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JFD WHE-3 Operation And Maintenance Manual

With remote panel
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Download this manual See also: Operation & Maintenance Manual
Operation and Maintenance Manual
Water Heater Electric ‐ WHE‐3
With Remote Panel
Part Number: 
KI40018
AA, AB and AC
Document Number:
KI‐OM‐0591
Revision:
3

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Summary of Contents for JFD WHE-3

  • Page 1 Operation and Maintenance Manual Water Heater Electric ‐ WHE‐3 With Remote Panel Part Number:  KI40018 AA, AB and AC Document Number: KI‐OM‐0591 Revision:...

  • Page 3: Table Of Contents

    ABLE ONTENTS Page Table Of Contents Approval Sheet Danger, Warning and Caution Introduction ........... . 1 Basic Description .
  • Page 4 Part Identification ..........29 Hoses.

  • Page 5: Approval Sheet

    © 2017 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 6 Intentionally blank KI-OM-0591 Rev 3...

  • Page 7: Danger, Warning And Caution

    ANGER ARNING AND AUTION Danger, Warnings, Cautions and Notes where used within this manual are placed prior to the text to which they are pertinent. Their uses are as follows; INFORMS THE READER OF AN OPERATION OR CONDITION WITCH MAY INVOLVE RISK TO LIFE.
  • Page 8 Intentionally blank viii KI-OM-0591 Rev 3...

  • Page 9: Introduction

    WHE-3 unit from a remote location, usually dive control, through the use of a remote control panel hard wired to the main WHE-3 unit. The system will control the heating of seawater within an inlet-to-outlet temperature rise range of 0 to 50°C (32 to 122°F) with fine selectable remote control.

  • Page 10: Theory Of Operation

    1.3.1 Basic Control The temperature control system of the WHE-3 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 11 1.3.2 Fluid System The WHE-3 may function with either salt water or fresh water as the heating medium. The unit is provided with two inlets for fluid, one for fresh water and one for seawater. The fresh water line is typically used for flushing the system after use. The freshwater line is fitted with a check valve to prevent salt water contamination of the fresh water supply.

  • Page 12: Electrical System Overview

    Figure 1 WHE-3 Gauge identification Electrical System Overview The WHE-3 electrical system comprises a 380 or 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.

  • Page 13: Heater System And Heater Selection

    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. The following table shows the control structure of the heater banks and the composition of the heater groups.
  • Page 14 of the fluid outlet. The 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 feedback received from the PT100 temperature probe mounted into the outlet manifold.
  • Page 15 Component Component ID Function Description Run Light (Green) Remote indication that the pump motor contactor is operational and power is supplied to heater switches. Wired Motor On to the normally open contact of the start switch S2NO and the auxiliary C1/1 of the motor contactor C1. Run Light (Green) L3-L7 Lamp indication of heater bank power on.
  • Page 16 Component Component ID Function Description Switch Push Button This switch is used to make and break the circuit to the motor contactor and the heater selection switches. This is the main Motor Start/Stop start/stop switch for the unit. Switch Rotary 2p S3-S7 The heater ON/OFF switches control the switching of power to the coils of the respective heater contactors...

  • Page 17: Installation

    The unit mounting should allow free access on three sides of at least 0.6 to 1 m for service and maintenance. The WHE-3 remote control panel is fabricated using 316 stainless steel and designed to fit into a standard 19” rack mounting arrangement.

  • Page 18: Electrical Installation

    Initial System Check The following initial system checks should be conducted to ensure that the WHE-3 and remote control panel are in good working order and the unit is correctly set up for operation.

  • Page 19: Start Up And Function Check - Local Control

    To complete priming shut the vent valve and supply valve(s). Start Up and Function Check – Local Control After installation is complete the WHE-3 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 20 Pump Oil Level - Check the oil level in the pump crankcase (level with dot on sight glass). Pump Rotation - To check the rotational direction of the motor push the start button and then stop button. This will momentarily power the pump motor. Confirm the correct rotation of the pump as indicated by the rotation arrows on the both sides of the pump.

