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Spirax Sarco EasiHeat Installation And Maintenance Instructions Manual
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Spirax Sarco EasiHeat Installation And Maintenance Instructions Manual

Spirax Sarco EasiHeat Installation And Maintenance Instructions Manual

Dhw potable and process water heating compact heat transfer solution
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4819050/4
IM-P481-04
CTLS Issue 4
Spirax EasiHeat
TM
DHW Potable and Process Water Heating
Compact Heat Transfer Solution
Installation and Maintenance Instructions
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Fault finding
6. Maintenance
© Copyright 2018
IM-P481-04 CTLS Issue 4
1
Printed in GB

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Summary of Contents for Spirax Sarco EasiHeat

  • Page 1 4819050/4 IM-P481-04 CTLS Issue 4 Spirax EasiHeat DHW Potable and Process Water Heating Compact Heat Transfer Solution Installation and Maintenance Instructions 1. Safety information 2. General product information 3. Installation 4. Commissioning 5. Fault finding 6. Maintenance © Copyright 2018...
  • Page 2 Copyright © Spirax Sarco Limited 2018 All rights reserved Spirax Sarco Limited grants the legal user of this product (or device) the right to use the Work(s) solely within the scope of the legitimate operation of the product (or device). No other right is granted under this licence. In particular...
  • Page 3 On no account is the Spirax Sarco EasiHeat unit to be lifted by any other part, other than the base.
  • Page 4 1.1 Intended use Referring to the Installation and Maintenance Instructions, name-plate and Technical Information Sheet, check that the product is suitable for the intended use/application. The Spirax Sarco EasiHeat DHW potable and process water heating compact heat transfer unit complies with the...
  • Page 5 1.9 Tools and consumables Before starting work ensure that you have suitable tools and/or consumables available. Use only genuine Spirax Sarco replacement parts. 1.10 Protective clothing Consider whether you and/or others in the vicinity require any protective clothing to protect against the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and dangers to eyes and face.
  • Page 6 The base unit of the Spirax Sarco EasiHeat™ DHW provides the core of the system, while options (see Sections 2.2) provide additional features such as: high limit package, stop valve package and energy monitoring.
  • Page 7 The product nomenclature is a reflection of the core items and unit options that have been ordered and supplied – See the table below: Spirax Sarco EasiHeat DHW nomenclature example: Domestic hot water EHD = Spirax Sarco EasiHeat™ DHW 1 = DN20 2 = DN25 3 = DN32 CV size...
  • Page 8 3.1 Steam and condensate connections It is important that the steam supply (and compressed air if pneumatic actuation is selected) to the Spirax Sarco EasiHeat™ DHW unit is supplied as dry and as clean as possible, in accordance with good steam engineering practice.
  • Page 9 Note: PT100 temperature sensors 3 wire Power supply 10 - 16 A 3.5 Electrical connections The following are available for customer connection to the Spirax Sarco EasiHeat™ system if required: Terminal designation Description Type 1 x N/O contact Enabled/running signal...
  • Page 10 Remote operation and retransmission connections Terminal designation Description Type Remote set point 4-20 mA input Remote enable 24 Vdc signal Retransmission value 4-20 mA output 001- 001+ 24.3 CHANNEL 13 REMOTE SYSTEM CHANNEL 0 4-20mA ENABLE RETRANSMISSION REMOTE PID OF PV OR VALVE LOOP POSITION SETPOINT...
  • Page 11 Terminal layout overview X1 - X5 X6 - X8 X9 - X10A X10B - 10C PT100 4 - 20 mA 4 - 20 mA actuator Bypass pump inputs inputs outputs signals X13A-C X14 - X16 Bypass valve High limit volt free remote valve signals...
  • Page 12 4. Commissioning 4.1 Mechanical commissioning We recommend that you use the service and support of a Spirax Sarco commissioning engineer. procedure: Details of this service can be found by contacting Spirax Sarco. Check that all of the electrical connections are...
  • Page 13 4.2 TVA quick commissioning: The TVA flowmeter is factory set to display data in metric units (changeable to imperial if required by following the flow chart, Figure 10, or the individual product Installation and Maintenance Instructions (IMI)). All commissioning of the TVA is through the arrow buttons located on the front display see Figure 8. LCD display 5 button keypad 3 screws...
  • Page 14 4.3 TVA flowmeter commissioning chart To navigate around the first level menu use the up and down arrows, to enter any sub menu use the right arrow. Fig. 10 TVA configuration displays Normal run mode Default = 7452 but display sequence user settable.
  • Page 15 Configuration sub-menus BASIC dAtA xxxx MEtER OUtPUtS 4-20 mA SORCE FLOW POWER SEt 4 mA xxxxx in kg /h or lb /h, kW or Btu/h. SEt 20 mA xxxxx CHECK 4 mA OP = 4mA CHECK 20 mA OP = 20 mA Connect a DVM and use the up and down keys...
