Allard Boiler EB120 User Manual

EB120  
Advanced Ethanol Boiler  
Allard Research and Development  
Copyright © 2008 – Allard Research and Development, LLC. – All Rights Reserved  
EB120 Advanced Ethanol Boiler  
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Chapter One : Specifications  
Power  
Voltage  
(V)  
Phase  
(N~)  
1/3  
Current  
(A)  
Dimensions  
(W×H)  
Model  
(kw)  
EB-120  
12.0  
230/400  
52./17  
20"×8.25"×19"  
1. Parameters and dimensions of EB-A controller (chart 2)  
Model  
Timer Range  
(minutes)  
15-240  
Temperature Dimension(mm)  
L*W*H  
Remarks  
EB-A  
173 F  
5.75"×3.5"× 1"  
When the time widow displays ”Long”  
the boiler will operate continuously until  
it is switched off.  
Chapter Two: The EB120 Advanced Ethanol Boiler.  
Parts description  
No.  
1
Part  
Description  
ElectroMagnetic  
solenoid  
Automatically controls the beer in  
2
3
4
5
Water level probe  
Pressure relief valve  
Steam outlet  
Overheat switch  
Detect the water level  
Operates if the pressure in the boiler exceeds 1.2kg/ c m2  
Steam outlet  
Boil dry protector operates at 105℃  
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6
Heat element  
Heat element  
7
Proportional Solenoid  
Cooling Water Out  
Cooling Water In  
Power entry  
Automatically controls the cooling water flow  
Output that connects to the Still cooling water input  
Connections for the cooling water output  
The rout of power wire  
8
9
10  
11  
12  
Control cable entry  
The tout of control cable  
Accessorial  
board  
circuit Connect and control the heat element  
13  
14  
15  
16  
17  
18  
19  
20  
terminal  
Connection for power supply  
Connection for earth wire  
Drain valve  
Earth wire plug  
Drain valve  
Pump  
Pump  
Beer in  
Connect to pump for beer iput  
Exhaust valve  
Exhaust valve  
Drain outlet  
Main circuit board  
Outlet for drain  
Control center  
Parts description of EB-A controller.  
No.  
1
Part  
Description  
On/Off  
Pump  
Turns the system On and Off  
Operates an external (user supplied) pump  
2
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3
Drain Control  
Operates Drain, and used to set Cooling Water Flow Rate  
Preset Run Time and Distillation Control Temperature  
Increase button  
4
Set  
5
6
Decrease button  
7
C/F & Enter  
Enter Key. Also change from Fahrenheit to Centigrade  
Displays the remaining time of the boiler operation  
Displays the detected temperature of distillation column  
Beer Input pump operating  
8
Time display  
9
Temp display  
10  
11  
12  
L1  
L2  
L3  
Cooling water inlet in operation  
Indicator LED for draining green is for auto drain, red is for  
manual drain  
13  
14  
L4  
L5  
Overheat Indicator  
Tank Overheat Indicator. Red means the boiler was cut off  
as the heating elements are too hot (usually because of a  
lack of beer input)  
15  
16  
L6  
L7  
Cooling water proportional valve operation indicator  
Indicates the detected temperature is lower than the preset  
temperature and boiler is heating.  
17  
L8  
Indicates the detected temperature is higher than the  
preset temperature and the boiler is in idle mode.  
Chapter Three: Installation  
Disconnect all power before installation.  
If the boiler is installed in an inaccessible place, ensure that the electrical power, beer supply, and  
water supply can be easily turned off in an emergency.  
The minimum water inlet pressure is 3.6 psi (0.25 bar) and the maximum is 30 psi (2 bar), for  
pressures in excess of this, use an inline pressure regulator before connecting to the boiler system.  
The steam pipe from the boiler to still should be kept to a minimum, pipes longer than 10 feet (3  
meters) should be insulated to prevent heat loss. Steam pipes will be hot during use and must be  
protected against accidental contact.  
Keep the number of right angle bends to a minimum and ensure that the run of does not create a  
trap into which condensate would gather and cause a blockage (i.e. the pipe must not go down and  
then up).  
