Page 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...
Page 2 (Intentionally Blank)
Page 3: Chapter 4 - Maintenance
© 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 prior written permission from JFD or, if this document has been furnished under a contract with another party, as expressly authorised under that contract.
Page 4 (Intentionally Blank) Approval Sheet KI-OM-6768 R0...
Page 5 Whilst every effort has been made to ensure the accuracy of the information provided in 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.
Page 6 3,000 operating hours, whichever occurs first. Any component or sub-system which is established by JFD to be patently defective will, at JFD’s option, be repaired or replaced on condition that such defective equipment is returned to the JFD manufacturing facility, freight pre-paid.
Page 7 ABLE OF ONTENTS 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 KI-OM-6768 R0 Table of Contents...
Page 8 (Intentionally Blank) Table of Contents KI-OM-6768 R0...
Page 9: Table Of Contents
1 - G HAPTER ENERAL ESCRIPTION ONTENTS Page Intruduction ........................2 1.1.1 Basic Description ......................2 Specifications ........................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 ................
Page 10: Basic Description
NTRODUCTION The Divex Electric Powered Water Heating Unit, (WHE-3), has been designed and manufactured for use in professional diving systems. KI40018AA will control the heating of seawater within an inlet-to- outlet temperature rise range of 0 to 50ºC (32 to 122ºF) with fine selectable control. The system incorporates a positive displacement pump, electric heaters and all electrical controls necessary to provide a complete water heating system for deep diving.
Page 11: Theory Of Operation
HEORY PERATION 1.3.1 Basic Control The temperature control system of the WHE-03 has been designed to be simple and effective. The unit heats water in the heater tank using five banks of heater elements. These heater banks are controlled with five switches, mounted on the electrical enclosure. The banks of heaters are configured to deliver a variety of heating capacities depending on the combination of banks selected.
Page 12: Fluid System
MPORTANT The calculated required temperature rise may be indicated on the heater bank selection table as a maximum for one configuration and a minimum on the subsequent selection of heater banks. In this case practical application will dictate which configuration should be used.
Page 13: Electrical System Overview
The pump is a positive displacement pump and provides consistent supply flow rate. accumulator is fitted to reduce the effect of pulsation caused by the pump. The fluid from the pump flows through a flexible reinforced hose to a pressure relief valve which may be set between 7-70 bar and is sufficiently sized to allow full flow bypass if a downstream blockage occurs.
Page 14: Heater System And Heater Selection
1.3.4 Heater System and Heater Selection The heaters are arranged into heater banks comprised of groups of heater elements. Each heater bank is controlled by a switch mounted in the control panel. The switch supplies 24V to the coil of the contactor/s of the relevant bank.
Page 15: Control System
1.3.5 Control System The 24 VDC control circuit is used to control the contactors, relays, timer and the safety circuits in the system. The contactors, controlled by switches mounted in the control panel door, switch the high voltage to the heaters and the pump. The temperature of the output fluid is regulated by dumping excess capacity thereby increasing the flow rate of fluid through the heater tank and lowering the output temperature of the fluid outlet.
Page 16 Component Component ID Function Description Contactor 1 Pump contactor coil Contactor 2-10 C2-C10 Heater contactor coils Hour Meter The hour meter records the running hours of the pump and is wired through the auxiliary contact on the pump contactor C1/1. Run Light (Green) Local indication that the pump motor contactor is operational and Motor On...