  • Page 16 Fig. 11 PULSE The next menu Sorce will need FLOW to be selected. Obtain the correct flow data from the Spirax Sarco EasiHeat specification sheet supplied for accuracy, thereafter navigate down the menu and input: Minimum flow = 4 mA...
  • Page 17 4.4 HMI quick start commissioning procedure: The HMI display is a 7" touch screen, and the following procedures detail a basic set-up of the control system from initial power up. Fig. 13 When ready the above screen will appear, touch the screen. If the unit has not been configured for previous use following page will appear.
  • Page 18 Fig. 15 After unlocking the system (by using the unlock code) and setting the time and date or if the unit has been returned to factory default one of the following four pages will appear (pre-confi gured for designated region): Fig.
  • Page 19 The system will advance automatically to allow the selection of the relevant Spirax Sarco EasiHeat unit - The type of Spirax Sarco EasiHeat unit that is available is dependent on the flag selection. The next screen (Figure 20) requires confirmation of the system to be configured.
  • Page 20 Fig. 22 System configuration should match the mechanical configuration of the Spirax Sarco EasiHeat control system of the plant, proper configuration will show or hide options available after configuration. Some of the screens may contain additional options which with specified configuration may be hidden; all the options are described in this document.
  • Page 21 Spirax Sarco EasiHeat mechanical and control system configuration options are detailed as follows: Fig. 23 High-limit selection Independently Single Double safety installed controlled controlled safety interlock interlock Fig. 24 ¼ turn actuator selection Valpes DP27E Fig. 25 Linear actuator selection...
  • Page 22 TVA installed and remote set point selected On T VA flowmeter selection a data entr y point shall be displayed in order for effective scaling of the flowmeter (full engineering range for the 4-20 mA signal input to the Spirax Sarco EasiHeat system).
  • Page 23 A continue button will appear after system configuration which will navigate to the logged energy data for the Spirax Sarco EasiHeat system. Press the continue button to navigate to the energy set up page. Fig. 33 Accurately enter specific energy data to ensure valid energy data can be calculated.
  • Page 24 In addition enter the custom fuel set points by selecting the custom fuel type. Fig. 34 Custom fuel parameters to be set: Fuel calorific value Fuel specific gravity Fuel emission factor Fuel conversion heat factor Energy setting will not affect control process, to obtain correct values of the calculated energy, the accurate data settings are essential.
  • Page 25 Service menu Energy logging trends 4.5.1 Home mimic This button will always navigate you back to the overview of the Spirax Sarco EasiHeat system that has been selected and configured. From this home screen the overall status and control of the Spirax Sarco EasiHeat systems operation can be performed, depending on the security level access.
  • Page 26 Fig. 36 V1 dialog page contains two value fields, the top one show the actual valve position, and the bottom one can be used to move the valve to requested position in manual mode. Automatic mode Manual mode Open/Start Close/Stop The light indicator shows what mode is selected.
  • Page 27 PID set point This pop-up menu depending on the communications, allows users to either set the local temperature set point or view the remote or BACnet temperature set point and enter the Spirax Sarco EasiHeat system PID associated ramp up and ramp down time bases. If the configuration were set to BACnet, it is possible to override the configuration and change it to local enable.
  • Page 28 BACnet, it is possible to override the configuration and change it to local enable configuration. Fig. 38 Spirax Sarco EasiHeat OFF mode Spirax Sarco EasiHeat ON mode Remote or communications enable Communications enable override with local Spirax Sarco EasiHeat IM-P481-04 CTLS Issue 4...
  • Page 29 Zoom The zoom pop-up provides a more detailed view of the key process parameters. Fig. 39 IM-P481-04 CTLS Issue 4...
  • Page 30 Anti-legionella To minimise the growth of legionella bacteria from growing in the water pipeline a routine has been programmed into the EasiHeat control system. The anti-legionella control and set-point page is accessible from a button located on the main screen.
  • Page 31 HMI (Figure 42). Fig. 41 The next step is to set the anti-legionella boost temperature that the EasiHeat must achieve during a cycle. Note that the temperature setting must not exceed that of the Independent High Limit (IHL) if fitted.
  • Page 32 Finally the unit must be manually enabled from the enable request pushbutton located on the HMI, the user can stop the anti-legionella boost cycle at any time by pressing the same button. Fig. 43 IM-P481-04 CTLS Issue 4...
  • Page 33 In order to operate the anti-legionella cycle in the automatic or timed mode, select AUTO. This is confirmed by the Automatic set-point entry fields being available and confirmed by the LED on the HMI. The next step is to set the anti-legionella boost temperature that the EasiHeat must achieve during the cycle.
  • Page 34 4.5.2 PID set points This page allows you to set the PID control factors (entries available only for engineers). Fig. 45 Proportional band (P factor of the PID control) Proportional gain (P factor of the PID control) Integral factor (I factor of the PID control) Derivative factor (D factor of the PID control) Desired value (local, remote or communications set point) IM-P481-04 CTLS Issue 4...
  • Page 35 Current value of the controlled variable (T2 temperature) Manipulated value (valve position request) PID real time trend page (Allows to configure the PID set points with view of the actual signals) The following screen is accessible from above PID Loop Set Points page (available only for engineers). We are able to switch between proportional band and proportional gain.
