No 1234 BOILER WATER Sa FIELD WIRED TEMPERATURE SETTING FACTORY WIRED PUMP TERMINAL POWER INPUT ELEMENT RELAYS 120 Vac 60 Hz 120 Vac 60 Hz Figure 3 BiTronic Controller Layout BT Series Electric Boilers Installation Operating and Maintenance Instructions Transformer Power Rating 40 VA Input Voltage 120 Vac 60 Hz single phase Output Voltage 24 Vac 60 Hz Power Output
7. the time of boiler installation PRESSURE amp FLOAT TEMPERATURE GUAGE AIR VENT PRESSURE AIR RELIEF VALVE PURGER El ES nm gt SUPPLY To E 24 l y P HEATING SYSTEM 14d 137 12 e WN CIRCULATOR GATE MAIN POWER E a VALVE SUPPLY N v i 7 TO DRAN EH A EXPANSION TANK J HEATING RETURN P gt KRE GATE j VALVE 7 MAKE UP T i WATER gt KA U GATE VALVE DRAIN PRESSURE REDUCING FILL VALVE Figure 2 Piping Arrangement BT Series Electric Boilers Installation Operating and Maintenance Instructions Wiring Section 3 3 1 ELECTRICAL WIRING All electrical wiring must be done in accordance with the Canadian Electrical Code CSA C22 1 Part 1 and or any local regulations and codes in Canada or the National Electrical code ANSI NFPA 70 latest edition and or any local regulations and codes in U S A Verify the nameplate rating and check the related codes to properly size conductors switches and overcurrent protection Several openings are provided on the right and bottom of the casing for different voltage connections For wire connections refer to the wiring diagram sticker on the back of the boiler front cover All circuit breakers ahead of and at the boiler must be OFF Remove the boiler front cover by removing 4
8. to OL sensor Operating sensor fault Perform Sensor Check described in 7 2 and replace sensor if necessary Internal control fault Neutral wire of sensors is disconnected or misconnected High limit or operator sensor fault Perform Sensor Check described in 7 2 and replace control board if necessary Black wire of sensors must be connected to CL Perform Sensor Check described in 7 2 and replace sensor if necessary Internal control fault Thermostat fault Internal control fault 11 Perform Sensor Check described in 7 2 and replace control board if necessary Disconnect thermostat from controller turn thermostat to maximum setting and check continuity With thermostat disconnected from board voltmeter should read 24V DC across terminals T1 and T2 BT Series Electric Boilers Installation Operating and Maintenance Instructions od PROBLEM SOLUTION CHECK No heat when called by thermostat and e Main fuses blown if applicable e Check main fuses and replace if stage LEDs are lit blown e Internal control fault e Turn stage LEDs on by adjusting thermostat to maximum setting and check for 24V AC across stages 1 2 and 3 e Anti Cycle Cube fault With corresponding Stage powered place a jumper wire across the Anti Cycle Cube terminals If the main contactor s does not close perform main contactor check If the main contactor s are working t
9. up to 5A or 600VA When the thermostat calls for heat the controller will operate the boiler to regulate the water temperature at a pre selected setpoint The system pump is on whenever there is a thermostat calling for heat Multi stage electric boilers have a number of advantages over conventional on off single stage boilers Instead of switching on off all heating elements using sequencers each stage of a multi stage boiler is controlled directly by the controller to minimize both temperature fluctuations and reduce the number of on off operations of the contactors heating elements The on off times of each of the stages are separated by a pre determined minimum time interval to avoid a surge in line current The average cycle time of each of the heating elements shall be greatly increased This ensures better temperature stability extends the life of the boiler and increases energy efficiency 2 3 BOILER LOCATION The boiler is intended for indoor installation only and must not be subjected to water spray or leakage It may be installed in an enclosed space and attached directly to a combustible surface Allow ample space around the boiler to ensure all connections and controls are readily accessible The minimum required clearances for service are shown in the following table Minimum Clearance Provides service access for left side 18 inches elements right side 12 inches plumbing connections front 12 inches ele