Page 17 Component Component ID Function Description Fault Relay The fault relay de-energizes during fault when the normally Low Water Level closed contact on the float level de-bounce timer is open. The timer is triggered by the normally closed contact of the float switch.
Page 18 (Intentionally Blank) Chapter 1 KI-OM-6768 R0...
Page 19 2 - I HAPTER NITIAL ONTENTS Page Installation ............................. 12 2.1.1 General Mounting and Unit Placement ..................12 2.1.2 Fluid Connections ......................... 12 2.1.3 Electrical Installation ........................13 Initial System Check ........................13 2.2.1 Fluid System Priming Procedure ....................13 2.2.2 Start Up and Function Check ......................
Page 20: Installation
NSTALLATION 2.1.1 General Mounting and Unit Placement The Electric Powered Hot Water Heating Module, WHE-03, is built into a robust stainless steel frame, which ensures that all the required systems and controls can be securely mounted inside a single convenient assembly. The unit should be securely mounted in an area that is protected from environmental elements.
Page 21: Electrical Installation
2.1.3 Electrical Installation The electrical requirements of the system are 460 VAC 20 V and 60 Hz. The power supply cable installed should be capable of handling 315A as the unit is fitted with a 315A isolator. Supply cable should be a suitably rated armoured cable, to an approved marine standard specification. The mains power input to the system should be fitted to the bottom right hand side of the stainless steel electrical enclosure.
Page 22: Start Up And Function Check
To complete priming shut the vent valve and supply valve(s). 2.2.2 Start Up and Function Check After installation is complete the WHE-03 must be thoroughly checked prior to being put into service. The following procedure outlines the steps used in conducting a comprehensive start-up and functional check.
Page 23 Heater Bank Selection - Determine the temperature rise required through the unit to provide the correct temperature of fluid at the user. Use the heater selection table, (See Table 3.1), mounted on the panel door to determine which heater banks should be used to achieve calculated temperature rise.
Page 24 (Intentionally Blank) Chapter 2 KI-OM-6768 R0...
Page 25 3 - O HAPTER PERATION ONTENTS Page General ............................18 Operator Controls ......................... 21 Operating Start-Up Procedure ...................... 22 Shutdown Procedure ........................23 KI-OM-6768 R0 Chapter 3...
Page 26: General
ENERAL The Divex Electric Powered Water Heating Module, WHE-03, has been designed to run with the minimum amount of operator input. The temperature controller governs the process based on the set point and feedback from the PT100 probe giving the measured output temperature (PV). The operator is required to input the set point to the controller and switch on the appropriate heater banks to provide the required capacity.
Page 27 Fig 3.1 Graph of Temperature Loss vs. Umbilical Length The above graph is based on the approximate temperature loss through a 1/2” Synflex or equivalent, used in conditions with 2-5ºC (35-45ºF) water temperature. Step 2 – Determine temperature rise required. To determine the required temperature rise (T ) through the unit subtract the inlet temperature rise...
Page 28 Temp Rise Heater On (•) Heater 1 Heater 2 Heater 3 Heater 4 Heater 5 ºC (ºF) 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) •...
Page 29: Operator Controls
The above heater selection will supply the approximate heating capacity required to produce the specified temperature rise through the unit. The controller will accurately control the outlet temperature and keep this temperature at the set point. MPORTANT Table 3.1 is intended as a guide. Due to variations in installations, operating conditions and working environments.
Page 30: Operating Start-Up Procedure
