RECO HX2 Series Nstallation, Operation And Maintenance Manual Download | Manualshive

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Installation, Operation,
and Maintenance Manual

I

NSTALLATION

,

O

PERATION

,

AND

M

AINTENANCE MANUAL

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Summary of Contents for HX2 Series

Page 1: ...Installation Operation and Maintenance Manual INSTALLATION OPERATION AND MAINTENANCE MANUAL ...

Page 2: ...nd Weights Horizontal Units 2 5 Operation 3 1 Operating Instructions and Guidelines Start Up 3 1 3 2 Operating Instructions and Guidelines Shut Down 3 2 3 3 System Wiring Diagram 3 3 Maintenance 4 1 HX2 Maintenance Schedule 4 1 4 2 Troubleshooting 4 1 4 3 HX2 Tube Bundle Maintenance 4 5 4 4 Flange Bolt Tightening Sequence and Torque Values 4 7 4 5 Circulator Pump Maintenance 4 7 4 6 Strainer Maint...

Page 3: ...m as the heating medium Designed to the guidelines of TEMA BOCA and IAPMO these heaters can heat up to 150 GPM from 40 F to 140 F as standard with higher capacities possible At the heart of the control system is the Control Master panel with a digital PAC controller The Control Master has an easy to navigate LCD panel for local monitoring and set point adjustment It accepts remote set point change...

Page 4: ...temperature distribution across all temperature sensors while also reducing scaling and sediment build up on the tube bundles in the process ASME constructed and stamped tank assures safe operation to 150 PSIG All wetted parts on the heated side are lead free and comply with NSF Standard 61 and the requirements of the U S Safe Drinking Water Act Support stand can comply with International Building...

Page 5: ...unt of water GPM to be heated and amount of heating F to be done must be known Heating is commonly specified in increments of 80 F 40 F to 120 F or 100 F 40 F to 140 F The first step is to locate the correct chart from the four that follow Next locate the appropriate Steam Supply Pressure available PSIG along the X axis and the amount of water to be heated GPM along the Y axis Where the two inters...

Page 6: ...0 80 90 100 110 120 130 140 150 160 0 10 20 30 40 50 60 70 80 90 100 Water to be Heated GPM SteamSupply Pressure PSIG 40 F to 120 F Single Wall Copper Tubes 12030 10030 08030 06030 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 0 10 20 30 40 50 60 70 80 90 100 Water to be Heated GPM SteamSupply Pressure PSIG 40 F to 120 F Double Wall Copper Tubes 12036 12030 10036 10030 08036 08030 06036...

Page 7: ...0 90 100 110 120 130 140 0 10 20 30 40 50 60 70 80 90 100 Warer to be Heaterd GPM SteamSupply Pressure PSIG 40 F to 140 F Single Wall Copper Tubes 12030 10030 08036 08030 06036 06030 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 0 10 20 30 40 50 60 70 80 90 100 Water to be Heated GPM SteamSupply Pressure PSIG 40 F to 140 F Double Wall Copper Tubes 12036 12030 10036 10030 08036 08030 06036 06030...

Page 8: ...h 8 diameter x 36 long heating element 316L stainless steel tank copper double wall tubes and standard Modbus communication interface with the building automation system CU Heater Series BAS Interface HX2 Series Water Heater M Modbus A BACnet IP B BACnet MS TP Orientation H Horizontal V Vertical Heater Tube Style DW Double wall SW Single wall Heater Size Nominal 06030 6 D x 30 L 06036 6 D x 36 L T...

Page 9: ...y contact RECO USA or your local authorized sales as well as the common carrier who delivered the unit s 2 2 General Installation Instructions and Guidelines 2 2 1 The HX2 is designed for indoor use only unless specified otherwise Install the unit so there is adequate room around the unit for servicing Provide clear access see Figures 1 7 and 1 8 to permit tube bundle removal 2 2 2 The unit should...

Page 10: ...vided by RECO USA is necessary for optimal system performance A condensate strainer and steam trap are provided loose as standard with mounting and connection to be done in the field by others 2 2 13 A suitable means such as a gravity drain or condensate pump system must be provided to remove condensate from the unit and otherwise prevent condensate from collecting and blocking its ability to free...

Page 11: ...l PAC It is set to the specified outlet water temperature and modulates the control valve position to maintain the inflow of steam corresponding to the demand for hot water Upon reaching the desired water outlet temperature the control valve will back off to the point it may fully close Outlet water temperature is controlled to 4 F 2 4 2 The high temperature alarm is set to 10 F above the outlet t...

Page 12: ...34 25 38 1 5 FNPT 24 0 17 75 1 5 FNPT 2 FNPT 35 0 1 125 1 155 10030 10036 4 3 46 75 99 0 33 75 49 1 5 FNPT 24 0 17 75 2 5 150 Lb RFSO 37 0 1 380 1 420 12030 12036 4 3 46 75 100 0 33 75 51 1 5 FNPT 24 0 17 75 3 150 Lb RFSO 39 0 1 655 1 705 Notes 1 Dimensions A and B are nominal sizes for ANSI 150 lb raised face slip on RFSO flange 2 All dimensions in inches unless noted otherwise 3 Weights shown ar...

