Alfalaval Heatpac EHS-71 User guide

Marine & Diesel Equipment
Heatpac® EHS-71 System
System Instructions
Product No.
Printed
Book No.
9016616-01 to -07
Jun 2015
9020063-02 V1

Alfa Laval reserve the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
S - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB Jun 2015.
The original instructions are in English

Contents
1 Warning signs in text 7
1.1 Warning signs 7
2 Scope 9
3 System Description 11
3.1 Basic Concept 11
3.1.1 Principle Diagram 11
4 Heatpac Working Principle 17
5 Operating instructions 19
5.1 Before Start 19
5.2 Start-up 19
5.3 Operation 20
5.4 Stop 20
6 Alarms and Fault Finding 21
6.1 Alarm Indication 21
7Diagrams 23
7.1 Electrical System Layout 23
7.2 Cable List 24
7.3 Interconnection Diagram 25
7.4 Installation Diagram 26
8 Installation 27
8.1 General Installation 27
8.2 Electrical Installation 28
3

!
Study instruction manuals and observe the
warnings before installation, operation,
service and maintenance.
Not following the instructions can result
in serious accidents.
In order to make the information clear only
foreseeable conditions have been considered.
No warnings are given, therefore, for situations
arising from the unintended usage of the
machine and its tools.
5

!

1 Warning signs in text
1.1 Warning signs
Pay attention to the safety instructions in this
manual. Below are definitions of the three
grades of warning signs used in the text where
there is a risk for injury to personnel.
D
!ANGER
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.
!WARNING
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
!CAUTION
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.
NOTE
NOTE indicates a potentially hazardous situation
which, if not avoided, may result in property damage.
7

1 Warning signs in text

2Scope
The Heatpac®EHS-71 system is designed
for the heating of mineral oils in a centrifugal
separator cleaning system and/or in a fuel
conditioning system (FCM).
This system description is valid for the Heatpac®
EHS-71 Heating System.
9

2 Scope

3 System Description
3.1 Basic Concept
The Heatpac®EHS-71 basic concept comprises
an electric heater of EHM type combined with
an electronic control unit, power unit, and a
number of ancillary components.
3.1.1 Principle Diagram
G1120811
11

3 System Description
3.1.1.1 Basic Equipment
G1119711
1. Oil heater
2. Temperature sensor
3. Safety valve
4. Temperature sensor
5. Pressure gauge
6. Needle valve
7. Copper washer
8. Nipple
9. Washer
10. Self-sealing nipple
11. Power unit
12. Control cabinet
12

3 System Description
Basic Equipment EHS-71, 7/8 kW
Pos Qty Part No. Name Remark
580974 80 Oil heater, 7 kW, 230 V 230 V
580974 81 Oil heater, 7 kW, 400 V 400 V
580974 82 Oil heater, 8 kW, 440 V 440 V
580974 83 Oil heater, 8 kW, 480 V 480 V
1 1 580974 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
580940 80 Power Unit 7-24 kW 400V,440V,480V,690V
11 1 9017568 80 Power Unit 7-22 kW, 230 V 230V
12 1 9016858 80 Control cabinet kit
Basic Equipment EHS-71, 14/16 kW
Pos Qty Part No. Name Remark
580975 80 Oil heater, 7 kW, 230 V 230 V
580975 81 Oil heater, 7 kW, 400 V 400 V
580975 82 Oil heater, 8 kW, 440 V 440 V
580975 83 Oil heater, 8 kW, 480 V 480 V
1 1 580975 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
580940 80 Power Unit 7-24 kW 400V,440V,480V,690V
11 1 9017568 80 Power Unit 7-22 kW, 230 V 230V
12 1 9016858 80 Control cabinet kit
13

3 System Description
Basic Equipment EHS-71, 22/24 kW
Pos Qty Part No. Name Remark
580976 80 Oil heater, 7 kW, 230 V 230 V
580976 81 Oil heater, 7 kW, 400 V 400 V
580976 82 Oil heater, 8 kW, 440 V 440 V
580976 83 Oil heater, 8 kW, 480 V 480 V
1 1 580976 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
580940 80 Power Unit 7-24 kW 400V,440V,480V,690V
11 1 9017568 80 Power Unit 7-22 kW, 230 V 230V
12 1 9016858 80 Control cabinet kit
Basic Equipment EHS-71, 36/40 kW
Pos Qty Part No. Name Remark
580977 81 Oil heater, 7 kW, 400 V 400 V
580977 82 Oil heater, 8 kW, 440 V 440 V
580977 83 Oil heater, 8 kW, 480 V 480 V
1 1 580977 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580942 80 Power Unit 36-40 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit
14

