JFD WHE - 3 User manual

Operation and Maintenance Manual
for the
Electric Water Heater WHE - 3
(440V X 24VDC)
Part Number: KI40018AA
Document Number: KI-OM-6768
Revision: 0

(Intentionally Blank)

i
KI-OM-6768 R0 Approval Sheet
APPROVAL SHEET
Document Information
Advitium No Title Classification Current Revision Date
KI-OM-6768 Installation, Operating and Maintenance
Manual – WHE-3, Part - KI40018AA
Commercial in
confidence
0 08/01/2016
Revision History
Rev Date BY CHK APP Comments
0 08/01/2016 J. Lastakauskiene V. Garzon P. Black Original For Issue
Original Approvals
Responsibility Name Position Date
Author Jurgina Lastakauskiene Engineering Administrator January 2016
Checked Vladimir Garzon Mechanical Engineer January 2016
Approval Philip Black Senior Mechanical
Engineer
January 2016
Copyright Details
© 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.

ii
Approval Sheet KI-OM-6768 R0
(Intentionally Blank)

iii
KI-OM-6768 R0 Disclaimer/Warranty
DISCLAIMER
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.

iv
Disclaimer/Warranty KI-OM-6768 R0
WARRANTY
JFD Ltd warrants that its Water Heater Electric (WHE-3), conforms to the current product
specification at the date of delivery and that the product will be free of patent defects in materials or
workmanship for a period of twelve months from the date of delivery or for the first 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. On completion of any repair or replacement, the equipment
will be returned to the customer FOB Cape Town/Aberdeen, South Africa/United Kingdom. By
agreement and upon prepayment by the customer of any transportation, on-site accommodation
and subsistence expenses, JFD may dispatch personnel to perform on-site repairs.
The product specification and warranty terms are subject to alteration without prior notice and do not
form part of any contract made between JFD and its customer.
This equipment should only be operated by suitably qualified persons conversant with the operation
and maintenance of diver hot water systems. Before operating the equipment, the user must be
fully acquainted with the instructions contained in this manual, as well as the individual component
manufacturer’s operating and maintenance information provided in the Appendixes.
Only genuine manufacturer's spare parts may be used in this JFD product. Use of other
manufacturer’s parts may cause degradation of performance or failure and will invalidate the
warranty.
The following information is required by JFD when ordering spare parts:
• Customer’s / owner’s name
• Equipment serial number
• Spare part type / description
• Part number

v
KI-OM-6768 R0 Table of Contents
TABLE OF CONTENTS
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

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Table of Contents KI-OM-6768 R0
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1
KI-OM-6768 R0 Chapter 1
CHAPTER 1 - GENERAL DESCRIPTION
CONTENTS
Page
1.1 Intruduction ....................................................................................................................... 2
1.1.1 Basic Description .............................................................................................................. 2
1.2 Specifications .................................................................................................................... 3
1.3 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 ................................................................................7
1.3.5 Control System ................................................................................................................. 8

2
Chapter 1 KI-OM-6768 R0
1.1 INTRODUCTION
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.
1.1.1 Basic Description
The WHE-03 assembly is comprised of a motor, pump, heater tank, pipe work and control panel.
These components are mounted into a robust stainless steel frame. The system requires a constant
supply of seawater and runs from a 440-480V, 3-phase, 60 Hz power supply. The output is heated
seawater at pressures up to 68 bar and 45 litres/min.
1.2 SPECIFICATIONS
Shipping Weight 590 kg
Dry Weight 460 kg
Power Requirements 440 VAC, 3-phase, 60 Hz, 180 kW, 240 to 260 A
Input Fluid Fresh Water or Seawater
Input Pressure 3 to 10 bar
Input Flow 45 litres/min minimum
Output Pressure Up to 68 bar
Output Flow Up to 45 litres/min
Temperature Rise Control Range 0 to 50ºC (32 to 122ºF)
Temperature Control 1ºC (2ºF)