Page 13: ... 39 41 1 5 2 FNPT 35 1 180 1 210 10030 10036 4 3 23 75 99 0 33 75 39 75 74 1 5 FNPT 24 39 41 2 5 150 Lb RFSO 37 1 435 1 475 12030 12036 4 3 23 75 100 0 33 75 40 75 77 1 5 FNPT 24 39 41 3 150 Lb RFSO 39 1 710 1 765 Notes 1 Dimensions A and B are nominal sizes for ANSI 150 lb raised face slip on RFSO flanges 2 All dimensions in inches unless noted otherwise 3 Weights shown are net weight for a stand...

Page 14: ...SECTION 2 INSTALLATION HX2 SERIES 2 6 THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 15: ...ctivate Enable the circulator pump at the control panel LCD display Never operate the pump without the unit being filled with water and all isolation valves open or damage to the pump will result from dry running 3 1 6 Gradually open the control valve to allow steam to enter the tube bundle Monitor the tank temperature until the desired temperature is reached If the temperature regulator shuts off...

Page 16: ...ng live steam to the unit 3 2 2 Close the hot water discharge valve at the tank outlet 3 2 3 Close the building recirculation valve isolating the unit from the building steam line 3 2 4 Close the water inlet valve to cut off incoming cold water to the unit 3 2 5 Turn off all electrical power to the unit control panel 3 2 7 With the unit now isolated by the valving and de energized electrically lif...

Page 17: ...IOM SECTION 3 OPERATION HX2 SERIES 3 3 3 3 System Wiring Diagram Sizes 0630 and 0636 ...

Page 18: ...IOM SECTION 3 OPERATION HX2 SERIES 3 4 3 4 System Wiring Diagram Sizes 0830 Through 1236 ...

Page 19: ...Exchanger Gaskets Heat Exchanger Tube Bundle Manual Shut Off Valves Piping Connections Pressure Temperature Relief Valve Solenoid Valve Steam Trap Support Stand Strainer Vacuum Breaker 4 2 Troubleshooting The table below is a quick summary of common problems encountered and their most likely causes along with a recommendation for how to correct them These are by not intended to be an all inclusive...

Page 20: ...n pressure for the steam in the heating coil as the water temperature in the tank approaches shut off 3 The Condensate return piping has not been installed properly and the condensate is not able to freely drain Remedy Re route the condensate return line and assure there are no restrictions in that line and that the condensate is either being pumped away or free to gravity drain 4 The outlet steam...

Page 21: ...undle Maintenance All HX2 units feature a U tube heat exchanger coil that should be removed and inspected at least once every two years One of the common situations with the tube bundle involves the water composition which make them susceptible to fouling and or scaling This is most commonly found in the tank on the exterior of the heating tubes and units experiencing fouling or scaling need to be...

Page 22: ...ander Do not roll tubes that are not leaking Note that double wall tubes are not field repairable 4 3b HX2 Tube Bundle Installation If the tube bundle is dismantled for any reason it should be reassembled using new gaskets a Remove the old element gaskets and clean gasket surfaces Install two new gaskets one ring gasket between the tubesheet and the shell flange and one rib gasket between the tube...

Page 23: ...s The following bolt tightening pattern and torque values should be used whenever tightening a flange A recommended practice is to do this in 3 steps leading up to the final torque values rather than attempting to complete this in one sequence Fig 4 1 Bolt Tightening Sequence and Torque Values ...

Page 24: ...arranty b To avoid electrical shock disconnect the power supply to the pump at the control panel before attempting any work on it c In the event the retaining screws have been pulled out of the housing do not replace them Use of any other screw may short out the stator windings creating a risk of electrical shock d When installing electrical connections do not apply mechanical loads to the capacit...

Page 25: ...mine the disk springs for damage If they are in good condition then tighten the gland nut until disk springs are ﬁrmly compressed then back the nut oﬀ 1 16th of a turn If damaged take the stem apart down to the gland ﬁt new disk springs with their outer edges touching and replace and retighten with the stem nut Any further maintenance will require dismantling the valve TABLE 4 3 CONTROL VALVE TORQ...

Page 26: ...e used stem seals and body seals including the thrust washer should be discarded and replaced d After cleaning the rest of the valve parts examine them for wear corrosion or mechanical damage Replace any defective parts e Apply an adequate amount of lubricant that is compatible with the media being handled around the ball seats stem and thrust washer f For stem re assembly the disassembly procedur...

Page 27: ... the cursor is at line 1 of the 11 items on this screen menu There are four menu levels MAIN OPER SETUP and CONFIG The main menu lists the primary values and access to other menus The Main menu MAIN displays the primary controller information and provides access to the other menus The Operator menu OPER is used to select local or remote set points adjust the local set point or to manually test the...

Page 28: ...ocated in the panel box for reference A 2 1 Pump Control The circulating pump is intended to run continuously It is disabled at the time of shipment to prevent dry running if power is applied to the panel at the time of installation but before filling the unit with water To turn the pump on or off follow the instructions below Step 1 From the MAIN MENU scroll down to GO TO OPER MENU and press the ...

