JFD WHE - 3 User 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

KI-OM-0591 Rev 3 iii
TABLE OFCONTENTS
Page
Table Of Contents
Approval Sheet
Danger, Warning and Caution
1Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Basic Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Electrical System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Heater System and Heater Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.6 Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 General Mounting and Unit Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2 Fluid Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.3 Electrical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4 Initial System Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Start Up and Function Check – Local Control . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Start Up and Function Check – Remote Control . . . . . . . . . . . . . . . . . . . . . . 13
3 Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Heating Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Operator Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Operating Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.1 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Pump Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Pump Specific Fault Diagnosis and Maintenance . . . . . . . . . . . . . . . . . . . . . 22
5.2 General Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

iv KI-OM-0591 Rev 3
6 Part Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.1 Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Appendix A Temperature Controller Parameter Settings
Appendix B Manufacturer Related Documents
Appendix C System Drawings

KI-OM-0591 Rev 3 v
APPROVAL SHEET
Document Information
Advitium No Title Classification Rev Date
KI-OM-0591 Operation & Maintenance Manual
Water Heater Electric - WHE-3
Commercial in
Confidence
3 05/09/2017
Revision History
Rev Date BY CHK APP Comments
0 23/02/2011 Roy Carli Nick Maske Nick Maske First Issue
1 12/07/2011 Roy Carli Nick Maske Nick Maske ECN: CT00312
2 26/10/2012 Debbie Allen Vladimir Garzón Mark Stevens ECN: 14885
3 05/09/2017 JR Cusson A. Bennett P. Black ECN: 21209
Revision 3 Implemented
Responsibility Name Position
By JR Cusson Technical Author
Checked A. Bennett Mechanical Engineer
Approved P. Black Senior Mechanical Engineer
Copyright Details
© 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.
Disclaimer
Whilst every effort has been made to ensure the information within this document is correct at the time of
publication, JFD Ltd reserves the right to make changes without notification. Users are recommended to visit
www.jfdglobal.com for the most up-to-date versions of manuals.
Review
This document is subject to review and revision in accordance with ISO 9001.

vi KI-OM-0591 Rev 3
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KI-OM-0591 Rev 3 vii
DANGER, WARNING AND CAUTION
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.
INFORMS THE READER OF AN OPERATION OR STATE WITH POTENTIAL FOR
PERSONNEL INJURY.
Informs the reader of an operation or state with potential for damage to equipment.
Note Informs the user of additional information for clarification or to assist with an
operation.

viii KI-OM-0591 Rev 3
Intentionally blank

KI-OM-0591 Rev 3 1
Introduction
1 Introduction
The JFD Electric Powered Water Heating Unit, (WHE-3), has been designed and
manufactured for use in professional diving systems. The WHE-3 with Remote Control
additionally allows the remote fine control of the outlet water temperature. It allows operator
manipulation of the temperature set point on the 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. 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 Basic Description
The WHE-3 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, 3 phase, 60 Hz or 380, 3 phase,
50 Hz power supply. The output is heated seawater at pressures up to 68 bar and 45 litres/
min.
The remote control panel of the WHE-3 is a 19” rack-mounted face plate comprising the
following:
• Fine Temperature Control Potentiometer
• Water Outlet Temperature Display
• Pump Run Indication
• General Fault Indication
• Emergency Stop Push Button
The remote control panel is supplied with the remote controlled WHE-3 unit as standard,
however a remote panel may be fitted to a standard WHE-3 with minimal modifications.
Note The temperature controller used in a remote controlled version of the WHE-3
differs to that of a standard WHE-3. The remote version makes use of a controller
with control set point input and a retransmission module to accommodate the
integration of the remote control panel.
1.2 Specifications
Shipping Weight 590 kg
Dry Weight 460 kg
Power Requirements AA, AC 440 VAC, 3 phase, 60 Hz, 180 kW, 240 to 260 A
AB 380 VAC, 3 phase, 50 Hz, 180 kW, 260 to 280 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 50°C (32 to 122°F)

2KI-OM-0591 Rev 3
Introduction
Temperature Control ± 1°C (± 2°F)
1.3 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. 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.
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 water temperature Td + T∆h
= 43 + 11ºC
= 54ºC
∆T Temperature rise through the WHE To - Ti
= 54 - 5ºC
= 49ºC (Use heater banks 1, 2, 3, 4
and 5)
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, 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.
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 B for instructions regarding switching
between local and remote temperature set-point adjustment.
Notes 1 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

KI-OM-0591 Rev 3 3
Introduction
which configuration should be used. The higher capacity configuration is usually
used to allow for better control.
2 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.
3 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.
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. 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.
Note Fluid supply to the unit by the vessel must be maintained above 45 litres/min at
3 bar for correct operation.
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 50 µm 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.
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.