PERATING TART ROCEDURE Pre-operation checks should be done on the following: • Machinery is secure – No damage to mountings, brackets, pipe connections etc. • Belt drive – In a good condition, belts correctly tensioned and belt guard secure. • Pipe work and valves –...
Page 31: Shutdown Procedure
HUTDOWN ROCEDURE Turn off all electric heaters. Push Pump Stop Button. Turn off main power switch. Shut sea water valve and open fresh water valve to flush the entire system with fresh water for at least 15 to 20 minutes after each usage. This will flush out the heating system, plumbing, valves, umbilical and most important, the breathing gas heat exchanger and the hot water suit.
Page 32 (Intentionally Blank) Chapter 3 KI-OM-6768 R0...
Page 33 4 - M HAPTER AINTENANCE ONTENTS Page Routine Maintenance ........................26 4.1.1 Periodic Maintenance ........................26 Pump Maintenance ........................26 4.2.1 Helpful Information ........................26 4.2.2 Pump Specifications ........................27 KI-OM-6768 R0 Chapter 4...
Page 34: Routine Maintenance
OUTINE AINTENANCE Good maintenance practices are essential to ensure satisfactory operation and extend the service life of the equipment. All steel and painted parts should be periodically cleaned and repainted where necessary. 4.1.1 Periodic Maintenance Periodic maintenance of the unit should be conducted in order to identify and replace worn components.
Page 35: Pump Maintenance
Shut-off valves in the inlet or discharge plumbing to be sure they are fully open Pump Service – JFD advises that the service of the CAT pump on the WHE-3 unit should be carried out by an approved CAT service agent or JFD regional office.
Page 36: Pump Specifications
4.2.2 Pump Specifications Metric Flow 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...
Page 37 5 - T HAPTER ROUBLESHOOTING The tables in this section are designed as a troubleshooting guide to aid in the identification of faults and outline possible corrective action. PECIFIC AULT IAGNOSIS AND AINTENANCE Problem Possible Cause Solution Pulsation Faulty Pulsation Damper. Check pre-charge of pulsation Damper;...
Page 38 Problem Possible Cause Solution Water In the May be caused by humid air Change oil at 3 month or 500 hour Crankcase condensing into water inside the intervals using Divex part no. crankcase. DO03764 Leakage of packing seals. Over- Replace packing. Check pressure pressure or faulty pressure regulator regulator.
Page 39 Problem Possible Cause Solution Water Will Not Heat Circuit breakers tripped in heating Switch off - reset breaker(s). If circuits. breaker(s) trip again when switched on, investigate cause. (In an emergency faulty element may be switched off, leaving other banks operational).
Page 40 Problem Possible Cause Solution Hot Water Output Will Too many or too few heaters on. Check graphs and table to determine Not Maintain Control amount of heat necessary. Temperature Control valve faulty. Clean and check or replace. Emergency Corrective Action Shut temperature control valve off by depressing the button on the side of the valve actuator housing and turn the...
Page 41 Problem Possible Cause Solution Pump Varies In Speed Belts slipping. Check tension on belts. If tension is loose, tighten belt by adjusting tension bolts on motor mount. Check belts condition. If belts are torn, ragged, or in poor condition, replace. Water Temperature Insufficient number of heaters on for Turn on one additional heater.
Page 42 Problem Possible Cause Solution System Inoperable, No Burned out fault light. Replace. fault INdicator Faulty fault relays, R1 and R2. Replace. No 24 VDC Control Control power supply unit faulty. Check output of power supply. If it is Power not 24 V on the feed with 440 V on the supply, replace power supply unit.
Page 43: Ki-Om-6768 R0 Chapter
6 - A HAPTER PPENDIX ONTENTS Page Appendix A - Part Identification ........................36 Appendix B - Spare Parts List ........................40 Appendix C - Wiring Diagrams ........................43 Appendix D - Piping and Flow Schematic ....................44 Appendix E - RKC FB100 Digital Controller Manual ..................45 Appendix F - Temperature Controller Parameter Settings ................
