Custom Design & Fabrication Monkey PWH-100/3 User manual

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Operations Manual
Monkey
Hot Water Heater
Model # PWH-100/3
120VAC 60HZ 20AMP
Manufactured By: Custom Design &
Fabrication
Do Not Remove
This Page
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Read this Manual and Understand
Completely Before Start Up
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Check System Function for Safety
Before Each Start Up
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Do Not Use Heater Where System Failure
Could result in a Threat to Divers Life
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Do Not Operate If Any Part of the System
Does Not Function Properly
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Manufacturer and Distributors are not
Responsible for Misuse of this Equipment
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Monkey Heater Specifications
The Monkey Hot Water Heater System is a complete, lightweight, portable, diver’s water
heating system. The system uses a positive displacement submersible pump to provide
water to the inlet side of the heater during operations. The system comes ready to operate

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with the exception of an electrical power source and fuel. The electrical power required
to operate the system is 120 VAC, 60Hz, 20 amp, single phase.
The heating unit is mounted and enclosed in a steel, welded, square tubular frame,
measuring 46” x 26” x 30.5”, weighing approximately 300lbs. The submersible water
pump with a 25 foot umbilical is packed in the frame with the fuel tank.
The heating unit is designed to operate on a 120 VAC, 60Hz, 20 amp, single-phase power
source, using #1 or #2 diesel oil.
The unit is rated at 350,000 B.T.U. an hour output and is capable of heating the outlet
water to temperatures in excess of 200° F., depending on the size of the fuel nozzle used
and the inlet water temperature. The heater will maintain the set operating output
temperature to +/- 1° F. Do not heat salt water is excess of 135 degrees F for it may
crystallize inside the coils.
Fuel consumption is dependent on the size of the fuel nozzle in use. For example a 0.75
size nozzle will use approximately 3/4 gallons of fuel per hour, while a 2.0 nozzle will
use approximately 2 gallons of fuel per hour.
Inlet water is provided to the heater by means of the 11-g.p.m. positive displacement
submersible pump, provided with the system. The pump has a maximum combined
pumping-lift head capability of 600 feet at 40 psi.
The submersible pump is designed to operate from a 120 VAC, 60Hz, 15 amp, single
phase power source. A 15-amp switched outlet is mounted on the heater unit for use with
the submersible pump only.
CAUTION!
It is required that the diver uses a hot water suit liner. This will help
to eliminate hot spots which could cause burns and provide
thermal protection in case of hot water heat loss.
Recommended Suit Injection Temperature
At
2 G.P.M. Flow Rate
For depths of 0 to 100 feet:

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Water Temperature to 50° F. = 96° - 98° F.
Water Temperature to 30° F. = 100° - 102° F.
For Depths of 100 to 240 feet.
Water Temperature to 50° F. = 100° - 103° F.
Water Temperature to 30° F. = 103° - 105° F.
The recommended injection temperature is a base line and will need to be adjusted
depending on the following factors.
a. Flow Rate (g.p.m.) to the diver. (Higher the rate, lower the temperature.)
NOTE!
The minimum recommended flow rate for 1/2 ID hose is 2 g.p.m.
For 5/8” and 3/4” ID hose, the minimum recommended flow rate is 4
g.p.m.
b. Heat Loss from hot water hose.
NOTE!
The heat loss is dependent on: ID and OD of hose, length of hose,
ambient air and water, and length of hose in the water.
c. Ambient water temperature.
d. Breathing medium.
e. Breathing gas temperature.
f. Physical condition of diver.
g. Work diver is performing.
Hot Water Hose Heat Loss
On an average, the heat loss for a 300 foot, 1/2” ID, 1¼” OD hot water hose
with an injection water temperature of 110° F. and a flow rate of 2 g.p.m., in
an ambient water temperature of 35° F., will be about 18° F. (Base Line).
The heat loss for a 1/2 ID, 7/8” OD hose, will be about 36° F. (Base Line).