4KI-OM-0591 Rev 3
Introduction
A complete flow diagram is provided in Appendix C.
Figure 1 WHE-3 Gauge identification
1.4 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. The control circuit provides power supply to all control, indication and
safety circuits.
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.
The remote control panel requires cable connection to the WHE-3 unit and these connections
are detailed in the electrical drawings provided in Appendix C.
The WHE-3 main panel and remote control panel are 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.

KI-OM-0591 Rev 3 5
Introduction
1.5 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 Heater Component Identification
Note The total heater bank capacity is the combined capacity of the related element
grouping. (e.g. Heater bank 5 = Heaters H5.1, H5.2, H5.3 & H5.4 = 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.
1.6 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
Bank
No. Switch No. Element Grouping
No.
Element Group-
ing Composition Circuit Breaker
ID
Contactor
ID Element Grouping
kW
Total
Bank
kW
1 1 Heater H1.1 3 x 4.5 kW Elements MCB3 C2 13.5 13.5
2 2 Heater H2.1 3 x 4.5 kW Elements MCB4 C3 13.5 27.0
Heater H2.2 3 x 4.5 kW Elements MCB5 C4 13.5
3 3 Heater H3.1 3 x 4.0 kW Elements MCB6 C5 25.5 39.0
Heater H3.2 3 x 4.5 kW Elements
Heater H3.3 3 x 4.5 kW Elements MCB7 C6 13.5
4 4 Heater H4.1 3 x 4.0 kW Elements MCB C7 25.5 49.5
Heater H4.2 3 x 4.5 kW Elements
Heater H4.3 3 x 4.0 kW Elements MCB C8 24.0
Heater H4.4 3 x 4.0 kW Elements
5 5 Heater H5.1 3 x 4.0 kW Elements MCB10 C9 24.0 48.0
Heater H5.2 3 x 4.0 kW Elements
Heater H5.3 3 x 4.0 kW Elements MCB11 C10 24.0
Heater H5.4 3 x 4.0 kW Elements

6KI-OM-0591 Rev 3
Introduction
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. Refer to Table 2 and Figure 2 below for the control panel layout and part
identification.
Figure 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).
Table 2 Control component identification
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.

KI-OM-0591 Rev 3 7
Introduction
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.
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.
Component Component ID Function Description

8KI-OM-0591 Rev 3
Introduction
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

KI-OM-0591 Rev 3 9
Installation
2Installation
2.1 General Mounting and Unit Placement
The Electric Powered Hot Water Heating Module, WHE-3, 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 316 stainless steel and designed to fit into a standard 19” rack mounting
arrangement. The remote control is to be connected to the WHE-3 via a multi-core shielded
cable.
2.2 Fluid Connections
The WHE-3 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 relative 3/4” NPT penetrator of 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-3 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.
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.
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.

10 KI-OM-0591 Rev 3
Installation
DUMP LINE RESTRICTION
To ensure correct machine operation, the dump line should never restrict flow of
dumped water.
2.3 Electrical Installation
The electrical requirements of the system are:
ELECTRICAL SUPPLY FREQUENCY
A 380 V supply at 60 Hz may cause damage to the skid. A 440 V supply at 50 Hz whilst
not causing damage, will reduce heating capacity.
The power supply cable installed should be capable of handling 315 A as the unit is fitted with
a 315 A isolator. Supply cable should be a suitably rated armoured cable, to an approved
marine standard specification.
The mains power input to the system should be fitted to the bottom right hand side of the
stainless steel electrical enclosure. The mains power cable should be installed through a
suitable gland and correctly grounded to the armour. Mains cable connections to the isolator
terminals must be tightened and checked.
POWER CONNECTION
ENSURE THAT THE POWER SUPPLY IS TURNED OFF BEFORE CONNECTING ANY
WIRING
After the mains power cable is installed, check for acceptable grounding and continuity. Do
not start up the system until these tests have been conducted.
2.4 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.
Variant Requirements
AA, AC 440 VAC ±20 V and 60 Hz
AB 380 VAC ±20 V and 50 Hz