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KI-OM-6768 R0 Chapter 1
1.3 THEORY OFOPERATION
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. When all five heater circuits are on, the total rated heater output is approximately 180 kW.
The appropriate heater circuits must be selected manually according to the relative temperature rise
required. A schedule is attached to the front of the control panel door indicating the heater banks to
be used for the required temperature rise.
Example: Temperature rise through the WHE and heater bank selection
The above example shows that if a bottom temperature of 43ºC is required with a temperature drop
through the hose to the diver of 11ºC and an inlet water temperature of 5ºC. The temperature
required at the outlet of the WHE would be 54ºC. The Temperature rise through the unit would be
49ºC. The heater selection schedule shown in Table 3.1, indicates that heater banks 1 through to 5
should be used as this would provide a temperature rise of 47-50ºC through the unit.
Once the correct configuration of heater banks has been selected, the temperature controller
regulates the temperature of the outlet by adjusting the flow rate of water passing through the heater
tank. This is achieved by controlling the electric actuator on the bypass valve. The valve is
connected in such a way that it will dump water overboard to increase the flow rate through the
heater tank. A higher flow rate through the heater reduces effective temperature rise and maintains
the desired set point temperature. The temperature controller monitors temperature at the fluid
outlet manifold using a PT100 temperature sensor and adjusts the temperature control valve
position to achieve the set point temperature.
If applicable (when remote, control panel installed) switching the temperature controller input from
local to remote input allows fine control of the outlet temperature by adjustment of the potentiometer
on the remote control panel. Manipulation of the potentiometer will change the set point of the
temperature controller. Refer to the temperature controller manual in Appendix F for instructions
regarding switching between local and remote temperature set-point adjustment.
Td- Required outlet water temperature, at diver = 43ºC
T∆h- Temperature drop (Hose from deck to diver) = 11ºC
Ti- WHE Inlet water temperature is = 5ºC
To- WHE desired outlet temperature = Td+T∆h
= (43 + 11)ºC
= 54ºC
∆T - Temperature rise through the WHE = To+Ti
= (54 – 5) ºC
= 49ºC
(Use heater banks 1, 2, 3, 4 and 5)

4
Chapter 1 KI-OM-6768 R0
1.3.2 Fluid System
The WHE-03 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, and is fitted with a check valve to prevent salt water
contamination of the fresh water supply. The unit uses small immersion heater elements mounted in
the flange plates at either end of the stainless steel heater tank to heat the fluid. The flow rate of the
fluid through the heating tank is governed by the action of the bypass valve.
The flow rate of fluid from the heater tank to the divers is determined by the motor speed and the
ratio of the pulley set used to couple the motor to the pump. The pump is a positive displacement
pump and is supplied with a pulley arrangement to provide a flow rate of 45 litres/min.
The fluid to be heated enters the unit at the chosen inlet and flows through a manifold and a quarter-
turn hand valve. The manifold is equipped with analogue temperature and pressure gauges to
provide operator feedback on the fluid supply. The fluid is then piped to the fresh water inlet tee and
distributed to two separate inlet filters. The filters may be isolated using hand valves on the inlet and
outlet of each filter. These filters clean input water of particulate matter down to 50µm in order to
protect the piston pump and umbilical coupling from being damaged and prevent clogging of the
heating water tubes in the diver suits. The inlet filters are each fitted with pressure gauges in order
to monitor pressure drop across the filter and indicate the condition of the filter cartridge. A pressure
regulating valve fitted after each filter outlet ensures that fluid is supplied from filters to heater tank at
a consistent and safe pressure, (Factory setting is 2 bar).
The fluid flows through the heater tank which houses immersion heater elements where fluid is
heated. The heater tank is fitted with a pressure relief valve (PRV), set to 2.5 bar. A float switch
housed in the level control tank mounted on top of the heater tank is used to ensure the heater
elements and pump are not run without sufficient supply. If the level in the tank drops the level
switch shuts down the system. From the level control tank, the fluid is distributed to the temperature
control valve, manual temperature control valve and pump. The manual control valve controls the
process in the same way as automatic control valve and is provided to control the outlet temperature
if automatic control is inactive. The pump supply is directly coupled to the level control tank.
IMPORTANT
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. The higher capacity configuration is usually used to allow for better control.
If the bypass dump valve remains fully open during normal operation, indicating heating
over-capacity then the lower kW heater configuration should be used to improve control
and unit performance.
If the bypass valve remains fully closed during normal operation, indicating heating
under-capacity or a possible heater bank fault then a higher kW configuration should be
used to improve control.
IMPORTANT
Fluid supply to the unit by the vessel must be maintained above 45 litres/min at 3 bar for
correct operation.

5
KI-OM-6768 R0 Chapter 1
The pump is a positive displacement pump and provides consistent supply flow rate. An
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. During
normal operation, the fluid flows to the outlet via the outlet manifold. The outlet manifold is fitted
with both pressure and temperature gauges to provide operator feedback.
A complete flow diagram is provided in Appendix E - page 45.
Fig 1.1 WHE-3 Gauge Identification
1.3.3 Electrical System Overview
The WHE-03 electrical system comprises a 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.
The control circuit provides power supply to all control, indication and safety circuits.
The WHE-3 main panel operated with a 24 VDC control system. Ideally this should be supplied
directly from the WHE-3 unit, however it may utilize an independent supply if required. Terminals are
provided on the remote panel and in the WHE-3 main panel to facilitate installation and faultfinding.
DANGER
HIGH VOLTAGE – HIGH CURRENT
This is a high voltage / high current system and only trained,
competent personnel should attend to installation, service and
maintenance requirements. All relevant safety procedures must
be followed.