  • Page 21: Start Up And Function Check - Remote Control

    The function of the WHE-3 remote control must also be thoroughly checked prior to being put into service. This should be done after the start up and function checks on the WHE-3 unit have successfully been completed. The following procedure outlines the steps used in conducting remote control start-up and functional checks.

  • Page 22: Operations

    Operations General The JFD Electric Powered Water Heating Module, WHE-3, 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).
  • Page 23 Figure 3 Graph of Temperature Loss vs. Umbilical Length Note 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. Determine temperature rise required (T rise To determine the required temperature rise (T ) through the unit, subtract the inlet...
  • Page 24 Table 3 Heater Selection for Required Temperature Rise Heater on () Temp Rise °C (°F) 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) ...

  • Page 25: Operator Controls

    For remote control the WHE-3 operator will select the heater banks to be used and start the pump motor locally. Once the controller has been set to use the remote set-point input the remote control may be used for the fine control of the outlet temperature.

  • Page 26: Operating Start-Up Procedure

    Figure 5 General Arrangement Operating Start-Up Procedure Carry out pre-operation checks 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. •...

  • Page 27: Shutdown Procedure

    The system should now be operating and all systems functioning correctly. Allow the outlet temperature to rise to the set point and monitor the control of the process to confirm correct heater bank selection and temperature output. Note The supply inlet pressure should be maintained above 3 bar with a sufficient flow rate to supply the unit with 45 lit/min.

  • Page 28: Maintenance

    4.2.4 Heater Elements Heater element cover plates should be removed to check for leaks and, if necessary, check element insulation. To remove any elements use WHE-3 element socket, JFD part no. DO05547. Note Heated seawater is extremely corrosive and heater elements will not last indefinitely.

  • Page 29: Pump Specifications

    • Shut-off valves in the inlet or discharge plumbing to be sure they are fully open 4.3.2 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. 4.3.3...

  • Page 30: Troubleshooting

    Troubleshooting The tables in this section are designed as a troubleshooting guide to aid in the identification of faults and outline possible corrective action. Pump Specific Fault Diagnosis and Maintenance Problem Possible Cause Solution Pulsation Faulty Pulsation Damper Check pre-charge of pulsation Damper;...
  • Page 31 Water in crankcase May be caused by humid air Change oil at 3 month or 500 hour condensing into water inside the intervals using JFD part no. DO03764. crankcase. Leakage of packing seals. Over- Replace packing. Check pressure pressure or faulty pressure regulator.

  • Page 32: General Troubleshooting Chart

    General Troubleshooting Chart Problem Possible Cause Solution Low output pressure. Leaking relief valve. Check relief valve function, repair or replace. Water inlet to system low or turned Turn inlet water on. Check water off. supply and hose sizing. Insufficient flow in water feed lines Check inlet hose diameter is sufficient to system.
  • Page 33 Problem Possible Cause Solution Motor fault - will not run. Fault in wiring to contractor, control Trace wiring; make sure there is no circuit to main control circuit is broken circuit to wiring. If there is, broken. correct malfunction. 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...
  • Page 34 Problem Possible Cause Solution Large flow in overboard Manual bypass valve left open. Close valve. dump line. Too many heaters on for load on Refer to table to determine proper system. number of heaters on or shut one heater off and monitor temperature. System will not run, fault No water is coming to system.
  • Page 35 Problem Possible Cause Solution Contactors buzzing. Dirt, debris or rust on pole pieces of Disassemble contactor and sand pole contactors. pieces and clean. Low frequency on system. Check frequency. If frequency is below 60 Hz, see if frequency can be increased.
  • Page 36 Problem Possible Cause Solution No 24 VDC control power. Control power supply unit faulty. Check output of power supply. If it is not 24 V on the feed with 440 V on the supply, replace power supply unit. Control power fuse F3 burned out. Replace. Fault lights will not come Faulty fault relays.

