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Operation and Maintenance Manual

for the

Electric Water Heater WHE - 3

(440V X 24VDC)

Part Number: KI40018AA

Document Number: KI-OM-6768

Revision: 0

Содержание KI40018AA

Страница 1: ...Operation and Maintenance Manual for the Electric Water Heater WHE 3 440V X 24VDC Part Number KI40018AA Document Number KI OM 6768 Revision 0 ...

Страница 2: ... Intentionally Blank ...

Страница 3: ...iginal Approvals Responsibility Name Position Date Author Jurgina Lastakauskiene Engineering Administrator January 2016 Checked Vladimir Garzon Mechanical Engineer January 2016 Approval Philip Black Senior Mechanical Engineer January 2016 Copyright Details 2015 JFD Copyright of this document is the property of JFD and it may not be copied used or otherwise disclosed in whole or in part except with...

Страница 4: ...ii Approval Sheet KI OM 6768 R0 Intentionally Blank ...

Страница 5: ...this document JFD 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 ...

Страница 6: ...y transportation on site accommodation and subsistence expenses JFD may dispatch personnel to perform on site repairs The product specification and warranty terms are subject to alteration without prior notice and do not form part of any contract made between JFD and its customer This equipment should only be operated by suitably qualified persons conversant with the operation and maintenance of d...

Страница 7: ... 6768 R0 Table of Contents TABLE OF CONTENTS Page Chapter 1 General Description 1 Chapter 2 Initial Set Up 11 Chapter 3 Operation 17 Chapter 4 Maintenance 25 Chapter 5 Troubleshooting 29 Chapter 6 Appendix 35 ...

Страница 8: ...vi Table of Contents KI OM 6768 R0 Intentionally Blank ...

Страница 9: ...ION CONTENTS Page 1 1 Intruduction 2 1 1 1 Basic Description 2 1 2 Specifications 3 1 3 Theory Of Operation 4 1 3 1 Basic Control 4 1 3 2 Fluid System 5 1 3 3 Electrical System Overview 7 1 3 4 Heater System and Heater Selection 7 1 3 5 Control System 8 ...

Страница 10: ...Description The WHE 03 assembly is comprised of a motor pump heater tank pipe work and control panel These components are mounted into a robust stainless steel frame The system requires a constant supply of seawater and runs from a 440 480V 3 phase 60 Hz power supply The output is heated seawater at pressures up to 68 bar and 45 litres min 1 2 SPECIFICATIONS Shipping Weight 590 kg Dry Weight 460 k...

Страница 11: ... of 47 50ºC through the unit Once the correct configuration of heater banks has been selected the temperature controller regulates the temperature of the outlet by adjusting the flow rate of water passing through the heater tank This is achieved by controlling the electric actuator on the bypass valve The valve is connected in such a way that it will dump water overboard to increase the flow rate ...

Страница 12: ...ate the condition of the filter cartridge A pressure regulating valve fitted after each filter outlet ensures that fluid is supplied from filters to heater tank at a consistent and safe pressure Factory setting is 2 bar The fluid flows through the heater tank which houses immersion heater elements where fluid is heated The heater tank is fitted with a pressure relief valve PRV set to 2 5 bar A flo...

Страница 13: ...Gauge Identification 1 3 3 Electrical System Overview The WHE 03 electrical system comprises a 440 VAC power circuit and a 24 VDC control circuit The power circuit is the electrical supply for the heaters pump motor and DC power supply unit The control circuit provides power supply to all control indication and safety circuits The WHE 3 main panel operated with a 24 VDC control system Ideally this...

Страница 14: ...he power supply Additionally as heater banks have separate control circuits and protection the failure of any single bank of heaters will not affect the operation of the other banks Bank No Switch No Element Grouping No Circuit Breaker ID Contactor ID Element Grouping kW Element Grouping Composition 1 1 Heater 1 1 MCB3 C2 13 5 kW 3 x 4 5 kW Elements 2 2 Heater 2 1 MCB4 C3 13 5 kW3 3 x 4 5 kW Eleme...

Страница 15: ... valve is opened is determined by the controller based on feedback received from the PT100 temperature probe mounted into the outlet manifold Several safety interlocks are incorporated into the control system which provide protection against low fluid level in the heater tank over temperature and motor overload The control circuit also includes indication via LED s and the controller display for o...

Страница 16: ...erload trip Wired to contact R5 1 of relay R5 Fault Light Red Over Temperature L9 Lamp indication of system over temperature fault wired to the relay contact R1 2 of relay R1 Fault Light Red Low Level L10 Lamp indicating low water level fault This fault is linked to the contact R2 2 of the low level relay R2 Power On White Indication L11 Lamp indicating 24 VDC power to control circuit form the 24V...