10. 26 lb FAdd 45 Ib for package models 1 2 WATER TEMPERATURE RISE vs FLOW RATE BT Series Electric Boilers Installation Operating and Maintenance Instructions NOTE The boiler should be properly sized for its heating application and maintain an adequate water flow rate during operation Significantly oversizing the boiler or decreasing boiler water flow rate will cause excessive stage cycling and result in premature failure of the contactors Water flow rate vs temperature rise formulas in US gallons per minute GPM and liters per minute LPM GPM 6 94 x kW Temp Rise F 14 6 x kW LPM Temp Rise C Table 2 Water Temperature Rise vs Flow Rate in GPM LPM Model KW 10 F 5 6 C 20 F 11 C 30 F 17 C 40 F 22 C 6BT 4 2 16 2 1 8 1 4 5 1 0 4 9BT 9 6 2 23 3 1 12 2 1 8 1 6 6 12BT 12 8 3 31 4 2 16 2 8 10 2 1 8 15BT 15 10 4 39 5 2 20 3 5 13 2 6 10 18BT 18 12 5 47 6 2 24 4 2 15 3 1 12 20BT 20 13 9 52 6 9 27 4 6 17 3 5 13 24BT 24 16 6 63 8 3 32 5 5 21 4 2 16 27BT 27 18 7 70 9 4 36 6 2 23 4 7 18 30BT 30 20 8 78 10 4 40 6 9 26 5 2 20 34BT 34 23 6 89 11 8 45 7 9 29 5 9 23 38BT 38 26 4 99 13 2 50 8 8 33 6 6 25 42BT 42 29 1 109 14 6 56 9 7 36 7 3 28 45BT 45 31 2 117 15 6 60 10 4 39 7 8 30 48BT 48 33 3 125 16 6 64 11 1 41 8
11. 3 32 54BT 54 37 5 141 18 7 72 12 5 46 9 4 36 1 3 GENERAL DIMENSIONS ol x 2 LAG BOLT SECURE TO WALL MOUNTING BRACKET Ti 1 GAP 24 MAIN POWER Sl Y UPPL RSA r LEFT SIDE Figure 1 General Dimensions 16 FRONT RIGHT SIDE af NPT OUTLET SENSOR ACCESS WALLS 120 Vac _4 POWER SUPPLY jac A THERMOSTAT NPT PRESSURE _ WY RELIEF VALVE Vi MAIN POWER SUPPLY 147 NPT INLET 5 5 AN SS RIGHT SIDE BT Series Electric Boilers Installation Operating and Maintenance Instructions Installation Instructions Section 2 2 1 RECEIVING INSPECT SHIPMENT FOR POSSIBLE DAMAGE All goods are carefully manufactured inspected checked and packed by experienced workers The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage shortage in shipment or non delivery must be filed immediately against the carrier by the consignee 2 2 INTRODUCTION Super Hot Electric Boilers are controlled by a three stage electronic temperature controller The controller controls the boiler water temperature with three stages and turns stages on based on the heating demand time delay and the preset boiler outlet water temperature The controller also can control 120Vac circulating pumps rated
12. NG TERMINAL BLOCK B3_ SOME MODELS C N Im lo llr GROUND LUG TB2 CONTACTOR CONTROLLER MOUNTING PLATE BITRONIC_CONTROLLER FUSE BLOCK SOME MODELS FUSE SOME MODE LS ANTI CYCLING CUBE MAIN POWER SUPPLY TERMINAL BLOCK TB1 FRONT CASING PANEL HIGH LIMIT amp OPERATING SENSOR ASSEMBLY RIGHT PANEL Figure 4 Replacement Parts 2 SS BT Series Electric Boilers Installation Operating and Maintenance Instructions Notes Section 9 BT Series Electric Boilers Installation Operating and Maintenance Instructions Index Section 10 11 0 INDEX Section anar li ii aa da Page 1 0 Dimensions and Specifications 1 1 Technical SpecifiCatONS eiotissialiconn taria aks eee a a iio dit ia 2 1 2 Water Temperature Rise vs Flow Rate ccccccccceceeeceeeeeceneececeeeeesenanaeceeeeeceseeeaaeeeeeeeeeeennanaees 3 1 3 General DIMENSIONS avivar anta aia 3 2 0 Installation Instructions 2 1 A A E nina a An nee a A ee es ee 4 2 2 A ie rece be iss eee ea Saab Cag a CLG aoe Saeed ga a a tg ela 4 2 3 Boiler EOCATIOM seas A EG Ed a E ad CR eae 4 2 4 Wal mOuntinGwc Gli A A a ead 5 2 5 PIPING 200d i a eee ee ee ee 5 3 0 Wiring 3 1 Electrical Wining 70d ects ie hae Sok etl eds a Sot he ee Pe 6 4 0 Startup Instructions 4 1 ELTS EE A AAR reer a AE A T NS 7 4 2 e r a a adn ad a a E aia tad 7 5 0 Mainten