  • Page 37: Part Identification

    Part Identification Figure 6 General Arrangement Front View Figure 7 Inlet, Outlet and Pressure Relief Valve KI-OM-0591 Rev 3 Part Identification...
  • Page 38 Item Description JFD 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 (AA and AC)
  • Page 39 Item Description JFD Part No. Front Dump Manifold DO05900 Figure 8 General Assembly Rear Side View KI-OM-0591 Rev 3 Part Identification...
  • Page 40 Figure 9 Control Valve, Thermostat and Filter Arrangement Item Description JFD Part No. Heater Element (Inside Heater Tank) 4.0 kW (AA and AC) DO02798-SPARE Heater Element (Inside Heater Tank) 4.0 kW (AB) DO39912 Heater Element (Inside Heater Tank) 4.5 kW (AA and AC) DO02776-SPARE Heater Element (Inside Heater Tank) 4.5 kW (AB)

  • Page 41: Hoses

    Item Description JFD Part No. Manual Temperature Control Valve DO03326 Bleed Valve VB36264 Temperature Control Valve DO02788 Zinc Anode 1/2” NPT, 100 mm DO02369 Hoses JFD Part No. Service 3.1 Cert 3.2 Cert Heater Tank Relief Valve to Dump Manifold...
  • Page 42 Item Description JFD Part No. Remote Set Point Signal Generator DO04798 Remote Pump Running Indication DO04990 Remote General Fault Indication DO04992 Remote Emergency Stop Button DO03260 KI-OM-0591 Rev 3 Part Identification...

  • Page 43: Spare Parts List

    Spare Parts List Description JFD 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...
  • Page 44 DO04921 Module Diode Plug-In 6 - 220 Vdc DO03910 Neoprene Gasket (2 mm thick, 364 mm Diameter) DO02760 Oil JFD Cat Pump Lube SAE 40 DO03764 Overload Thermal 3 Pole, 9-14 A DO02904 Pocket Thermostat 1-1/4 BSP brass Boss DO03961...
  • Page 45 Description JFD Part No. Kit Seal for CAT 7012.1 SS Relief Valve DO02723-KIT Spare Element WHE-3 for DO02798 DO02798-SPARE Heater Selection Table DO03009 Main Isolator DO05796 Motor Pulley (Using Taper Lock Bushing, Part No. DO02831) DO02830 Pump Pulley (Using Taper Lock Bushing, Part No. DO02829)
  • Page 46 Intentionally blank KI-OM-0591 Rev 3 Part Identification...
  • Page 47 PPENDIX EMPERATURE ONTROLLER ARAMETER ETTINGS To set the parameters of the display press the SET key for 2 seconds. Use the SET key to page through the function blocks. Use the shift (<) key to select the parameter to change. Change the setting using the arrow keys.
  • Page 48 To enter the Setup Setting Mode, press the Shift (MODE) key while pressing the SET key. Move through the parameters by pressing the SET key. Use the mode key to highlight a digit and use the arrow keys to change the highlighted digit. Table 2 Setup Setting Mode Temperature...
  • Page 49 To enter the Engineering Mode, press the Shift (MODE) key for 2 seconds while pressing the SET key. Move to the required function block using the arrow keys. To page through the selected function block press the SET key. When at the correct parameter highlight the digit to be changed using the MODE key and use the arrow keys to change the highlighted digit.
  • Page 50 Table 3 Engineering Mode (Continued) Temperature Engineering Mode Controller Parameter Function Spec. Description Block Value Code Description LoGC Output assignment oTT1 Timer 1 oTT2 Timer 2 oTT3 Timer 3 oTT4 Timer 4 Energized/De-energized 0011 Status of DO 1-4 ALC1 Alarm (ALM) lamp lighting condition 1 0001 Lamp status of EV1-4 ALC2 Alarm (ALM) lamp lighting condition 2 0000...
  • Page 51 Table 3 Engineering Mode (Continued) Temperature Engineering Mode Controller Parameter Function Spec. Description Block Value Code Description Event 3 type Type of input used to trigger this event Eho3 Event 3 hold action EIL3 Event 3 interlock Event 3 differential gap Prevents chattering of event output EVT3...
  • Page 52 Table 3 Engineering Mode (Continued) Temperature Engineering Mode Controller Parameter Function Spec. Description Block Value Code Description Control action Direct, reverse, heat/cool water, air etc. lddP Integral/derivative time decimal point position Derivative gain 6.0 ON/OFF action differential gap (upper) 1.0 ON/OFF action differential gap (lower) 1.0 AoVE Action (high) at input error...
  • Page 53 Table 3 Engineering Mode (Continued) Temperature Engineering Mode Controller Parameter Function Spec. Description Block Value Code Description AT Bias Offset AT cycles 0=1.5, 1 =2, 2=2.5, 3=3 cycles AT differential gap time 10.0 Aton Output value with AT turned on 105.0 AToF Output value with AT turned off...
  • Page 54 Table 3 Engineering Mode (Continued) Temperature Engineering Mode Controller Parameter Function Spec. Description Block Value Code Description Open/Close output neutral zone Open/Close output differential gap Action at feedback resistance (FBR) input error Feedback adjustment preparation Control motor time Integrated output limiter 150.0 Valve action at STOP ST Start condition...
  • Page 55 PPENDIX ANUFACTURER ELATED OCUMENTS The following details web links where manufacturers’ operating, service and maintenance information for the major components of the WHE-3 may be sourced. RKC FB100 Digital Controller Manual https://www.rkcinst.co.jp/english/pdf_manual/imcb25e3.pdf BELIMO Control Valve (Belimoseoul Part Number R2020-6P3-S2+LR24A-SR) http://belimoseoul.com/data/medium/3c6db9b8997c2f27dd43695fc64656db.pdf Water Pressure Reducing Valve (Caleffi part number 5360) http://www.caleffi.com/sites/default/files/file/01026_05en.pdf...
  • Page 56 Intentionally blank KI-OM-0591 Rev 3...
  • Page 57 ..C.7 Schematic, Water, Heater Electric, WHE-3 Upgrade, With PV’S 3.1 Cert Sheet 1 of 2 ............C.8 Sheet 2 of 2 .