Страница 17: ...and break the circuit to the motor contactor and the heater selection switches This is the main start stop switch for the unit Switch Rotary 2p Heater Selection S3 S7 The heater ON OFF switches control the switching of power to the coils of the respective heater contactors Switch Fault Reset S8 The fault rest switch unlatches the over temperature and low level fault interlocks and allows normal fu...

Страница 18: ...10 Chapter 1 KI OM 6768 R0 Intentionally Blank ...

Страница 19: ...T UP CONTENTS Page 2 1 Installation 12 2 1 1 General Mounting and Unit Placement 12 2 1 2 Fluid Connections 12 2 1 3 Electrical Installation 13 2 2 Initial System Check 13 2 2 1 Fluid System Priming Procedure 13 2 2 2 Start Up and Function Check 14 ...

Страница 20: ...le pipe connection depending on the installation requirements The plumbing used should be capable of withstanding the maximum working pressure of 68 bar All valves fittings tubing and manifolds connected to the hot water system must be capable of working at this pressure If the system is not required to deliver this pressure the internal relief valve may be set to a lower setting and all the attac...

Страница 21: ...ectly set up for operation 2 2 1 Fluid System Priming Procedure After the electrical and pipe work installations have been completed purge the piping system of air in order for the pumps to function properly and for the electric heater elements to be fully immersed Use the following procedure to correctly prime the system 1 Open the salt or fresh water input valve slightly to allow water to flow i...

Страница 22: ...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 parameters and functions 5 Changing Set Point In local mode the set point is changed using the controller interface by pressing the Set key to enter the SV Setting Mode and modify SV set point value Change the control...

Страница 23: ...g of excess hot water 12 Filter Check Two water filters are provided to clean inlet water One for operation and the other for stand by The pressure drop across each filter should be between 0 5 1 bar Check the pressure drop after running the unit for a 4 to 5 hour settling in period The filter will trap all contaminants introduced into the system during installation and should be regularly checked...

Страница 24: ...16 Chapter 2 KI OM 6768 R0 Intentionally Blank ...

Страница 25: ...17 KI OM 6768 R0 Chapter 3 CHAPTER 3 OPERATION CONTENTS Page 3 1 General 18 3 2 Operator Controls 21 3 3 Operating Start Up Procedure 22 3 4 Shutdown Procedure 23 ...

Страница 26: ...graph in Fig 3 1 to determine the temperature loss along the umbilical hose select the length of the umbilical hose on the vertical y axis and move horizontally to the right until the line is intersected then move vertically upward to the horizontal x axis The value on the x axis will yield the approximate temperature loss Tloss through the specified length of umbilical Add the temperature loss th...

Страница 27: ... required 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 After calculating Trise use the Table 3 1 to determine the heater banks to be used Locate the temperature rise in the left column Read across to determine which heaters are required to achieve the...

Страница 28: ...e 3 1 for a 43 47ºC 77 85ºF temperature rise heater banks 2 3 4 and 5 should be switched on Temp Rise ºC ºF Heater On Heater 1 Heater 2 Heater 3 Heater 4 Heater 5 0 4 0 7 4 8 7 14 8 11 14 20 11 14 20 25 14 18 25 32 18 22 32 40 22 25 40 45 25 29 45 52 29 32 52 58 32 36 52 65 36 40 65 72 40 43 72 77 43 47 77 85 47 50 85 90 Umbilical Hose Length 180 m Desired Temperature at Bottom Tb 35ºC 95ºF Inlet ...

Страница 29: ... also equipped with several analogue gauges displaying fluid temperature and pressure throughout the system The layout of the operator interface is shown in Fig 3 2 Fig 3 2 General Arrangement IMPORTANT Table 3 1 is intended as a guide Due to variations in installations operating conditions and working environments It is important to monitor the function of the unit to ensure that the process is c...

Страница 30: ...ance 3 Check the inlet water temperature and determine the required temperature rise as outlined in chapter 3 4 Press the pump start button The pump should start and no fault indicator lights should be illuminated If any faults are present refer to chapter 5 page 29 for troubleshooting 5 Enter the required outlet temperature into the controller as the control set point value SV section 2 2 2 step ...

Страница 31: ...m pipework with fresh water 5 Shut the fresh water valve off Open the drain valve and tank vent valve and allow the water to drain from the system IMPORTANT During the flushing process ensure that the entire system is flushed out by momentarily opening the venting valve and both dump valves CAUTION DRAIN SYSTEM To prevent damage due to freezing of the water in the system it is important to drain a...

