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DIVEX MHE-02, Installation, Operating And Maintenance Manual

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DIVEX MHE-02 Installation, Operating And Maintenance Manual Download Page 9

vii

KI-OM-523 R2

Disclaimer

III. DISCLAIMER

Whilst every effort has been made to ensure the accuracy of the information provided in this
document, Divex makes no guarantees therefore.

Misuse of the equipment described in this manual could result in injury. It is the responsibility
of the user to ensure that the equipment is used and maintained correctly and in accordance
with the instructions provided in this manual in order to ensure safety of life and to prevent
injury.

Summary of Contents for MHE-02

Page 1: ...INSTALLATION OPERATING AND MAINTENANCE MANUAL for the Mini Water Heater Electric Model MHE 02 440 VAC Supply x 24 VDC Controls Document No KI OM 523 Legacy No 05984 805 Part No KI40026AA...

Page 2: ...Intentionally Blank...

Page 3: ...AC Supply x 24 VDC Controls REV DATE BY CHECK APP COMMENTS 0 31 03 2010 R Carli N Maske R Faustmann First Issue 1 11 06 2010 R Carli N Maske R Faustmann Update as per ECN CT 00276 2 26 10 2012 V Garzo...

Page 4: ...ii Approval Sheet KI OM 523 R2 Intentionally Blank...

Page 5: ...5 1 3 4 Electrical System Detail Control Logic and Component Identification 5 1 3 5 Heater System and Heater Selection 6 1 3 6 Control System 7 CHAPTER 2 INITIAL SET UP 11 2 1 Installation 11 2 1 1 Ge...

Page 6: ...RECOMMENDED SPARE PARTS LIST ACQUISITION FORM 39 B 1 Recommended Spare Parts List Spares Kit KI40026AA KIT 39 B 2 Recommended Spare Parts Not in Spares Kit KI040026AA KIT 41 APPENDIX C SPARES ACQUISI...

Page 7: ...KI OM 523 FILENAME AND PATH EQUIPMENT TYPE Mini Water Heater Electric MHE 02 440V x 24V EQUIPMENT SERIAL NO CUSTOMER VESSEL LOCATION IF KNOWN DATE OF ISSUE IMPORTANT Please quote the above informatio...

Page 8: ...vi Data Sheet KI OM 523 R2 Intentionally Blank...

Page 9: ...document Divex makes no guarantees therefore Misuse of the equipment described in this manual could result in injury It is the responsibility of the user to ensure that the equipment is used and maint...

Page 10: ...viii Disclaimer KI OM 523 R2 Intentionally Blank...

Page 11: ...formation IV CONFIDENTIAL INFORMATION This document is confidential and is the property of Divex It may not be distributed to persons or organizations other than the intended recipient without the pri...

Page 12: ...x Confidential Information KI OM 523 R2 Intentionally Blank...

Page 13: ...y transportation on site accommodation and subsistence expenses Divex may dispatch personnel to perform on site repairs The product specification and warranty terms are subject to alteration without p...

Page 14: ...xii Warranty KI OM 523 R2 Intentionally Blank...

Page 15: ...ph of Temperature Loss vs Umbilical Length 18 Fig 3 2 General Arrangement 20 Fig A 1 MHE 02 General Arrangement Isometric View 35 Fig A 2 MHE 02 General Arrangement Side View 36 Fig A 3 MHE 02 General...

Page 16: ...xiv List of Tables and Figures KI OM 523 R2 Intentionally Blank...

Page 17: ...SCRIPTION The MHE 02 assembly Includes a motor pump heater tank pipework and a control panel These components are mounted into a robust stainless steel frame The system requires a constant supply of s...

Page 18: ...ired temperature rise through the unit would be 36 C The heater selection table shown in Table 3 1 indicates that heater banks 1 2 and 3 should be used for the required temperature rise through the un...

Page 19: ...ing hand valves on the inlet and outlet of each filter Only one filter should be used under normal operation with the other on standby and ready to be put into operation These filters clean input wate...

Page 20: ...e same way as the automatic control valve and is provided to control outlet temperature if automatic control is inactive The pump supply is directly coupled to the level control tank The pump is a pos...