3 System Description
Basic Equipment EHS-71, 50/56 kW
Pos Qty Part No. Name Remark
580978 81 Oil heater, 7 kW, 400 V 400 V
580978 82 Oil heater, 8 kW, 440 V 440 V
580978 83 Oil heater, 8 kW, 480 V 480 V
1 1 580978 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580942 81 Power Unit 50-72 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit
Basic Equipment EHS-71, 65/72 kW
Pos Qty Part No. Name Remark
580979 81 Oil heater, 7 kW, 400 V 400 V
580979 82 Oil heater, 8 kW, 440 V 440 V
580979 83 Oil heater, 8 kW, 480 V 480 V
1 1 580979 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580942 81 Power Unit 50-72 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit
15

3 System Description
Basic Equipment EHS-71, 100/130 kW
Pos Qty Part No. Name Remark
580979 91 Oil heater, 130 kW, 400 V 400 V
580979 92 Oil heater, 130 kW, 440 V 440 V
580979 93 Oil heater, 130 kW, 480 V 480 V
580979 94 Oil heater, 130 kW, 690 V 690 V
580978 91 Oil heater, 100 kW, 400 V 400 V
580978 92 Oil heater, 100 kW, 440 V 440 V
580978 93 Oil heater, 100 kW, 480 V 480 V
1 1 580978 94 Oil heater, 100 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580944 80 Power Unit 100-130 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit
16

4 Heatpac Working Principle
Oil to be heated is fed continuously to the
EHM heater. A temperature sensor in the
outlet senses the oil temperture and signals
the control unit. The control unit compares the
values received with the set parameter values.
The control unit then signals the power unit to
increase or decrease the electrical supply to the
heater as required.
The system temperature is monitored and
displayed in the control unit. If the preset alarm
levels are exceeded, an alarm indication is
given.
The Heatpac®EHS-71 system has a standard
safety function, comprising a high temperature
sensor (Pt100) located in the heater and
connected to an electronic temperature limiter
located in the power unit. A signal from this
equipment directly shuts off the heater, thus
protecting it from overheating. This equipment
works independently of the control unit.
The heating system is also interlocked with the
feed pump, so that the heater is stopped when
the pump is stopped.
A safety valve protects the heater from
excessive pressure.
17

4 Heatpac Working Principle

5 Operating instructions
5.1 Before Start
1. Check the external condition of the heating
system for leaks or damage. Make sure
that the necessary valves are open.
2. Set the main switch to position 1 and the
function switch to position OFF.
!CAUTION
Check that the High Temperature Switch, Pump
Interlock, and Safety Valve are functioning properly.
See the appropriate booklets.
5.2 Start-up
1. Compare the parameter values in the
control unit with the plant set values shown
on the inside of the control unit.
NOTE
Where there is booster heating (e.g. during
manoeuvering when marine diesel or lighter
fuel is used) the temperature set point must be
reduced to a temperature suitable for the fuel
used.
2. Start the oil pump if not already running.
3. Start the heater via the control unit.
The temperature increases up to the set
point, and can be read on the control unit
display.
NOTE
Where there is booster heating, the temperature
setpoint must gradually be raised to normal
operating temperature at the same time as the
change-over from light to heavy fuel.
19

5 Operating instructions
!WARNING
To avoid risk for overheating and fire, make sure that
there is full oil flow at all times during operation.
!CAUTION
If the safety valve opens, or the high temperature
switch trips repeatedly, the heater should be opened
up for inspection and cleaning.
5.3 Operation
The Heatpac®electric heating system requires
no special attention during normal operation.
For further information on alarm functions, see
6 Alarms and Fault Finding on page 21.
5.4 Stop
1. Stop the heater via the control unit.
NOTE
Where there is booster heating, the temperature
setpoint must gradually be lowered to a
temperature suitable for the fuel used.
2. If the oil feed pump is to be stopped, wait 1
minute after the heater has been switched
off before stopping the pump.
!CAUTION
Be sure to switch off the heater system before
stopping the oil feed pump.
20