Service manual

ManualsBrandsAllied Engineering ManualsHeating System6MSE

PN4330651

INSTALLATION AND SERVICE MANUAL

Models 6MSE to 54MSE for Hydronic Heating

6 kW to 54 kW, 208 Vac to 600 Vac, Single or Three Phase

MINI-STAR

ELECTRIC BOILER

WARNING

Risk of electric shock. This unit may be connected to more than one

electrical circuit. Turn off all electrical supply 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.

Manufactured by

Allied Engineering Company

Division of E-Z-Rect Manufacturing Ltd.

Manufacturers of Gas and Electric Boilers, Heat Exchangers, Electric Boosters, Indirect Tanks

94 Riverside Drive, North Vancouver, B.C. V7H 2M6 • Telephone 604-929-1214 • www.alliedboilers.com

Branches: Calgary • Edmonton • Toronto • Denver

Post these instructions in a visible place.

DATE OF INSTALLATION :

INSTALLED BY :

PHONE :

Featuring the

BC-1 Controller

with Outdoor Reset and DHW Override

(OPTIONAL)

Summary of content (20 pages)

PAGE 1
INSTALLATION AND SERVICE MANUAL MINI-STAR® ELECTRIC BOILER Models 6MSE to 54MSE for Hydronic Heating 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. Turn off all electrical supply circuits before servicing. IMPORTANT • The boiler must be installed in accordance with all applicable national, provincial/state, and local codes, laws, regulations, and ordinances.
PAGE 2
MSE Series Electric Boilers – Installation and Service Manual Dimensions and Specifications 1.1 Section 1 TECHNICAL SPECIFICATIONS Maximum Operating Pressure: Maximum Operating Water Temperature: Water Capacity in Boiler: Inlet and Outlet Pipe Size: Controller Pump Switch Capacity: 90 p.s.i. 210ºF 6.6 US Gallons 1 1/4” NPT 5A Maximum Table 1: Super Hot MSE Series Electric Boiler Specifications.
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MSE Series Electric Boilers – Installation and Service Manual 1.2 WATER TEMPERATURE RISE vs FLOW RATE 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): 6.94 x kW Temp.
PAGE 4
MSE Series Electric Boilers – Installation and Service Manual Installation Instructions 2.1 Section 2 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.
PAGE 5
MSE Series Electric Boilers – Installation and Service Manual 2.4 WALL MOUNTING CAUTION: Failure to correctly position the boiler may result in element burn out. For example, installing the boiler with the front casing panel facing upwards will 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).
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MSE Series Electric Boilers – Installation and Service Manual 2.6 SYSTEM OPERATING REQUIREMENTS MSE series electric boilers are designed for use in closed loop hydronic systems and are not intended for open systems, such as domestic hot water and pools, where water is continually replenished. Operating the boiler in an open system will result in premature failure due to corrosion of the boiler.
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MSE Series Electric Boilers – Installation and Service Manual Wiring 3.1 Section 3 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.
PAGE 8
MSE Series Electric Boilers – Installation and Service Manual Electrical Connections For all electrical connections: Strip wire ends and insert into the terminal block. Tighten terminal screw clamps to securely hold the wire. CAUTION - Risk of damage to the controller: Do not apply power to any connections on Terminal Block TB4 or TB5, except L1 & L2.
PAGE 9
MSE Series Electric Boilers – Installation and Service Manual 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 block. Tighten terminal screw clamps. Attach ground wire to ground terminal block on the control panel. Startup Instructions 4.
PAGE 10
MSE Series Electric Boilers – Installation and Service Manual BC-1 Controller Information Section 5 WARNING The following section is intended as a quick reference guide for the BC-1 Controller Manual. Read all instructions and the BC-1 Controller Manual before placing the boiler in operation or making any adjustments. Adjustments must be made by a qualified heating technician. 5.1 CONTROLLER INFORMATION Control Board Dimensions: 4-3/4” (L) x 2-7/8” (W) x 1-7/8” (H).
PAGE 11
MSE Series Electric Boilers – Installation and Service Manual 5.2 CONTROLLER DISPLAY The BC1 uses a Liquid Crystal Display (LCD) as a method of supplying information. You use the LCD in order to setup and monitor the operation of your system. The BC-1 uses three push buttons (Item, ▲, ▼) for selecting and adjusting settings. As you program your control, record your settings for future reference.
PAGE 12
MSE Series Electric Boilers – Installation and Service Manual Summary of BC-1 Display Text in Installer Mode VIEW MENU Display Text in Mode Description OUTDR 4,5 BOIL TARGET 1,2,3,4,5 Target boiler supply temperature the control is trying to maintain at the boiler supply sensor or the boiler outlet sensor BOIL SUP 2,5 Current boiler supply water temperature as measured by the boiler supply sensor.
PAGE 13
MSE Series Electric Boilers – Installation and Service Manual 5.3 CONTROLLER OPERATION When the controller is powered, the controller enters the operating mode if there are no sensor or high limit errors present. The user should select one of the following modes from the controller adjust menu: Mode 1 - Setpoint operation: Operates boiler stages to maintain fixed temperature at boiler outlet sensor when a heat demand is present.
PAGE 14
MSE Series Electric Boilers – Installation and Service Manual Sequence of Operation Thermostat (T1) closed - Thermostat creates a Heat Demand resulting in a boiler target based on the outdoor reset settings. The boiler pump (Pump1) operates. DHW Aquastat (A1) closed - DHW Aquastat creates Setpoint DHW Demand and activates external pump relay. The external pump relay causes the following actions: 1) Power for the boiler pump (Pump1) is broken. Pump1 does not operate.
PAGE 15
MSE Series Electric Boilers – Installation and Service Manual Maintenance Instructions 6.1 Section 6 SERVICE HINTS a. 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.
PAGE 16
MSE Series Electric Boilers – Installation and Service Manual Troubleshooting Guide 7.1 Section 7 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, beware of 120V power while troubleshooting near the line-in terminals (L1&L2), pump terminals (P1&P2), transformer and pump fuse.
PAGE 17
MSE Series Electric Boilers – Installation and Service Manual PROBLEM CAUSE • Flow Switch is open • Element fault. SOLUTION / CHECK • Check for closed circuit between FS-5 and FS-6 and 24V (AC) across FS-6 and C-1. 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.
PAGE 18
MSE Series Electric Boilers – Installation and Service Manual Replacement Parts 8.1 Section 8 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 Department Allied Engineering Company 94 Riverside Drive North Vancouver, B.C.
PAGE 19
MSE Series Electric Boilers – Installation and Service Manual Notes Section 9 19
PAGE 20
MSE Series Electric Boilers – Installation and Service Manual Index Section 10 Section Page 1 Dimensions and Specifications .................................................................................................... 2 1.1 Technical Specifications................................................................................................................... 2 1.2 Water Temperature Rise vs Flow Rate..........................................................................................