Page 21: ...LOGIC AND COMPONENT IDENTIFICATION The main isolator located in the electrical panel is used to switch the main power of the unit on and off As detailed in the heater power circuit in APPENDIX D power...

Page 22: ...equential switching of the banks reducing the instantaneous load on the supply As heater banks have separate control circuits and protection the failure of any single bank of heaters will not effect t...

Page 23: ...he amount of fluid dumped is controlled by an electronic controller that operates the actuator on the control valve The amount to which the valve is opened is determined by the controller based on fee...

Page 24: ...eater Bank On L2 L4 LED indication of heater bank power on Supply to heater contactor coil Run Light White Control Power On L5 LED indicating 24 VDC power to control circuit Fault Light Red Pump Trip...

Page 25: ...ontact of the float switch This arrangement is used to reduce nuisance faults attributed to level switch vibration or bouncing The normally open contact R2 1 is used in the safety circuit to remove po...

Page 26: ...latched with a twist release Switch Fault Reset S6 The fault rest switch unlatches the over temperature and low level fault interlock circuits and allows normal function Switch Float FS The float swit...

Page 27: ...lative 3 4 NPT penetrator of the unit Flexible hoses with suitable connections may also be used to facilitate the integration of the unit into an installation The maximum acceptable water inlet pressu...

Page 28: ...m should be fitted to the bottom right hand side of the stainless steel electrical enclosure The mains power cable should be installed through a suitable gland and correctly grounded to the armour Mai...

Page 29: ...n the heater tank 7 To complete priming shut the vent valve and supply valve s 2 2 2 START UP AND FUNCTION CHECK After installation is complete the MHE 02 must be thoroughly checked prior to being put...

Page 30: ...roller display indicates the Measured Value PV Set Value SV and run indication for the Auto tuning AT Output 1 and 2 OUT1 OUT2 and Alarm 1 and 2 ALM1 ALM2 The display is used during setting to show pa...

Page 31: ...e Table 3 1 mounted on the panel door to determine which heater banks should be used to achieve calculated temperature rise Switch on the required heater bank switches sequentially Refer to trouble sh...

Page 32: ...selection and supplies it will deliver water heated to within 1 C of the controller set point Confirm that the unit controls the process as specified CAUTION SYSTEM FLUSHING When the system is not in...

Page 33: ...e determining this capacity Approximate length of umbilical in water LU Approximate operating temperature of fluid desired at bottom Tb Inlet water temperature Tin Step 1 Determine total outlet temper...

Page 34: ...d To determine the required temperature rise Trise through the unit subtract the inlet temperature Tin from the required total outlet temperature calculated in Step 1 Step 3 Heater bank selection Afte...

Page 35: ...0 5 0 9 13 5 5 10 9 18 27 0 10 15 18 27 40 5 15 22 27 39 54 0 22 29 39 51 67 5 29 35 51 62 81 0 35 42 62 74 94 5 IMPORTANT The required temperature rise shown in Table 3 1 indicates the differential b...

Page 36: ...d switches for heater bank selection The MHE 02 is also equipped with several analogue gauges displaying fluid temperature and pressure throughout the system The layout of the operator interface is sh...

Page 37: ...n optimum performance 3 Check inlet water temperature and determine required temperature settings See Section 3 1 4 Press the pump start button The pump should start and no the fault indicator lights...

Page 38: ...uate flushing of the system pipe work with fresh water 5 Shut fresh water valve off Open the drain valve and tank vent valve and allow water to drain from the system IMPORTANT During the flushing proc...

Page 39: ...rs The inlet water filter elements should be checked following the first few hours of operation in a new installation and after long periods spent out of service Under normal working conditions the fi...

Page 40: ...he CAT pump on the MHE 02 unit should be carried out by an approved CAT service agent or Divex regional office Filter Inspection The most common cause of low pump pressure is damage due to foreign mat...

Page 41: ...r 7 to 155 bar Inlet Pressure Range 1 4 to 4 bar 1 4 to 4 bar Speed Maximum Allowable 767 rev min 1150 rev min Max Maximum Fluid Temperature 71 C 71 C Crankcase Capacity 1 26 ltr 1 26 ltr Inlet Ports...