13. ahrenheit Pre set operating temperature range 100 F to 210 F Fixed high limit temperature 230 F All stages on off temperature differential 4 F Operating Temperature Adjustment Internal temperature potentiometer on the controller or external temperature potentiometer optional extra Anti Cycle Cube external Delay On Make Time Range 0 1 to 8 minutes adjustable Input Voltage 24 V Maximum Load Current 1 Amp BT Series Electric Boilers Installation Operating and Maintenance Instructions 6 2 CONTROLLER OPERATION When the controller is powered up the green Power light will come on If no sensor or high limit errors are present the controller enters the operating mode Once in operating mode the controller uses the operating sensor to continuously monitor the boiler water temperature When the thermostat calls for heat the controller will switch on the system pump and the yellow Pump light The control system will switch on the each stage s with yellow Stage light s in sequence followed between each stage with an interstage delay as set by the Anti Cycle Cube When the yellow Stage light for stage 2 or stage 3 switches on the Anti Cycle Cube will begin counting delay time to energize its stage contactor s and will energize its stage contactor s only after the time delay has elapsed This feature prevents short cycling which can quickly wear out contactors and cause rapid temperature fluc
14. ance Instructions 5 1 SONICO AMS A ETEA EE AAE TEE ea 8 6 0 Controller Information 6 1 BiTronic Controller INfOriMathon sd cist ainia dit 8 6 2 Controller Operatii itsin idad 10 6 3 Temperature Seng aeaee e e EAEEREN E iA 10 6 4 AnteGycle Cube SelM i aaa iaa EA 10 6 5 Controller MOUntin Get icon cit 10 6 6 Protection from LIQuidS iii cscccidcks eves dlls rta tilda ii ia 10 7 0 Troubleshooting Guide 7 1 Troubleshooting h cse noite A ca eet eed 11 7 2 Sensor Check isso sea Vi oda aetna have lea a deve neal E E E N 13 8 0 Replacement Parts 8 1 Order ai A A A ieee 14 9 0 NOS 0 AAA AA A A AS ron 15 10 0 a0 in A A A A a as 16
15. boiler is rated at 30 psi or as required by order but the maximum working pressure cannot exceed 90 psi for CSA or A S M E approved boiler Once the system is filled with water all trapped air must be removed to avoid air locks which can reduce flow rate and cause thermal shock Figure 2 also illustrates the connections to the air purger not supplied by manufacturer and expansion tank in the line from the boiler to the radiation units Additional air purgers should be installed at high points in the system to assist in removing air which can accumulate from the water supply line All high points must be vented b Startup Procedure Perform the following procedure as a check for proper boiler and system operation 1 Set the boiler operating temperature to the designed heating water temperature by adjusting the dial of potentiometer located on the bottom left of the controller Figure 3 Use a small screwdriver to adjust the arrow on the temperature adjustment dial to the water temperature required This boiler is also equipped with a non adjustable high limit temperature device set at 230 F as safety limit control The high limit temperature device has an automatic reset function 2 The stage 1 stage 2 and stage 3 contactors are each connected in series with Anti Cycle Cubes Use a small screwdriver to adjust the arrow on the Cube adjustment dial to the required stage time delay The recommended Anti Cycle Cube settings are two minutes fo