  • Page 36 4.5.3 Settings menu The settings displayed (with blue surround) are default settings after the country flag has been selected, changes can be made if required. Fig. 47 Time/date configuration page Language selection page Temperature units selection Flowmeter units selection (Energy monitoring only) Energy units selection (Energy monitoring only) IM-P481-04 CTLS Issue 4...
  • Page 37 There is also the possibility of changing the language (from the pre-configured options) by using the following selection menu without affecting the engineering units: Fig. 48 In addition, engineers are able to set or change the actual time and date for PLC and HMI. Fig.
  • Page 38 4.5.4 Alarms menu The following page shows all active alarms, an active alarm is indicated on all the mimic screens via the alarm bell in the top left hand corner of the screen. Fig. 50 There are also navigations to further alarm set point pages as well as the historical alarm list, located on the right of the display.
  • Page 39 Band alarm Band alarm temperature set point Band alarm delay time set point Band alarm reset time set point Deviation alarm °C Deviation alarm set point IM-P481-04 CTLS Issue 4...
  • Page 40 Rate of change alarm (DHW only) °C °C / min / min Temperature rate of change alarm set point 10.0 10.0 °C °C Process set point reduction set point Alarm reset time set point Reset high-limit alarm latch (PLC controlled high-limit only) Historical alarm page IM-P481-04 CTLS Issue 4...
  • Page 41 The following page provides access to historical alarm list. This allows the user to view previously triggered alarms. Fig. 51 Caution - high-limit Alarms indication icon setting Manual alarm indication icon If fitted, the high-limit controller should be set at a suitable level to protect plant, process and personnel. Care should be taken to ensure sufficient difference between the process set point and the high-limit set point, to avoid any unwanted high limit tripping.
  • Page 42 4.5.5 Trend menu This menu provides historical trend monitoring of the process values, useful for analysing the historical reactions of the Spirax Sarco EasiHeat system to process conditions. Fig. 52 IM-P481-04 CTLS Issue 4...
  • Page 43 Energy trend page button (energy monitoring only) Flow trend page button (energy monitoring only) Temperature trend page button PID process trend page button Scroll trend left Zoom in Zoom out Move trend to Refresh trend Scroll trend trend tend actual position right IM-P481-04 CTLS Issue 4...
  • Page 44 4.5.6 Service menu The following page provides service information and allows engineering level users to navigate to pages containing process information. Fig. 53 Save trends to USB memory stick This LED if green confirms that the memory stick is connected and the data format is correct (FAT32 only allowed) This LED is switched on only during the trend dump, do not remove the memory stick before it is switched off or data may be lost...
  • Page 45 Last service due at number of hours Next service due at number of hours Process enable event count High-limit event count Local Spirax Sarco engineer contact details dialog page Hardware monitoring pages (input/output overview) Restore commissioned set points (access level 2) IM-P481-04 CTLS Issue 4...
  • Page 46 4.5.7 Hardware monitoring The following pages provide only an overview of the input and outputs; it is not possible to set any set points. Fig. 54 Figures 55, 56, 57 and 58 display the analogue input and output values. Fig. 55 CPU IM-P481-04 CTLS Issue 4...
  • Page 47 Fig. 56 Digital input Fig. 57 Analogue inputs Fig. 58 Analogue retransmission outputs IM-P481-04 CTLS Issue 4...
  • Page 48 Local Spirax Sarco engineer contact details dialog page Fig. 59 4.5.8 Energy pages Energy monitoring pages provide the user access to view the total value of the power and carbon use, total of CO emission and calculated total cost of energy that has been used. By pressing the green fi eld underneath the 'Total Between Two Dates' allows two dates to be set for the total to be calculated between.
  • Page 49 To finalise the mechanical commissioning of the system: Open all condensate drain valves. Slowly open the steam inlet valve. Monitor the process temperature to ensure that it is within the acceptable limits. The Spirax Sarco EasiHeat unit is now ready for service. IM-P481-04 CTLS Issue 4...
  • Page 50 5. Fault finding Fault Possible cause Remidial action Loss of incoming supply Check incoming supply Unit does not power up Check all mains fuses F1 - F4 and Control fuses Internal fuse blown AF1, CF1 - CF7 Check all mains fuses F1 - F3 and Control fuses Internal fuse blown CF1 - CF7 Loss of 24 Vdc...
  • Page 51 TVA commissoining Scaling value incorrect match those on the HMI (this data is found on the TVA input is not Spirax Sarco engineers 4-20 mA page) showing correctly Polarity of 4-20 mA Reverse polarity and wire as per electrical...
  • Page 52 6. Maintenance Note: Before actioning any maintenance observe the 'Safety information' in Section 1. 6.1 General For maintenance of the individual components that make up the system, please see the relevant product specific IMI’s for the components concerned. 6.2 High limit device testing The purpose of the test is to ensure that the system operates satisfactorily when required to do so.