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Heat loss for the 5/8” and 3/4” ID hot water hose, under the same conditions,
will be about 12° F. (Base Line).
If the flow rate is increased by 2 g.p.m., the heat loss will decrease by about
4° F. from the above base line temperature loss.
As the ambient water temperature increases, the heat loss will decrease. The
percent of decreased heat loss to water temperature is 40° = 94%, 50° =
86%, 60° = 65%, and 70° = 40%.
Example
To figure the heat loss for a dive in 50° ambient water using 1/2” x 7/8” hot
water hose, with a flow rate of 4 g.p.m.:
36° - 4° = 32° x 86% = 27.5° F. heat loss.
To figure what the heater output should be set at, add the recommended suit
injection temperature and the hot water heat loss.
These figures are based on extreme ambient weather conditions. If the
ambient air is warm, then heat loss will be less and heater output should be
decreased.
Nozzle Size
Subtract input water temperature from the final recommended heater output
temperature, multiply by the gallons per minute output, multiply by 510 (salt
water) or 495 (fresh water), and divide by 100,000. Use the next smaller
nozzle if answer does not come out to a nozzle size in the spare parts kit.
PUMP SET UP (Before Set-Up Procedures)
1. Remove pump from case.
2. Inspect the water tight electrical connection at the pump and the power cord
for damage. If damage is evident, have a qualified electrician repair it before use.

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WARNING!
DO NOT OPERATE ANY ELECTRICAL COMPONENT
IN THIS SYSTEM WITHOUT USING A
GROUND FAULT CIRCUIT INTERRUPTER (GFCI)
3. It is recommended that the pump is operated at a depth of 3 to 5 feet below
Mean Low Water (MLW) or 2 feet from the bottom to prevent pump clogging.
WARNING!
DO NOT OPERATE PUMP IN THE VICINITY
OF WORK LOCATION IF PUMPING CONCRETE OR
OTHER HAZARDOUS MATERIALS ARE PRESENT IN
THE WATER. SUCH MATERIALS CAN DAMAGE THE
PUMP AND HEATER SYSTEM AND CAUSE SEVERE
BURNS AND SKIN IRRITATIONS TO THE DIVER.
WARNING!
ALWAYS DISCONNECT THE PUMP FROM THE
POWER SUPPLY BEFORE SET UP OR REMOVAL
FROM THE WATER.
Set-Up Procedures
1. Set up the unit in the are to be used.
2. Pump must be plugged into the outlet provided on the unit, for the unit to
function correctly.
3. Make all of the necessary connections.
a. Water from the submersible pump or other external source.

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1. If external source is used, electric valve must be installed at the unit
intake and connected to the power outlet provided. (Electric Valve must
fail closed.)
b. Connect hose(s) from heater outlet valve(s).
WARNING!
DO NOT OPERATE ANY ELECTRICAL COMPONENT
IN THIS SYSTEM WITHOUT USING A
GROUND FAULT CIRCUIT INTERRUPTER (GFCI)
c. Electrical connections from a portable generator, 3kw minimum output
or any other 120 VAC, 20 amp electrical source. The 15 amp electrical
outlet provided on the back circuit panel box is for use with the
submersible pump. ( 5kw generator is recommended.)
4. Fuel unit with either #1 or #2 diesel oil.
5. Make sure a flow of water is present through the system.
WARNING!
NEVER OPERATE THE FUEL PRESSURE AT THE
REGULATOR LESS THAN 100 PSI. FAILURE TO
OBSERVE THIS WARNING WILL RESULT IN
INCOMPLETE COMBUSTION, CAUSING EXCESSIVE
COIL SOOTING, HARMFUL VAPORS, EXCESSIVE
SMOKE AND POSSIBLE FLASHING.
6. Turn unit on, check to make sure burner has fired, and temperature display is
functioning.
a. Test flow switch.
b. To properly test flow switch function, shut down the water flow to the
heater. The unit should shut down if the switch is functioning properly.
NOTE
Once burner has fired, observe smoke color. If smoke is white, slightly
close vent opening on the burner assembly until smoke disappears. If
smoke is black, reverse procedure, slightly opening vent until smoke
disappears.