There must be no valve or other blockage in the steam pipe  
The steam pipe should be metal of other material that can withstand a constant 350 degrees F  
(150°C) temperature. Stainless Steel or Copper pipe is recommended. Do not use pipe that can rust.  
Do not permanently install the EB120 system outdoors. It can be used outdoors, but must be stored  
inside and protected from the weather. The unit is not weatherproof.  
Do not use the EB120 inside your house. A garage with the door open is fine, but never inside the  
living area.  
The EB120 should be level side-to-side and front to back and should be installed so that the arrows  
on the case point up.  
Do not install or operate the EB120 in close proximity to flammable or hazardous substances.  
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Beer, Water, and Steam connections  
a. The water supply pipe and steam pipe should comply with local standards.  
b. Connect the cooling water inlet of the EB120 to the main water supply using a flexible hose with  
3/4-inch fittings. Washing machine connection hoses are perfect for these connections, as they are  
made to withstand high pressure without bursting. We recommend braided stainless steel washing  
machine hoses, available at your local building supply store.  
c. Connect the Cooling Water Out to the water input of the distillation. These connections should also  
be made with either rigid copper pipe (at least ½ dia), or flexible washing machine hoses.  
d. Steam outlet (3/4 inch) use the same dimension Stainless Steel or Copper pipe to connect to the  
Distillation Column. During use the steam pipe will be very hot and must be protected against  
accidental contact. Note that according to the location it may be necessary to attach an additional  
length of pipe to the pressure relief valve in order to divert the steam flow to a safe direction should  
the valve operate.  
e. Connect the drain outlet to a suitable drain via a copper pipe with the appropriate fittings.  
Installation of controller and temperature probe.  
EB-A controller is waterproof and can be installed anywhere within close proximity of the distillation  
system.  
(1) Ideally the control panel should be installed at a height of approximately 5for ease of use.  
(2) Installation method: drill a 1.5(40mm) hole on mounting surface. Open the front cover of steam  
EB120 and connect the control cable (6 pin) and temperature sensor cable (2 pin) to the relevant  
ports.  
(3) Control panel installation: connect one end of the control cable to circuit board port in the boiler, and  
connect the other end to the controller.  
(4) Temperature probe installation: the temperature probe is installed into the distillation column at the  
control temperature point. This varies according to the size and type of still being used. This probe  
would be installed in the location normally used for a dial thermometer. The temperature probe has  
½male FIP fittings.  
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EB120 Temperature Probe  
Installations of power supply and control cables  
1. Confirm the correct voltage of power supply and wires.  
2. Remove the knock out for the power cable entry and use a rubber grommet to protect the cable,  
connect to the conductors to the correct terminals for single phase power supply use the copper  
bridge connectors, for 3 phase supply remove them.  
3. Remove the knock out for the control cable entry and use a rubber grommet to protect the cable,  
connect the cable to the relevant port on circuit board.  
4. Ensure the power supply wire and control cable remain separated to prevent magnetic field of power  
supply wire from disturbing control cable signal.  
For typical electrical connection in single-phase 220-volt operation, bridge the L1, L2, and L3 terminal  
connections together, and connect the AC Hot wire to one of the L connections. Next, bridge the 3  
neutral (N) terminal strips together and connect the AC neutral to one of the N connections. Last,  
connect the electrical ground to the ground terminal on the EB120 case.  
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EB120 Circuit Board  
Chapter Four : Testing and operation  
(1) Once the installation has been completed and checked, turn on power and water supplies and carry  
out the following test.  
(2) On the control panel press the on/off key, (the key has a time-lapse function, press it for I second),  
the time and temp displays the data.  
(3) Turn on your valve(s) to allow beer to flow to the boiler. The indicator LED is red on the remote. The  
internal pump will begin filling the boiler with beer. When the beer level rises to the low beer level  
sensor level the elements switch on and the heating indicator LED turns on. Several seconds later  
when the high beer level sensor is reached, the internal pump will stop, and the indicator LED  
changes to green.  
(4) After a few minutes of heating, the unit will begin producing steam.  