Страница 32: ...24 Chapter 3 KI OM 6768 R0 Intentionally Blank ...

Страница 33: ...25 KI OM 6768 R0 Chapter 4 CHAPTER 4 MAINTENANCE CONTENTS Page 4 1 Routine Maintenance 26 4 1 1 Periodic Maintenance 26 4 2 Pump Maintenance 26 4 2 1 Helpful Information 26 4 2 2 Pump Specifications 27 ...

Страница 34: ...et 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 filters should be changed when the pressure drop across the filter units rises above 1 bar The pressure drop across the filters is deduced by subtracting the outlet pressure indicated on the filter gauge from the...

Страница 35: ... and quantity of the items required Material Returns Should it become necessary to return a Cat Pump please secure approval and shipping directions from JFD Items authorised for return must be shipped with freight prepaid A full description of the operating conditions medium being used and full details of the problem with the pump Filter Inspection The most common cause of low pump pressure is dam...

Страница 36: ...w Rate 45 l min Pressure Range 7 to 155 bar Inlet Pressure Range 0 35 to 4 bar Speed 1150 rev min Maximum Fluid Temperature 70ºC Crankcase Capacity 1 26 ltr Inlet Ports 3 4 NPTF Discharge Ports 1 2 NPTF Pulley Mounting Either Side Shaft Diameter 30 mm Weight 20 kg ...

Страница 37: ...ion Inadequate water supply Install proper filter Check fluid supply available to the pump Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Worn inlet or discharge valves Replace worn valves valve seats and or discharge hose Leaking discharge hose Pump Runs Extremely Rough Pressure Very Low Restricted inlet or air entering the inlet plumbing Size inlet plumbing ...

Страница 38: ...ngers Replace plungers Abrasive material in the fluid being pumped Install proper filtration on pump inlet plumbing Excessive pressure and or temperature of fluid being pumped Check pressures and fluid inlet temperature be sure they are within specified range Over pressure of pumps Reduce supply pressure Running pump dry Do not run pump without water Strong Surging at Inlet and Low Pressure on Dis...

Страница 39: ...function If main power control circuit is open it may be due to some other fault in system such as low water over temperature relay created open circuit or float switch indicating low water If any of these fault indicators are on corrective action is required Overload relay tripped Reset overload relay and make sure that relay is set in the automatic position Defective pump motor contactor Remove ...

Страница 40: ...wing out of system through umbilical hose Faulty float switch Repair or replace float switch Overheated water in the heater tank Make sure that water is flowing through the system No water in heater tank Re prime system making sure that water is flowing through system Over temperature control needs adjustment Readjust over temperature controls whichever one is turning the system off if temperature...

Страница 41: ...er Check fault indicator lights to see if any lights 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 Circuit Breaker tripped Check reset If faulty replace Faulty main power contactor Replace Pump Turns On And Off Rapidly Faulty overload relay Replace M...

Страница 42: ...bias ratio and offset setting on the controller and the remote display Refer to the appendix section for the controller for manual and details on the controller parameter settings Remote Analog Dial Not Calibrated To Controller If there is incorrect scaling between the remote potentiometer and the temperature controller the pointer knob may be loose or incorrectly aligned Remove the pointer re ali...

Страница 43: ... D Piping and Flow Schematic 44 Appendix E RKC FB100 Digital Controller Manual 45 Appendix F Temperature Controller Parameter Settings 46 Appendix G Belimo Control Valve Manual 47 Appendix H Water Pressure Reducing Valve 48 Appendix I CAT Triple Pump Manual Model 1057 49 Appendix J Pulsation Dampener 50 Appendix K Pressure Regulator 51 Appendix L Float Switch 52 ...

Страница 44: ...36 Chapter 6 KI OM 6768 R0 APPENDIX A PART IDENTIFICATION Fig 6 1 General Arrangement Front View Fig 6 2 Inlet Outlet Relief Valve ...

Страница 45: ...3 Motor Pulley Taper Lock Bush Part No DO02831 DO02830 14 Pump Pulley Taper Lock Bush Part No DO02829 DO02828 15 Filter Gauge DOPBBA63BB02QJ2A 16 Filter Inlet Valve 3 4 DO32064 17 Check Valve DO02780 18 Fresh Water Inlet Valve 3 4 DO32064 19 Inlet Pressure Gauge DOPBBA63BB02QJ2A 20 Inlet Manifold Block DO05902 21 Salt Water Inlet Valve DO32064 22 Inlet Temperature Gauge DO05836 23 Outlet Pressure ...