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7. Crack open by-pass valve. Set the water flow pressure at 10 psi., using the
valve at the units water inlet.
8. Set fuel pressure at the fuel regulator to 120 psi.
9. Allow unit to run 5 minutes or until temperature remains constant on the
digital display.
NOTE
Starting operating temperature is recommended to be
at 100° F. and is only a guideline for starting
procedure. Fine-tuning of the temperature will be
when in actual use. It can be set or changed using the
water flow controls or the fuel pressure, set at the
regulator.
WARNING!
DO NOT OPERATE THE SYSTEM WITHOUT A DIVER
BY-PASS VALVE THAT CAN BE OPERATED BY THE
DIVER TO ELIMINATE WATER FLOW IF NECESSARY.
IN THE EVENT OF A UNIT MALFUNCTION, SEVERE
BURNS MAY OCCUR.
10. Once a comfortable working temperature has been achieved, fine adjustments
can be made at the fuel pressure regulator.
11. If all set-up procedures have been followed, you should be able to maintain
your operating temperature at +/- 1° F.
WARNING!
A SCALD SAFE® VALVE IS HIGHLY RECOMMENDED TO
BE INSTALLED AT THE DIVERS END, IMMEDIATELY
BEFORE THE DUMP VALVE, AS A SECONDARY LINE OF
DEFENSE AGAINST SCALDING.
HIGH-POINT TEMPERATURE CUT-OFF
After temperature has remained constant on the digital display for 3 minutes,
depress the set point button on the control panel. This changes the display to
read the present high-point temperature cutoff temperature. Adjustments can
be made as follows:

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For the primary digital readout
A. Press the center button and release. The display will read SP, wait approximately
two seconds, press the up or down button and the set points will be displayed.
B. Press and hold the up or down button until the desired set point is displayed.
3 degrees F over the working temperature is recommended.
C. Wait approximately 10 seconds. If the set pint was changed, the display will
flash then the SPC will return to display the sensor temperature. (If you do not
want to wait 10 seconds, press the center button once to adjust the differential
or press the center button twice to immediately display the sensor temperature.)
For your added safety C.D.F. has installed a Secondary High Limit Circuit.
This circuit will trip the unit, the pump receptacle, and stop water flow through
the unit in the event of a secondary high-limit trip.
NOTE!
IF THE SECONDARY HIGH LIMIT CIRCUIT TRIPS THE WATER
TEMPERATURE IN THE SYSTEM MUST DROP 15 DEGREES F BEFORE
THE SYSTEM WILL RESTART
The secondary high limit should be calibrated with the primary at the beginning of
each dive day or at each time the unit is restarted. Follow the operations manual start
up procedures as always and follow these additional steps:
A. After a constant divers working temperature has been achieved set the
primary high-limit as described in the manual.
B. Set the secondary high-limit in the same manner as the primary, changing
the set point temperature to 5 degrees F over the working temperature
instead of 3 degrees F.
C. Complete the remaining daily safety systems checkout as described in this
operations manual.
WARNING!
SUPPLY PUMP MUST BE CONNECTED TO THE OUTLET
PROVIDED ON THE UNIT FOR THE SECONDARY HIGH

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LIMIT TO FUNCTION CORRECTLY.
WARNING!
HIGH-POINT CUT-OFF TEMPERATURE SHOULD BE SET
NO HIGHER THAN 2°- 3° F. MAXIMUM OVER WORKING
TEMPERATURE TO PREVENT INJURY TO THE DIVER.
FAILURE TO OBSERVE THIS WARNING COULD RESULT
IN HEAT EXHAUSTION OR SEVERE BURNS TO THE DIVER.
WARNING!
ALWAYS KEEP CONTROL PANEL COVER CLOSED DURING
INCLEMENT WEATHER TO PREVENT DAMAGE TO
ELECTRICAL COMPONENTS IN THE SYSTEM.
WARNING!
SHOCK HAZARD! DO NOT TOUCH ANY ELECTRICAL
COMPONENTS IN THIS SYSTEM WHEN WET. SEVERE
SHOCK OR ELECTROCUTION COULD OCCUR.
WARNING!
COMBUSTIBLE MATERIAL PRESENT. KEEP AWAY FROM
SPARK OR OPEN FLAME.
FUEL HOOK-UP PROCEDURE
1. Portable fuel containers are provided for your convenience.
Each fuel tank has quick connect snap fittings.