Page 42: ...26 Chapter 4 KI OM 523 R2 Intentionally Blank...

Page 43: ...f valve check for worn and dirty valve seats Replace worn parts Inlet filter clogged or improperly size Clean Use 50 micron filter element Check more frequently Worn packing Abrasives in pumped fluid...

Page 44: ...seals Oil leaking at the rear portion of the crankcase Damaged or improperly installed oil gauge or crankcase rear cover o ring and drain plug o ring Replace oil gauge or cover o ring and drain plug...

Page 45: ...expected As the system s output depends upon the flow resistance if there is low resistance the pressure will be low but the flow rate will be maintained Water will not heat Circuit breakers tripped...

Page 46: ...gulator malfunction Clean regulator and reassemble If unit will not regulate pressure on pump to between 2 5 and 4 bar replace regulator EMERGENCY CORRECTIVE ACTION Bypassing the regulator will allow...

Page 47: ...justment Readjust over temperature controls whichever one is turning the system off if temperature of water is low Faulty over temperature switch Determine which over temperature switch is open circui...

Page 48: ...ghts are on If any fault lights are on remedy fault Example low water Water to system shut off and float switch will open thus keeping system off Main power switch not turned on Turn switch on Control...

Page 49: ...out fault light Replace Faulty fault relays R1 and R2 Replace No 24 VDC control power Control transformer faulty Check output of power supply If it is not 24 V on the feed with 380 V on the supply re...

Page 50: ...34 Chapter 5 KI OM 523 R2 Intentionally Blank...

Page 51: ...2 HP Hose Assembly DO 06035 3 Ball Valve NPT Heater Tank Bleed Valve XV500P 8 02 4 Ball Valve Brass Fresh Water Inlet Shut off Valve XV500P 12 02 5 Check Valve DO 02780 6 Sea Water In Manifold DO 059...

Page 52: ...2 02 13 Ball Valve NPT Filter Isolation Valves XV500P 12 02 14 Filter Housing NPT With 50 Filter Element DSA No DO 04793 DO 04768 15 Motor 4kW 4 pole DO 06051 16 Accumulator CAT S S DO 02724 17 Pump C...

Page 53: ...63BB02QJ2A 23 Sea Water Inlet Connection NPT 24 Gauge Temp 0 100 C Swivel Brkt Inlet Water Temperature Gauge DO 06068 25 Gauge Pressure 0 100 bar Back Entry Outlet Water Pressure Gauge PBBV63BB02QJ3A...

Page 54: ...2889 32 Emergency Stop DO 03260 DO 02891 DO 04827 33 Start Stop Switch Pump DO 04823 DO 02891 DO 02889 DO 06033 34 Heater Bank Rotary Selector Switchs 3 off DO 06031 DO 02889 DO 06032 35 Belt SPB x 12...

Page 55: ...lve Pressure Regulator 1 DO 02723 Item 18 Fig A 2 Valve 2 Way Proportional Actuated NPT 1 DO 02788 Item 19 Fig A 2 Gauge Temp 0 100 CDial Every Angle 1 DO 06068 Item 21 24 Fig A 2 Gauge Pressure 0 10...

Page 56: ...02304 Valve Globe NPT Brass 1 DO 03326 Oil Divex CAT Pump Lubeb litres 0 5 DO 03764 Circuit Breaker Miniature 50A 6kA 3pole 2 DO 05934 Circuit Breaker Miniature 20A 6kA 3pole 2 DO 05932 Circuit Breake...

Page 57: ...CZ121 DO 05957 Item 8 Fig A 1 Manifold MHE 2 Dump CZ121 DO 05956 Item 9 Fig A 1 Filter Housing NPT DO 04768 Item 14 Fig A 2 Actuator E Stop Latching Mushroom RED DO 03260 Item 32 Fig A 3 Legend Emerge...

Page 58: ...42 APPENDIX B KI OM 523 R2 Intentionally Blank...

Page 59: ...V500P 12 02 Oil Divex CAT Pump Lubeb litres DO 03764 Valve Check Brass Euro Stop DO 02780 Circuit Breaker Minia ture 50A 6kA 3pole DO 05934 Valve Pressure Reduc ing Brass DO 02359 Circuit Breaker Mini...