Page 44: Appendixa - Part Identification
A - P PPENDIX DENTIFICATION Fig 6.1 General Arrangement Front View Fig 6.2 Inlet, Outlet Relief Valve Chapter 6 KI-OM-6768 R0...
Page 45 Item Description Divex SA Part No Hour Meter DO03903 Temperature Controller DO03900 Power On Indication DO04991 Fault Reset Button DO04838 Pump On/Off Push Button with indication DO04823 Emergency Stop Button DO03260 Heater On/Off Rotary Switch DO02937 Heater Selection Table DO03009 Main Isolator DO05796 Fault indication (Red)
Page 46 Fig 6.3 General Assembly Rear Side View Fig 6.4 Control Valve, Thermostat and Filter Arrangement Chapter 6 KI-OM-6768 R0...
Page 47 Item Description Divex SA Part No Heater Element (Inside Heater Tank) 4.0 kW DO02798 Heater Element (Inside Heater Tank) 4.5 kW DO02776 Pump CAT 1057 DO02722 Motor DO02777 Pressure Reducing Valve (Set to 2 bar) DO02359 Filter Housing DO04768 Filter Element (Inside Housing, 10” 50µm) DO04793 Level Float Switch DO02779...
Page 48: Appendix B - Spare Parts List
B - S PPENDIX PARE ARTS Description Divex Part No. Shown as: Hour Meter DO03903 Item 1, Fig 6.1 Temperature Controller DO03900 Item 2, Fig 6.1 Power On Indication DO04991 Item 3, Fig 6.1 Fault Reset Button DO04838 Item 4, Fig 6.1 Pump On/Off Push Button with indication DO04823 Item 5, Fig 6.1...
Page 49 Description Divex Part No. Shown as: Contact Block Support for Switch S120 DO03897 Contact Element N/C Contact Block DO02891 Contact Element N/O Contact Block DO02889 Contactor 11 kW 3-pole 24V DO05936 Contactor 7.5 kW 3-pole 24V DO05935 Diode Safety Back EMF 24-48V DO05937 Spare Element, 4.5 kW 1 1/4'' BSPT 400 MIL DO02776-SPARE...
Page 50 Description Divex Part No. Shown as: Pump Pulley (Using Taper Lock Bushing, Part No DO02828 Item 14, Fig 6.1 DO02829) Inlet Manifold Block DO05902 Item 20, Fig 6.2 Water Dump Manifold DO05668 Item 25, Fig 6.2 Relief Valve DO02723 Item 27, Fig 6.2 PT100 Temperature Probe DO04564 Item 28, Fig 6.2...
Page 51: Appendixc - Wiring Diagrams
C - W PPENDIX IRING IAGRAMS (Drawings DO57930S1, DO57931S1, DO57932S1 and DO57933S1) KI-OM-6768 R0 Chapter 6...
Page 56: Appendixd - Piping And Flow Schematic
D - P PPENDIX IPING AND CHEMATIC (Drawings DO5993 S1/S2) Chapter 6 KI-OM-6768 R0...
Page 59: Appendixe - Rkc Fb100 Digital Controller Manual
E - RKC FB100 D PPENDIX IGITAL ONTROLLER ANUAL KI-OM-6768 R0 Chapter 6...
Page 62: Appendixf - Temperature Controller Parameter Settings
F - T PPENDIX EMPERATURE ONTROLLER ARAMETER ETTINGS Chapter 6 KI-OM-6768 R0...
Page 71: Appendixg - Belimo Control Valve Manual
G - B PPENDIX ELIMO ONTROL ALVE ANUAL KI-OM-6768 R0 Chapter 6...
Page 78: Appendixh - Water Pressure Reducing Valve
H - W PPENDIX ATER RESSURE EDUCING ALVE Chapter 6 KI-OM-6768 R0...
Page 85: Appendixi - Cat Triple Pump Manual - Model 1057
I - CAT T 1057 PPENDIX RIPLE ANUAL ODEL KI-OM-6768 R0 Chapter 6...
Page 98: Appendixj - Pulsation Dampener
J - P PPENDIX ULSATION AMPENER Chapter 6 KI-OM-6768 R0...
Page 101: Appendixk - Pressure Regulator
K - P PPENDIX RESSURE EGULATOR KI-OM-6768 R0 Chapter 6...
Page 106: Appendixl - Float Switch
L - F PPENDIX LOAT WITCH Chapter 6 KI-OM-6768 R0...

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Ki40018aa

JFD WHE - 3 Operation And Maintenance Manual

Table of Contents

Chapter 4 - Maintenance

Table of Contents

Chapter 5 - Troubleshooting

Table of Contents

Table of Contents

Chapter 6 - Appendix

Ki-Om-6768 R0 Chapter

Appendix A - Part Identification

Appendix B - Spare Parts List

Appendix C - Wiring Diagrams

Appendix D - Piping and Flow Schematic

Appendix E - RKC FB100 Digital Controller Manual

Appendix F - Temperature Controller Parameter Settings

Appendix G - Belimo Control Valve Manual

Appendix H - Water Pressure Reducing Valve

Appendix I - CAT Triple Pump Manual - Model 1057

Appendix J - Pulsation Dampener

Appendix K - Pressure Regulator

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