KI-OM-0591 Rev 3 11
Installation
2.4.1 Fluid System Priming Procedure
After the electrical and pipe work installations have been completed, purge the piping system
of air in order for the pumps to function properly and for the electric heater elements to be fully
immersed.
LOW WATER LEVEL OPERATION
The equipment may be severely damaged if heaters are supplied with power when
there is no water in the system.
Use the following procedure to correctly prime the system:
1 Open the salt or fresh water input valve slightly to allow water to flow into the system.
Water supply should be at sufficient pressure (3 bar minimum).
2 Check that all the ball valves on the filters are open.
3 With the vent valve on top of the level control tank open, leave the water supply on until
water flows out of the vent tube.
4 Close the vent valve and wait for water to flow through the pump and out of the HP
water outlet fitting.
5 Allow the water to run for 5 to 10 minutes in this mode.
6 Confirm that the heater tank is full by opening the tank vent valve to purge any residual
bubbles in the heater tank.
7 To complete priming shut the vent valve and supply valve(s).
2.5 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. Ensure that the controller is set in local control mode and carry
out all local control checks before commencing remote control checks. Refer to the
temperature controller manual in Appendix B for detail on how to switch between remote and
local operation switching.
1 Power Supply - Turn on the mains power to the unit. Input power must be as defined at
Paragraph 2.3.
FAULT INDICATION
The system will be prevented from being started if faults are indicated. Press the fault
reset button to clear any fault indication.
If fault indication is not reset or the fault recurs refer to troubleshooting for corrective
action.

12 KI-OM-0591 Rev 3
Installation
2 Pump Oil Level - Check the oil level in the pump crankcase (level with dot on sight
glass).
3 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.
Pulley rotation should be anti-clockwise when viewed from the control panel side of the
unit. Incorrect rotation may be solved by interchanging any two phases of the supply to
the motor.
4 Controller Setup and check - To power up the controller ensure that the main isolator
and all the circuit breakers are switched on. Check the controller settings before
function testing. The controller display indicates the Measured Value (PV), Set Value
(SV) and run indication for the Auto tuning (AT), Output 1 and 2 (OUT1, OUT2) and
Alarm 1 and 2 (ALM1, ALM2). The display is used during setting to show parameters
and functions.
5 Changing Set Point – In local mode the set point is changed using the controller
interface by pressing the “Set” key to enter the SV Setting Mode and modify SV (set
point) value. Change the controller set point, using the <R/S key to select the digit to be
changed and the arrow keys to change the digit. (Determine the required outlet
temperature from section 3.1).
6 Parameter Setting Mode - Refer to the controller manual in Appendix B for parameter
detail, selection and operation.
7 Fill Umbilical – Connect umbilical to HP water outlet port and open the salt water inlet
valve. Allow water to flow through the system until it flows out of the umbilical. Salt
water or fresh water may be used depending upon which is available.
8 Pump Motor Start - Push the pump Start button, the pump will start running and system
pressure will rise to balance the pressure drop down the length of umbilical. The flow
rate will be approximately 45 lit/min.
9 Pump Flow Rate - The pump is a positive displacement type and the flow rate may only
be limited by an under-supply of water to the pump. To check flow rate, use an inline
flow meter on the outlet or collect the water from the output in a container of known
volume and measure the time it takes to fill this know volume.
10 Heater Bank Selection - Determine the temperature rise required through the unit to
provide the correct temperature of fluid at the user. Use the heater selection table, (see
Table 3.1), mounted on the panel door to determine which heater banks should be
used to achieve calculated temperature rise. Switch on the required heater bank
switches sequentially. Refer to trouble shooting if any fault lights illuminate during this
operation.
11 Monitor Performance - Monitor the unit inlet and outlet temperature and the differential
temperature rise. The outlet temperature should rise until the set point is reached. As
the outlet temperature approaches the set point the controller begins to govern the
process by activating the automatic dump valve. The process should stabilize and
accurately maintain the temperature differential provided that the inlet flow and
temperature is sustained and consistent. The inlet water pressure should be a
minimum of 3 bar and should be maintained during dumping of excess hot water.
12 Filter Check - Two water filters are provided to clean inlet water. One for operation and
the other for stand-by. The pressure drop across each filter should be between
0.5 - 1 bar. Check the pressure drop after running the unit for a 4 to 5 hour settling-in
period. The filter will trap all contaminants introduced into the system during installation