16. ctrical components and fuses It may be preferred to locate the boiler close to the electrical supply panel BT Series Electric Boilers Installation Operating and Maintenance Instructions 2 4 WALL MOUNTING CAUTION Failure to correctly position the boiler may result in element burn out This boiler must be installed using the attached wall mounting brackets It is critical that the boiler be installed level and oriented as shown in Figure 2 below When correctly positioned the front panel is vertical and the 1 1 4 NPT outlet connection is directly above the 1 1 4 NPT inlet connection The wall mounting brackets on the boiler feature a key hole opening suitable to fit over the head of two previously installed 5 16 lag screws The key hole openings are located on 16 centers i e standard stud spacing on the top side of the hangers The lag screws must be suitably anchored to safely support the weight of the boiler including water content piping and wiring 2 5 PIPING The recommended piping arrangement is shown in Figure 2 Attach pump expansion tank drain valve pressure relief valve air vent pressure temperature gauge and flow switch as required Air vents should be installed at points just upstream from all drops in elevation of the piping system high points A boiler installed above radiation level or as required by an authority having jurisdiction must be provided with a low water cut off device at
17. cturing Ltd Manufacturers of Gas and Electric Boilers Stainless Steel Tanks Tankless Coils Electric Boosters C 94 Riverside Drive North Vancouver B C V7H 2M6 e Telephone 604 929 1214 e FAX 604 929 5184 US Branches Calgary e Edmonton e Toronto OPTIONAL PN4152451 BT Series Electric Boilers Installation Operating and Maintenance Instructions Dimensions and Specifications Section 1 1 1 TECHNICAL SPECIFICATIONS Maximum Operating Pressure 90 p s i Maximum Operating Water Temperature 210 F Water Capacity in Boiler 6 6 US Gallons Inlet and Outlet Pipe Size 1 1 4 NPT Controller Pump Switch Capacity 5A Maximum Table 1 Super Hot BT Series Electric Boiler Specifications Flange Type Elements Single Phase Three Phase BT Series Electric Boilers ETA MEA Model 6BT 9BT 12BT 15BT 18BT 20BT 24BT 27BT 30BT 34BT 38BT 42BT 45BT 48BT 54BT Note 3 Approximate shipping weights Super Hot Tame amp Amp Amp 8 Amp Amp 28 9 25 0 16 7 14 4 tos 87 MEN E E 20 24 so 102 60 27 1 3 143 20 a8 153 540 o seo a 12 z 2 0 2 43 2 1 Other models of the BT Series Electric Boiler may be available subject to inquiry 2 Delta connection unbalanced load amperage of high leg indicated Model Weight 6BT amp 9BT 114 lb 12BT to 18BT 116 lb 20BT amp 24BT 118 lb 27BT to 38BT 122 lb 42BT to 54BT 1
18. delay The recommended Anti Cycle Cube settings are two minutes for stage 1 five minutes for stage 2 and eight minutes for stage 3 Minimum Settings The stage 1 Cube should be set at a minimum of one minute The stage 2 Cube should always be set a minimum of two minutes longer than stage 1 The stage 3 Cube should always be set a minimum of two minutes longer than stage 2 6 5 CONTROLLER MOUNTING The controller mounts on the boiler control panel using six 6 sheet metal screws and 1 2 high plastic standoffs The indicator LEDs are visible on the top of the boiler casing 6 6 PROTECTION FROM LIQUIDS The controller and other components located within the control panel are sensitive to water and other liquids Measures must be taken to fully protect components on the control panel from contact with liquids This especially applies to overhead pipes which may leak or condensate causing damage BT Series Electric Boilers Installation Operating and Maintenance Instructions id Troubleshooting Guide Section 7 7 1 TROUBLESHOOTING For Use of Licensed Electricians Only WARNING RISK OF ELECTROCUTION HIGH VOLTAGE ALWAYS SHUT OFF MAIN POWER TO THE ELEMENT HEATING CIRCUIT BEFORE TROUBLESHOOTING Also be careful of 120V power while troubleshooting near Line in terminals L1 amp L2 Pump terminals P1 amp P2 and other areas of the controller This section is meant to assist the service technician when troubleshooting th