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2. Connect fuel hose to the tank. Connect the fuel by-pass line to the female
quick disconnect
3. OPEN FUEL VENT ON THE FILLER CAP.
4. Unit is self-priming.
SHUTTING THE SYSTEM DOWN
1. Shut the heater off at the control panel.
2. Allow the submersible pump to run until outlet water temperature is
between 80° - 90° F.
3. Shut off and unplug the submersible pump.
3. Remove the pump from the water and disconnect all pump fittings.
Invert the pump to remove all water.
5. Submerge the pump in a BIO safe solution of anti-freeze.
6. Reconnect the pump to the power supply to flood the system with anti-
freeze.
(Pump umbilical and unit require approximately three gallons of anti-
freeze.)
7. Free divers umbilical of water and/or flood with anti-freeze.
(An evacuation unit can be used to simplify this procedure. Evacuation
units are available in 3 or 6-gallon capacities.)
DAILY MAINTENANCE
1. Always check high point cut-off setting on display to ensure that it is
properly set, 2 - 3 degrees F above the working temperature

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2. Check outlet water temperature to verify that sensor is functioning
properly.
3. Calibrate secondary high limit 3 - 5 degrees F above working temperature
4. Test trip your safety valve.
NOTE
These daily checks will ensure the unit is functioning correctly.
WARNING!
DO NOT OPERATE UNIT IF ANY COMPONENT IN THE
SYSTEM IS NOT FUNCTIONING CORRECTLY.
TO DO SO COULD CAUSE SEVERE BURNS TO THE
DIVER OR CAUSE DAMAGE TO THE SYSTEM.
WEEKLY MAINTENANCE
1. Disconnect Power Supply
2. Replace any non-working parts, valves, gauges etc.
3. Review safety checklist for unit function.
4. Change fuel filter.
WARNING!
WHEN SERVICING, BE SURE HEATER IS
DISCONNECTED FROM POWER SOURCE TO PREVENT
ELECTRICAL SHOCK OR FIRE.

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MONTHLY MAINTENANCE
1. Disconnect Power Supply.
2. Replace any non-working parts.
3. Review safety checklist for unit function.
4. Change fuel filter.
5. Replace fuel nozzle
6. Inspect coils for soot build up.
7. Inspect fuel tank and fittings for dirt and water inside.
8. Inspect electrodes for damage.
9. Inspect circuits for corrosion and damage through the see-through widow.
Do not remove switch panel
YEARLY MAINTENANCE

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1. Change fuel filter.
2. Change fuel nozzle.
3. Inspect blower for corrosion.
4. Wash heater coil free of soot, using a wire brush or vacuum.
5. Remove 3 nuts from burner mounting flange.
6. Carefully remove burner and set aside. Leave electrical connections and
fuel hose intact.
7. Cover with waterproof plastic.
8. Replace gasket on burner flange.
9. Check parts inventory.
a. New fuel filter.
b. Replace lost or used fuel nozzles.
c. Replace hose fitting washers.
d. Replace any lost or worn fittings.
WARNING!
DO NOT OPEN ELECTRICAL CLOSURE FITTINGS OR
PANEL COVERS. THIS PROCEDURE SHOULD ONLY
BE DONE BY A QUALIFIED ELECTRICIAN.
NOZZLE CHANGING PROCEDURE
1. Disconnect Power Supply.