(5) Press the on/off key again to turn off the system. There will be no data on display and the boiler will  
stop.  
(6) Press the on/off key once more (temp and time display again), and after a few seconds the boiler will  
begin producing steam again. Let the boiler operate for a short while - the beer level will fall to the  
low beer level. Check that the internal pump automatically starts (the pump indicator LED (L1)  
becomes red). The pump indicator LED will go back to green when the boiler tank is full.  
(7) The time display counts down to show the remaining time, when it reaches 0 the boiler will stop  
heating. The run time can be adjusted, or overridden to run continuously.  
(8) 5 minutes after the system has been turned off, it will automatically go into the drain-down cycle. The  
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drain valve opens (drain indicator LED green).  
(9) You can also drain the boiler manually by pressing the drain key when the system has stopped  
heating. The drain indicator LED will indicate as red during this operation.  
(10) Once you have set the temperature required, the boiler will operate on all heating elements until the  
temperature is 4 degrees below the target temperature. Once the system is in full operation, the  
computer maintains the boiler temperature and it will selectively turn on or off heating elements as  
required. This approach helps to minimize the power consumption during operation.  
(11) The pump switch on the remote operates a relay on the EB120 circuit board. This can be used to  
control an external pump in your system. The maximum voltage that can be used through this relay  
is 120V, 5A.  
(12) Use the Enter key to change the temperature display between and and also to confirm the  
time and temperature setting.  
Setting Time and Control Temperature  
When the EB120 leaves the factory the default settings are 173 degrees Fahrenheit and 4 hours of  
operation. These can be adjusted as follows;  
(1) Time setting : press “set” key – the time display will flash - press “△”,”▽” to adjust the time,  
each press will increase or reduce 5 minutes. Once the desired setting is reached, press “enter” to  
accept, and the time display will stop flashing. You can adjust from the time from 15 to 240 minutes,  
or operate the unit with no time limitations or continuously. Note the controller has a memory  
function, and if the power cord is not disconnected, the next time you turn on EB120, the time you  
selected will be the default time.  
(2) Temperature setting: if you press “set” once after you finish setting the time or otherwise twice the  
temperature display will flash, enter the required temperature by pressing “△”,”▽” to adjust -  
every press will increase or reduce 1 degree. Once the required temperature has been set, press the  
“enter” key and the temperature display will stop flashing.  
Steam on Demand function  
To activate the steam on demand function, first preset the desired control temperature as described  
above, then press and hold the drain key for 5 seconds, L4 will turn red and the time displays “LONG”  
indicating that steam on demand is operational.  
Once the steam on demand function has started, the unit will operate for 30 minutes, and then stop until  
the function is started again.  
Note that the auto drain function will operate every time the steam stops.  
Adjusting the water flow control for the cooling coils in your distillation column  
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The water flow control can be fine tuned to help tightly control the specific characteristics of your  
particular still, and can help regulate varying input water pressures. There are four different presets  
that can be chosen for use during operation.  
To change the water flow rate control, turn on the EB120, and press and release the Drain key on the  
remote. The Temperature Display will flash and show one of four pressure settings; 1PS, 2PS, 3PS,  
4PS.  
Press the Drain key one or more times to cycle through the four choices. When you see the selection  
you want, press the Enter key to confirm. The Temperature display will stop flashing and return to  
displaying the temperature reading of the still.  
Finally, you MUST now press the On/Off button and turn the EB120 off, then press the On/Off button  
once more and turn the unit back on. These steps are required to store the new setting, and to prevent  
accidental changing of the water flow rate to the still.  
Chapter Five: Troubleshooting guide  
Please note that we recommend all repairs are carried out be a suitably qualified person.  
Trouble description Possible Cause  
Solution(s)  
When the boiler is  
turned on there is  
no display on  
Check:  
1. Power supply  
1. Check power supply voltage.  
2. If the indicator LED of power supply isn’t on,  
then check transformer or power supply.  
3. If the LED remains red, remove the controller  
turn off, reinstall the controller, and restart.  
4. Change circuit board  
2. Transformer  
3. Main circuit  
board  
control panel.  