19. e electric boiler As in any troubleshooting procedure it is important to isolate a problem as much as possible before proceeding Often the controller error message LEDs can be a great help in identifying the cause of a problem If you suspect a wiring fault carefully check all external wiring and wiring connections following the wiring diagram sticker on the back of the boiler s door An additional wiring diagram is enclosed with this manual PROBLEM Power LED green is not lit High Limit LED red on controller is lit Sensor LED red on controller is lit Both High Limit and Sensor LEDs red on controller are lit No heat when called by thermostat and stage LEDs are NOT lit Incorrect supply power SOLUTION CHECK Check for 115V AC across L1 and L2 Controller fuse blown Internal control fault High limit wire is disconnected or misconnected Check fuse and replace if necessary Replace controller Red wire of sensor must be connected to HL Operating sensor fault allows water temperature to reach the high limit Perform Sensor Check described in 7 2 and replace sensor if necessary High limit sensor fault Perform Sensor Check described in 7 2 and replace sensor if necessary Internal control fault Operating sensor wire is disconnected or misconnected Perform Sensor Check described in 7 2 and replace control board if necessary White wire of must be connected
20. est for voltage across Anti Cycle Cube terminals using AC voltmeter Voltage should read 24 V AC before the delay time has elapsed and approximately 2 5 V AC after delay time has elapsed Replace Anti Cycle Cube if necessary e Main contactor s fault e Check each contactor coil s terminals for a supplied voltage of 24V AC If present main contactor s are faulty and must be replaced If not present wiring continuity fault exists check and repair e Element fault RISK OF ELECTROCUTION MAIN POWER TO ELEMENTS MUST BE DISCONNECTED Next disconnect element wires from main contactor s and check for continuity If no continuity replace element If continuity the contactor is defective To confirm contactor defect check for continuity across main contactor when closed Pump runs constantly when there is no e Internal control fault e Replace controller call for heat Pump will not run e Pump ceased or burnt out e Repair or replace e Pump wiring fault e Check and repair wiring e Pump fuse blown e Check pump fuse and replace if necessary e Internal control fault e Replace controller Controller does not operate normally e Internal control fault e Replace controller Pressure relief valve discharges water e Relief valve not reseating properly e Quickly lift and release manual discharge lever on relief valve to assist proper reseating If this fails replace pressure relief valve
21. ock Tighten terminal screw clamps Attach ground wire to ground terminal block on the bottom control panel NOTE Outdoor Reset controllers must not be connected to the Bitronic Control System Outdoor Reset controllers will interfere with the Bitronic controller s normal staging routine and lead to excessive stage cycling and premature failure of the contactors BT Series Electric Boilers Installation Operating and Maintenance Instructions Startup Instructions Section 4 4 1 WARNING WARNING The following instructions are intended as a guide for qualified persons Before switching the power on fill the system with water and vent air Check for and repair any leaks in the water piping 4 2 STARTUP a Fill System Figure 2 shows the suggested set up for a make up water supply using a pressure regulator not supplied by manufacturer Do not apply full line make up water pressure to the system Fill the system to approximately 12 psi cold water if the expansion tank is pressurized at 12 psi The expansion tank should be sized to provide the system with enough volume for thermal expansion and contraction while maintaining operating pressures within safe and reasonable limits There should be no significant pressure fluctuations in systems having both an effective automatic fill valve and a properly sized expansion tank or expansion tank arrangement The standard pressure relief valve supplied with the