Страница 46: ...38 Chapter 6 KI OM 6768 R0 Fig 6 3 General Assembly Rear Side View Fig 6 4 Control Valve Thermostat and Filter Arrangement ...

Страница 47: ...4 Motor DO02777 35 Pressure Reducing Valve Set to 2 bar DO02359 36 Filter Housing DO04768 37 Filter Element Inside Housing 10 50µm DO04793 38 Level Float Switch DO02779 39 Mechanical Safety Thermostat DO02374 40 Relief Valve Tank Set to 2 5 bar DO02304 41 Manual Temperature Control Valve DO03326 42 Bleed Valve DO36264 43 Temperature Control Valve DO02788 44 Zinc Anode 1 2 NPT 100 mm DO02369 ...

Страница 48: ...Fresh Water Inlet Valve 3 4 DO32064 Item 18 Fig 6 2 Salt Water Inlet Valve 3 4 DO32064 Item 21 Fig 6 2 Inlet Temperature Gauge DO05836 Item 22 Fig 6 2 Outlet Pressure Gauge DOPSBA63BB02QJ3 Item 23 Fig 6 2 Outlet Temperature Gauge DO05836 Item 24 Fig 6 2 Pump Outlet Hose DO06069 Item 26 Fig 6 2 Filter Housing DO04768 Item 36 Fig 6 4 Filter Element In Filter Housing 10 50µm DO04793 Item 37 Fig 6 4 L...

Страница 49: ...d Thermal 10 15A DO05938 Pocket Thermostat 1 1 4 BSP Brass Boss DO03961 Power Supply 340 550V 24VDC 5A DO03904 Relay Base Socket Din Rail Mount DO04173 Relay Miniature 24 VDC Coil 4 C O DO04171 Terminal Din Rail 0 5 4 0 mm DO02901 Terminal Fuse 5x20 mm DO03902 Thermo pocket 316 SS 20 mm PKT x 75 mm O A DO04564 PKT Thermo pocket 316 SS 45 mm PKT x 95 mm O A DO04419 PKT Timer On Delay 24 VDC DO04840...

Страница 50: ...e DO02723 Item 27 Fig 6 2 PT100 Temperature Probe DO04564 Item 28 Fig 6 2 Outlet Manifold Block DO05901 Item 29 Fig 6 2 Front Dump Manifold DO05900 Item 30 Fig 6 2 Pump CAT 1057 DO02722 Item 33 Fig 6 3 Motor DO02777 Item 34 Fig 6 3 Pressure Reducing Valve DO02359 Item 35 Fig 6 4 Accumulator CAT S S 6031 70 bar M O P DO02724 Valve Relief 1 2 MNPT 3 50 psi Brass DO02304 Description Divex Part No Sho...

Страница 51: ...43 KI OM 6768 R0 Chapter 6 APPENDIX C WIRING DIAGRAMS Drawings DO57930S1 DO57931S1 DO57932S1 and DO57933S1 ...

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Страница 56: ...44 Chapter 6 KI OM 6768 R0 APPENDIX D PIPING AND FLOW SCHEMATIC Drawings DO5993 S1 S2 ...

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Страница 59: ...45 KI OM 6768 R0 Chapter 6 APPENDIX E RKC FB100 DIGITAL CONTROLLER MANUAL ...

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Страница 62: ...46 Chapter 6 KI OM 6768 R0 APPENDIX F TEMPERATURE CONTROLLER PARAMETER SETTINGS ...

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Страница 71: ...47 KI OM 6768 R0 Chapter 6 APPENDIX G BELIMO CONTROL VALVE MANUAL ...

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Страница 78: ...48 Chapter 6 KI OM 6768 R0 APPENDIX H WATER PRESSURE REDUCING VALVE ...

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Страница 82: ... Nominal flow rates Number of devices Private dwelling Public building Number of devices Private dwelling Public building Number of devices Private dwelling Public building ...

Страница 83: ... Nominal flow rates Number of devices Private dwelling Public building Number of devices Private dwelling Public building Number of devices Private dwelling Public building ...

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Страница 85: ...49 KI OM 6768 R0 Chapter 6 APPENDIX I CAT TRIPLE PUMP MANUAL MODEL 1057 ...

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Страница 98: ...50 Chapter 6 KI OM 6768 R0 APPENDIX J PULSATION DAMPENER ...

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Страница 101: ...51 KI OM 6768 R0 Chapter 6 APPENDIX K PRESSURE REGULATOR ...

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Страница 106: ...52 Chapter 6 KI OM 6768 R0 APPENDIX L FLOAT SWITCH ...

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