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Chapter 1 KI-OM-6768 R0
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. The following table shows the control structure of the heater
banks and the composition of the heater groups.
Table 1.1 Heater Component Identification
NOTE
The total heater bank capacity is the combined capacity of the related element grouping. (e.g.
Heater bank 5 = Group 5.1 +Group 5.2 = 24 kW + 24 kW = 48 kW)
The grouping of heater elements into banks allows the sequential switching of the banks, reducing
the instantaneous load on the power supply. Additionally, as heater banks have separate control
circuits and protection, the failure of any single bank of heaters will not affect the operation of the
other banks.
Bank
No. Switch No. Element Grouping No. Circuit Breaker ID Contactor ID Element Grouping
kW
Element Grouping
Composition
1 1 Heater 1.1 MCB3 C2 13.5 kW 3 x 4.5 kW Elements
2 2 Heater 2.1 MCB4 C3 13.5 kW3 3 x 4.5 kW Elements
Heater 2.2 MCB5 C4 13.5 kW3 3 x 4.5 kW Elements
3 3 Heater 3.1
Heater 3.2
MCB6 C5 25.5 kW 3 x 4.0 kW Elements and
3 x 4.5 kW Elements
Heater 3.3 MCB7 C6 13.5 kW 3 x 4.5 kW Elements
4 4 Heater 4.1
Heater 4.2
MCB8 C7 25.5 kW 3 x 4.0 kW Elements and
3 x 4.5 kW Elements
Heater 4.3
Heater 4.4
MCB9 C8 24.0 kW 3 x 4.0 kW Elements and
3 x 4.0 kW Elements
5 5 Heater 5.1
Heater 5.2
MCB10 C9 24.0 kW 3 x 4.0 kW Elements and
3 x 4.0 kW Elements
Heater 5.3
Heater 5.4
MCB11 C10 24.0 kW 3 x 4.0 kW Elements and
3 x 4.0 kW Elements

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KI-OM-6768 R0 Chapter 1
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. 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.
Several safety interlocks are incorporated into the control system which provide protection against
low fluid level in the heater tank, over-temperature and motor overload. The control circuit also
includes indication via LED’s and the controller display for operator feedback. The power and
control system wiring diagrams are detailed in the electrical schematics in Appendix C - page 43.
Refer to Table 1.2 and Fig 1.2 below for the control panel layout and part identification.
Fig 1.2 Control Panel Layout
The following table identifies the major control components, and outlines their function within the
control circuit. (Refer to wiring diagrams in Appendix C - for full wiring details).

8
Chapter 1 KI-OM-6768 R0
Component Component ID Function Description
Contactor 1 C1 Pump contactor coil
Contactor 2-10 C2-C10 Heater contactor coils
Hour Meter H1 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)
Motor On
L1 Local indication that the pump motor contactor is operational and
power is supplied to heater switches. Wired to the normally open
contact of the start switch S2NO and the auxiliary C1/1 of the
motor contactor C1.
Run Light (Green)
Motor On
L2 Remote indication that the pump motor contactor is operational
and power is supplied to heater switches. Wired to the normally
open contact of the start switch S2NO and the auxiliary C1/1 of
the motor contactor C1.
Run Light (Green)
Heater Bank On
L3-L7 Lamp indication of heater bank power on.
Fault Light (Red)
Pump Overload
L8 Lamp indicating pump fault/overload trip. Wired to contact R5/1
of relay R5.
Fault Light (Red)
Over Temperature
L9 Lamp indication of system over temperature fault wired to the
relay contact R1/2 of relay R1.
Fault Light (Red)
Low Level
L10 Lamp indicating low water level fault. This fault is linked to the
contact R2/2 of the low level relay R2.
Power On (White)
Indication
L11 Lamp indicating 24 VDC power to control circuit form the 24V
power supply.
Fuse
Transformer
Supply
F1 & F2 Fuses for short circuit protection or overload of the supply to the
power supply unit.
Fuse
Control Circuit
F3 & F4 Fuse for short circuit protection or overload of the supply from
the power supply unit to the control circuit.
Pump Overload O/L1 This overload trips if the pump draws excessive current. The
normally open contact of the overload supplies the pump run
indication. The normally closed contact of the overload is used
in the safety circuit.
Fault Relay
Over Temperature
R1 Fault relay de-energizes during fault when the over temperature
relay R3 or the thermostat contacts are open. The over
temperature relay is interlocked with its normally open R1/3
contact.