22. r stage 1 five minutes for stage 2 and eight minutes for stage 3 Minimum Settings The stage 1 Cube should be set at a minimum of one minute The stage 2 Cube should always be set a minimum of two minutes longer than stage 1 The stage 3 Cube should always be set a minimum of two minutes longer than stage 2 3 Turn up all room thermostats above room temperature 4 When power is supplied to the controller the power indicator LED green is always on When the thermostat calls for heat the pump will be energized immediately and the pump indicator LED yellow will light up Next the three stages are energized along with the stage indicator LEDs yellow one after another in sequence and based on the time delay which is user set by the Anti Cycle Cubes Once the boiler water temperature reaches the set point on the temperature adjustment dial the controller will regulate the boiler water temperature with three stages The number of stages which stay on is based on the heating demand and the set point of the boiler water temperature After all room thermostats are satisfied with the heat the controller de energizes the three stages one after another in sequence and then switches the pump off 5 Current may be checked by a qualified electrician at the feeder panel and compared to the values shown in Table 1 BT Series Electric Boilers Installation Operating and Maintenance Instructions Maintenance Instructions Section 5
23. tuations The elements will stay on until the supply water temperature reaches the temperature dial setting When the water temperature setpoint is reached the control will automatically cycle the stage s of the boiler on or off as necessary to maintain the supply water temperature The required number of stages which are activated is determined by the heating demand difference between boiler water temperature and design temperature setpoint After the call for heat has been satisfied the stage s of the boiler along with the Stage light s will switch off in sequence followed by the pump All stage outputs will shut off within 15 seconds upon a sensor short circuit The shut down sequence will switch off one activated element at a time and then the pump All stage outputs will shut off immediately followed by the pump after a delay if the high limit temperature is reached or there is a sensor open circuit The controller has a built in automatic reset function upon power interruption 6 3 TEMPERATURE SETTING The water temperature adjustment dial on the controller should always be set at the designed boiler water temperature A small screwdriver should be used to adjust the arrow on the temperature adjustment dial 6 4 ANTI CYCLE CUBE SETTING The stage 1 stage 2 and stage 3 contactors are each connected in series with Anti Cycle Cubes Use a small screwdriver to adjust the arrow on the Cube adjustment dial to the required stage time
24. ure use the following formula to calculate the expected voltage reading Sensor Temperature in F 459 4 180 DC voltage The voltage drop across HL amp CL and OL amp CL should be approximately equal when both sensors are working properly NOTE A measured voltage of 24 Vdc indicates an open circuit or faulty sensor Check for loose connections and wire continuity before replacing sensor 7 Disconnect sensor from HL CL and OL terminals Confirm 24 Vdc at HL amp CL and OL amp CL using a DC voltmeter 8 If both sensors are operating properly step 6 and sensor or hi limit error light is on replace controller BT Series Electric Boilers Installation Operating and Maintenance Instructions Replacement Parts Section 8 8 1 ORDERING Replacement parts or a replacement electric boiler may be purchased through any Allied Engineering Company distributor call us if you need help locating a distributor near your area If you require any technical assistance or have any comments about our product please write or phone us at Service Allied Engineering Company Department 94 Riverside Drive North Vancouver B C CANADA V7H 2M6 Tel 604 929 1214 Fax 604 929 5184 Email sales alliedboilers com z o DESCRIPTION LEFT PANEL FLANGE TYPE ELEM ENT GASKET FOR FLANG E TYPE ELEMENT TANK ASSEMBLY S HOWN WITH FLANGE ELEMENTS MOUNTING BRACKE CASI
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