  • Page 58: General Arrangement, Water Heater Electric, Whe-3 Ki40018 (All Variants)

    General Arrangement, Water Heater Electric, WHE-3 KI40018 (All Variants) Sheet 1 of 2 KI-OM-0591 Rev 3...

  • Page 59: Sheet 2 Of 2

    Sheet 2 of 2 KI-OM-0591 Rev 3...

  • Page 60: Wwhe-3 Electrical Schematic 24 Vdc Control Circuit - With Remote

    WWHE-3 Electrical Schematic 24 VDC Control Circuit - With Remote Sheet 1 of 2 KI-OM-0591 Rev 3...

  • Page 61: Sheet 2 Of 2

    Sheet 2 of 2 KI-OM-0591 Rev 3...

  • Page 62: Whe-3 Electrical Schematic (440 V) Heater Circuit (With Remote)

    WHE-3 Electrical Schematic (440 V) Heater Circuit (With Remote) KI-OM-0591 Rev 3...

  • Page 63: Whe-3 Electrical Schematic - With Remote Busbar Manufacturing Detail

    WHE-3 Electrical Schematic - With Remote Busbar Manufacturing Detail KI-OM-0591 Rev 3...

  • Page 64: Schematic, Water, Heater Electric, Whe-3 Upgrade, With Pv's 3.1 Cert

    Schematic, Water, Heater Electric, WHE-3 Upgrade, With PV’S 3.1 Cert Sheet 1 of 2 KI-OM-0591 Rev 3...

  • Page 65: Sheet 2 Of 2

    Sheet 2 of 2 KI-OM-0591 Rev 3...

  • Page 66: Schematic, Water, Heater Electric, Whe-3 Upgrade, With Pv's 3.2 Cert

    Schematic, Water, Heater Electric, WHE-3 Upgrade, With PV’S 3.2 Cert Sheet 1 of 2 C.10 KI-OM-0591 Rev 3...
  • Page 67 Sheet 2 of 2 KI-OM-0591 Rev 3 C.11...
  • Page 68 Intentionally blank C.12 KI-OM-0591 Rev 3...

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