Page 60: ...r Housing NPT DO 04768 Indicator LED Module White 18 30 VAC DC DO 06033 Actuator E Stop Latch ing Mushroom RED DO 03260 Switch Selector Illumi nated GRN DO 06031 Legend Emergency Stop DO 04827 Indicat...

Page 61: ...45 KI OM 523 R2 APPENDIX D APPENDIX D WIRING DIAGRAMS...

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Page 65: ...46 KI OM 523 R2 APPENDIX E APPENDIX E PIPING AND FLOW SCHEMATIC...

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Page 67: ...47 KI OM 523 R2 APPENDIX F APPENDIX F RKC CB100 DIGITAL CONTROLLER MANUAL...

Page 68: ...ntenance is required for safe and proper operation of this instrument Some components have a limited service life or characteristics that change over time Every effort has been made to ensure accuracy...

Page 69: ...a case loosen the screw once and tighten it again until the instrument is firmly fixed 6 The other mounting bracket should be installed in the same way as described in 3 to 5 When the instrument is m...

Page 70: ...ire of 0 25 to 1 65 mm2 Make sure that during field wiring parts of conductors can not come into contact with adjacent conductive parts 3 2 Terminal Configuration Alarm output Power supply Control out...

Page 71: ...0 Voltage 0 to 5 V DC 1 to 5 V DC 0 to 10 V DC Z 1010 Current 0 to 20 mA DC 4 to 20 mA DC Sampling cycle 0 5 seconds Input range Refer to Input range table Control method PID control ON OFF P PI or PD...

Page 72: ...Input type symbol Input range high Input range low Automatically Power ON PV SV Display Mode The controller will display the Measured value PV and the Set value SV The controller can be switched to RU...

Page 73: ...or PID control is performed Heat Cool PID action Proportional band setting on the heat side ON OFF action differential gap TC RTD inputs 2 0 2 C F Voltage Current inputs 0 2 of Input span TC RTD input...

Page 74: ...should be lengthened If setting time is not correct the LBA will malfunction by turning on or off at inappropriate times or not turning on at all 3 LBA deadband function The LBA may malfunction due t...

Page 75: ...y returns to PID control Requirements for AT cancellation The Autotuning is canceled if any of the following conditions exist When the Set value SV is changed When the PV bias value is changed When th...

Page 76: ...limiter high Refer to P 11 0001 SLL Setting limiter low Refer to P 11 PGdP Decimal point position Refer to P 11 7 2 Exit Initialization Mode When any parameter setting is changed in the Initializatio...

Page 77: ...function is not provided with the instrument when shipped from the factory no alarm output is available by changing SL4 and or SL5 SL4 is set to 0000 in the following cases When the instrument does no...

Page 78: ...C 0 to SLH C SLL to 3308 F 0 to SLH F TC E SLL to 1000 C 0 to SLH C SLL to 1832 F 0 to SLH F N SLL to 1300 C 0 to SLH C SLL to 2372 F 0 to SLH F T SLL to 400 0 C 199 9 to SLH C SLL to 752 0 F 199 9 t...

Page 79: ...iring take the following steps Apply pressure very carefully when removing internal assembly to avoid damage to the frame To conform to IEC61010 1 requirements for protection from electric shock the i...

Page 80: ...48 KI OM 523 R2 APPENDIX G APPENDIX G BELIMO CONTROL VALVE MANUAL...

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Page 87: ...49 KI OM 523 R2 APPENDIX H APPENDIX H WATER PRESSURE REDUCING VALVE...

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Page 89: ...bar bar bar bar...

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Page 91: ...Nominal flow rates...

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Page 94: ...50 KI OM 523 R2 APPENDIX I APPENDIX I CAT TRIPLEX PUMP MANUAL MODEL 1050...

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Page 107: ...51 KI OM 523 R2 APPENDIX J APPENDIX J PULSATION DAMPENER...

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Page 110: ...52 KI OM 523 R2 APPENDIX K APPENDIX K PRESSURE REGULATOR...

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Page 115: ...53 KI OM 523 R2 APPENDIX L APPENDIX L FLOAT SWITCH...

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