9
KI-OM-6768 R0 Chapter 1
Table 1.2 Control Component Identification
Fault Relay
Low Water Level
R2 The fault relay de-energizes during fault when the normally
closed contact on the float level de-bounce timer is open. The
timer is triggered by the normally closed contact of the float
switch. This arrangement is used to reduce nuisance faults
attributed to level switch vibration or bouncing.
The normally open contact R2/1 is used in the safety circuit to
remove power from the pump and heaters during fault.
The normally open contact R2/3 is used to interlock the relay.
To reset the fault circuit, the fault reset push button must be
pressed.
Fault Relay
(controller)
Over Temperature
R3 This relay is activated by the controller output. The normally
closed contact R3/1 of the relay is used in the over-temperature
relay R1 circuit.
Switch Push Button
Motor Start/Stop
S2 This switch is used to make and break the circuit to the motor
contactor and the heater selection switches. This is the main
start/stop switch for the unit.
Switch Rotary 2p
Heater Selection
S3-S7 The heater ON/OFF switches control the switching of power to
the coils of the respective heater contactors.
Switch
Fault Reset
S8 The fault rest switch unlatches the over-temperature and low
level fault interlocks and allows normal function.
Switch Mushroom
Emergency Stop
S9 This switch contact de-energizes the motor and heater control
circuits. The pump and heaters are switched off but the
controller and safety circuits remain energized.
Switch
Float
S10 The float switch mounted in the level control tank is used to
prevent the system function if the water level in the heater tank is
low. The contact is used to activate the de-bounce timer.
Timer T1 The de-bounce timer is used to eliminate nuisance faults due to
the bouncing of the float switch in the level control tank. The
normally closed contact T1 is used to de-energize the low level
relay R2. Timer is factory set to 2 seconds.
Component Component ID Function Description

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Chapter 1 KI-OM-6768 R0
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11
KI-OM-6768 R0 Chapter 2
CHAPTER 2 - INITIAL SET UP
CONTENTS
Page
2.1 Installation ..................................................................................................................................... 12
2.1.1 General Mounting and Unit Placement ......................................................................................... 12
2.1.2 Fluid Connections ......................................................................................................................... 12
2.1.3 Electrical Installation ..................................................................................................................... 13
2.2 Initial System Check ..................................................................................................................... 13
2.2.1 Fluid System Priming Procedure .................................................................................................. 13
2.2.2 Start Up and Function Check ........................................................................................................ 14

12
Chapter 2 KI-OM-6768 R0
2.1 INSTALLATION
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. 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 316L
stainless steel and designed to fit into a standard 19” rack mounting arrangement.
2.1.2 Fluid Connections
The WHE-03 requires both salt and fresh water supply with a minimum flow rate of 45 ltr/min at 3
bar. The recommended minimum tubing size is 1”. The fluid input connections are made by
attaching the 1″pipes to the relevant 3/4" NPT penetrators on the unit. Flexible hoses with suitable
connections may also be used to facilitate the integration of the unit into an installation. The
maximum acceptable water inlet pressure is 10 bar.
The WHE-03 outlet is a 3/4″NPT stainless steel penetrator. This may supply a valve manifold or a
single pipe connection depending on the installation requirements. The plumbing used should be
capable of withstanding the maximum working pressure of 68 bar. All valves, fittings, tubing and
manifolds connected to the hot water system must be capable of working at this pressure. If the
system is not required to deliver this pressure, the internal relief valve may be set to a lower setting,
and all the attached hot water delivery plumbing may be selected to suit this reduced pressure.
A 1” (minimum) pipe must be connected to the overboard dump fitting allowing unrestricted flow of
bypass and dumped fluid from the unit.
The 1” dump line may be connected to any water dump system that has minimal back pressure.
The volume of water being dumped during manual and/or automatic control may vary from 0 to
approximately 15 ltr/min. When the pump relief valve vents, this vented flow is added to the
temperature control bypass flow that is flowing through the overboard dump. In the event of full
restriction of the pump output line the total dumped flow through the dump line could reach 60 ltr/
min.
DANGER
DUMP LINE BLOCKAGE
To ensure safe operation of the unit the dump line must always be
open. Shutting off the dump line will compromise the system
safety and could lead to severe injury.
CAUTION
DUMP LINE RESTRICTION
To ensure correct machine operation, the dump line should never
restrict flow of dumped water.