Page 29: ...lves are set to 0 to keeps the control valve closed To open or close the control valve follow the instructions below Step 1 From the MAIN MENU scroll down to GO TO OPER MENU and press the ENTER key Step 2 Scroll down to EDIT CONTROL VALVES and press the ENTER key Step 3 Scroll down to MANUAL OVERRIDE and press the ENTER key Step 4 Using the UP DOWN keys select ENABLED or DISABLED and press the ENT...

Page 30: ...oint move to EDIT SP and press ENTER Step 3 Use the SETPOINT TYPE to toggle between LOCAL or REMOTE LOCAL is set at the panel and REMOTE is selected when the set point is supplied by a building automation system Step 4 Use the UP or DOWN buttons to adjust and then press the ENTER key Note that if the set point is changed the high and low temperature alarm settings should be verified and adjusted a...

Page 31: ...om of the main menu top PASSWORD HANDLING and press the ENTER key Step 2 Use the UP DOWN buttons to enter the password 1709 pressing the ENTER key after each digit is entered to access the Setup Menu Step 3 Scroll down to GO TO SETUP MENU and press the ENTER key Step 4 In the SETUP MENU scroll down to EDIT HIGHTEMPALARM and press ENTER ...

Page 32: ...MP ALARM setting is a secondary temperature control switch When reached it will log the event and will automatically reset when the temperature reaches HIGHTEMPALARM SP HIGHTEMPALARM DB These same conventions are used throughout the controller for navigating menus and adjusting settings Use the HOME BACK or GOTO menu buttons to return to the Main Menu A 5 Alarm Menu If there is an active alarm con...

Page 33: ...re no active alarms on critical items pressing the alarm key will show this screen A 6 Fault Detection As in the alarm messaging the controller s Fault Detection provides detailed information to simplify troubleshooting In the case of a faulty water outlet temperature sensor the controller can distinguish between and a shorted and open sensor For example in the screen shot below a short in the sen...

Page 34: ...vac l1 hot connection 2 HMI display 12 Fuse block 3 Internal panel 13 120 vac terminals 4 12 x 16 x 6 NEMA 4 enclosure 14 120 vac neutral terminals 5 Optional BACnet COMM MODULE 15 Hi limit relay 6 On off switch 16 24 VAC terminals 7 DIN mounting rail 17 24 VAC terminals 8 Terminal block clamp 18 120 24 VAC transformer 9 Ground screw 19 Siemens POL687 controller 10 Ground terminals ...

Page 35: ... 3 X6 UIO T3 4 5V 5VDC T3 5 24V 24VDC T3 6 X7 UIO O 10 VDC Control Valve 1 Signal T3 7 M C C T3 8 X8 UIO O 10 VDC Control Valve 2 Signal T4 1 D1 DI Remote Enable T4 2 M C C Common T4 3 D2 DI J Setback Setpoint T5 1 DU1 DI T5 2 DG C T5 3 DU2 DI T6 1 A T5 2 B RS 485 Modbus Connection T6 3 REF T7 1 CE KNX T7 2 CE T8 1 0 AC 24 VAC T8 2 24 AC 24 VAC T9 1 Q12 NC T9 2 Q11 C High Temp Limit Alarm T9 3 Q14...

Page 36: ...r 4 20 Ma Local Setpoint Set Point Entered at Panel Setpoint Type Default LOCAL REMOTE Uses Input Signal Go to OPER Menu Return to Previous Menu Pump Switch Set to ENABLE for ON DISABLED at Shipment Control Valve Power Status Display Normal Status ON OFF ON Alarm Status Control Signal Displays Current Controller PID Output Control Valve 1 Displays Valve 1 Signal Control Valve 2 Displays Valve 2 Si...

Page 37: ...0 Volts X7 CONTROL VALVE1 Analog out to Control Valve 1 0 Volts Min Set Point Set Max Water Temp Set Point Deg F Max Set Point Set Min Water Temp Set Point Deg F GO TO MAIN MENU Navigation to Other Menus GO TO SYS OVERVIEW Communications Communication Type Select MODBUS BACnet IP or BACnet MS TP MODBUS Module Sample Data only Configure Settings Per Your Connection Address 0 Baud Rate 9600 Parity E...

Page 38: ...tive Factor Adjust Derivative Time Seconds Setback Enable Status of Setback Enable Deg F Setback Set Point Amount of Change in Set Point if Enabled Deg F Edit Set Back Set Pt Adjust of Setback Enable Deg F High Temp Alarm SP View High Temp Alarm Set Point Deg F High Temp Alarm DB View High Temp Alarm Dead Band Deg F Edit High Temp Alarm Edit High Temp Alarm Set Point and Dead Band Deg F Low Temp A...

Page 39: ...IOM APPENDIX 1 THE CONTROL PANEL HX2 SERIES A 13 THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 40: ... property of RECO USA and unauthorized use of these trademarks as well as the information presented herein is expressly prohibited and constitutes a violation of the intellectual property rights of RECO USA Visit us at www reco usa com HX2 IOM REV 0 DEC 2019 ...

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