4. Controller  
5. Control cable or 5. Check the control cable port and controller.  
port  
System appears to  
be turned on, but  
the boiler is not  
heating.  
Check:  
(1) Indicator LED for beer level is red. Check beer  
input supply  
1. Beer supply.  
2. Beer pump  
(2) Check the connection of water level probe.  
(3) Check ground wire connection of circuit board  
and boiler.  
operation.  
3. Water level probe  
4. Main board  
5. Ground wire of boiler  
and circuit board  
6. Heating control  
board  
(4) Indicator LED for beer level is green. Check  
circuit board  
(5) Check if overheat switch is disconnected  
(6) Check heating elements  
7. Heating elements  
EB120 is turned on, Check:  
Possibly need to:  
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control panel is  
normal, and  
1. Main circuit board  
2. Relay circuit board  
3. Heating elements  
* Change main circuit board  
* Change relay circuit board  
* Change heat elements  
indicator LED for  
heating is on, but  
there is no steam  
output  
Temperature  
displays “LC”  
Check:  
Check connection or change beer level probe.  
Beer level probe  
connection  
Temperature  
displays “HC”  
Beer level probe detects 1. Check beer level probe connection  
a short circuit  
2. Check controller for short circuit  
Turn off EB120, and Check the proportional  
1. Try turning the system on and off again, or  
disconnect the system from the power  
connection, and reconnect.  
cooling water  
solenoid control valve  
continues to flow  
through the system.  
2. Check proportional valve. Clean it or change it  
Unplug from power Check:  
Change circuit board or water inlet valve  
supply, and cooling 1. Water inlet valve  
water continues to  
flow through the  
system.  
2. Circuit board  
Turn off EB120, but Check:  
Unplug or disconnect the unit from power.  
DO NOT CONTINUE TO USE WITHOUT FIRST  
CONTACTING YOUR DEALER!  
it continues to  
operate.  
f. Circuit board  
g. Controller  
h. Relays on accessory  
circuit board  
i. Water level probe  
Chapter Six: Regular Use and Maintenance  
The single biggest problem with boilers is the build up of scale resulting from dissolved solids within the beer.  
Scaling can cause the heating elements to fail, the beer level sensors not to function, and premature failure of the  
O-rings resulting in leaks from around the elements. The extent of the problem will vary according to the degree  
of impurities in the beer.  
* IMPORTANT NOTICE: DO NOT ATTEMPT TO RUN ANY MASH OR LIQUID WITH SUSPENDED  
IMPURITIES DIRECTLY THROUGH THE EB120 WITHOUT FIRST STRAINING AND FILTERING.  
DOING SO WILL CLOG THE BEER PUMP, SOLENOID VALVE, AND BOILER, AND WILL VOID  
YOUR WARRANTY. WE RECOMMEND PRE-SCREENING WITH A FINE STAINLESS STEEL  
SCREEN, THEN FILTERING WITH AT LEAST A 10-MICRON FILTER BEFORE ALLOWING YOUR  
BEER TO BE PUMPED INTO THE EB120.  
We also recommend descaling the boiler once every 50 to 100 hours of operation. To descale use a solution of  
weak acid crystals (such as citric acid) mixed with water. Citric acid crystals are available in packets for descaling  
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kettles from most hardware stores, brew supply stores, and are available online from Allard Research and  
Development. Follow the instructions supplied with the crystals and allow sufficient time for the solution to  
dissolve the scale before flushing out the boiler.  
System faults arising from a failure to descale the unit are not covered by warranty.  
Because heating and cooling cause expansion and contraction, it is important to inspect all the water and steam  
inlets and outlets as well as their pipes and connectors on a regular basis to ensure there are no leaks. The  
condition of the wiring and electrical integrity of the boiler system should be checked regularly.  
Warranty  
The EB120 has a one-year warranty from the date of purchase. This warranty excludes consumable items such as  
the electrical heating elements. Failures resulting from misuse or abuse, such as a failure to descale as above, or  
using beer that has not been adequately strained and filtered, are not covered under the warranty.  
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