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2. Close air vent on burner adjustment band.
3. Loosen the flare nuts and remove the fuel line between the solenoid valve
and nozzle pipe. Set aside. Caution! Be careful not to drop the nut into
the air vent!
4. Remove nozzle pipe retaining nut from nozzle pipe and set aside.
5. Loosen the coil clamp located on the other side of the coil and open the
burner lid. Carefully slide the nozzle pipe assembly downward and out
until the assembly becomes free and lifts out.
Caution! Be careful not to damage the ceramic insulators on the electrodes.
6. Replace the nozzle with the desired size.
7. Reset the electrodes or replace if damaged.
8. Replace the nozzle pipe assembly. Re-assemble all components by
reversing the disassembly procedures. Open air band on the burner
assembly. Make air adjustments following set-up procedures.
BE CAREGUL NOT TO MOVE ELECTRODE SETTINGS

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TROUBLESHOOTING
1. No water flow.
a. Check connection at outlet.
b. Pump may be frozen.
c. Pump may be burned out.
d. Check electrical circuit.
e. Check secondary high limit adjustment.
2. GFCI keeps tripping. (LED blinks, clicking sound is heard.)
a. Pump may be frozen.
b. Power surge.
c. Short in circuit.
d. Insufficient power supply.
3. Black smoke.
a. Not enough air.
b. Faulty solenoid valve.
c. Dirty fuel.
d. Electrodes misaligned.
e. Weak high voltage coil. (clean contacts.)
4. White smoke.
a. Too much air.
b. Not enough fuel.
5. Relay indicator blink. (Clicking is heard.)
a. Not enough electrical power. (Minimum 110 VAC.)
6. No fuel pressure.
a. Faulty regulator.
b. Clogged fuel filter.
c. Clogged fuel line.
d. Snap fitting not coupled properly.
e. Leak in fuel line or prime bulb.
f. Vent cap closed on fuel tank.
7. Burner won’t fire.
a. Same as above for fuel pressure.
b. Electrodes misaligned.
c. Weak voltage coil / dirty contacts.
d. Cracked ceramic on electrodes.
e. Water in fuel.
f. Not enough electrical power. (Minimum 110 VAC.)
g. Re-set button tripped. (Located on motor case.)

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8. Snap fitting leak.
a. Replace o-ring.
b. Replace fitting.
9. System freezes.
a. Shut system off. Turn pump off.
b. Slowly thaw with forced air heat.
WARNING!
DO NOT ATTEMPT TO THAW WITH OPEN FLAME
10. Overheating.
a. Faulty sensor.
b. Faulty relay(s).
c. Insufficient flow of water. (Check flow requirements for size of hose.)
11. Underheating.
a. Too much water flow. (Check flow requirements for size of hose.)
b. Low fuel pressure. (120 psi at the regulator.)
c. Fuel nozzle too small.
d. Soot on coil.
12. No PSI on manifold.
a. Open gate valve.
b. System frozen.
c. Cracked coil.
13. No power to heater.
a. Check electrical connection.
b. Push system by-pass switch.
WARNING!
IF SYSTEM FIRES, THERE IS A FAULTY CIRCUIT.
DO NOT OPERATE!

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14. LED erratic.
a. Faulty sensor.
b. Damp circuit. (Dry with forced air heat.)
c. Fluctuating supply water pressure.
15. Fuel tank collapse.
a. Open tank vent.
b. Vent may be plugged.
16. Low water pressure.
a. Insufficient water supply.
b. Kink or obstruction in water hose.
c. Pump by-pass opened too much.
17. Fuel pump won’t prime.
a. Obstructed fuel line.
b. Air leak in fuel line.
c. Fuel filter cap loose.
d. Faulty fuel pump.
18. Drip from bottom of combustion chamber.
Note! Check smell and/or feel of liquid
If diesel is present:
a. Faulty solenoid valve.
b. Loose nozzle.
c. Misaligned electrodes.
If diesel is not present:
a. Normal condensation from coil.
19. Motor hiss.
a. No lubrication in motor.
20. Thermal re-set on the motor trips.
a. Snap fittings on the fuel supply are not correctly engaged.
b. Fuel pump is not functioning.

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