pick heaters 6X7 User manual

PICK VARIABLE FLOW SERVICE MANUAL
1
INSTANTANEOUS STEAM INJECTION VARIABLE FLOW HEATER
SERVICE MANUAL

PICK VARIABLE FLOW SERVICE MANUAL
2
DO NOT DISPOSE OF THIS MANUAL
The information on the following pages will be useful after installation. Please direct this manual
to personnel responsible for the ongoing maintenance and operator of the Pick Heater.
IMPORTANT: DO NOT OPERATE THE PICK HEATER SYSTEM IN PARALLEL
WITH ANY OTHER HEATING SYSTEM, INCLUDING A SECOND PICK HEATER
SYSTEM.
CAUTION: NEVER USE HANDS OR OTHER PARTS OF THE BODY TO SEARCH
FOR WATER OR STEAM LEAKS IN THE SYSTEM. HIGH VELOCITY LIQUIDS OR
STEAM COULD PENETRATE THE SKIN AND CAUSE SERIOUS INJURY.
Any questions about the installation or operation of your Pick Heaters should be directed to your
local Pick Heater representative, or Pick Heaters at 800-233-9030. (Outside the US and Canada,
please call 262-338-1191 or Fax [phone].)

PICK VARIABLE FLOW SERVICE MANUAL
3
PICK INSTANTANEOUS STEAM INJECTION VARIABLE FLOW HEATER
INSTALLATION, START-UP AND OPERATION
Warranty……………………………...…………………………….……………………….……..3
Safety information……………...………………………………………………………….………4
Troubleshooting Tables………………………………………………………………………...5-10
Injection Tube Service …………………………………………..………………….……………11
Obtaining the Proper Cleaning Solution ………………………………………………...……….11
Cleaning…………………………………………………………………………………………..11
Heater Disassembly…………………………………………………………………...…….……13
Models 6X10 through 6X500…………………………………………..…………….….13
Model 6X7………………………………………………………………………….……13
Injection Tube Cleaning……………………………………………………………………….….14
Injection Tube Disassembly………………………………………………………………………14
Illustrations……………………………………………………………………….……..…….16-18
Reassembly/Installation of Injection Tube……………...……….………………………..……...19
Heater Reassembly……………………………………………………………………………….19
Pump Service………………………………………………………….……………………….…20
Relief Valve………………………………………………………………………………………20
Steam Control Valve……………………...………………………………………………………21
Steam Valve Opening Pressure Adjustment……………………………………………..21
Packing Gland Adjustment………………………………………………………………22
Temperature Controller Adjustment and Service………………………………………………...23
Other Troubleshooting Issues…………………………………………………………………….24
Replacement Parts...…………………………………………………………………………....…25
The Pick Heater Warranty
Every Pick heater is warranted to perform at its rated capacity when properly installed ad
maintained, and when operated under the conditions originally specified. Any change in operating
conditions, or unauthorized modifications to the equipment, will void this warranty.
Every Pick heater is warranted to be free from defective materials or workmanship for one year
following installation, or 18 months from the invoice date, whichever occurs first. Any defective
parts will be replaced FOB West Bend, WI. Please note that this warranty does not extend to
labor or installation costs involving replacement parts. Determination of repair or replacement
will be at the discretion of Pick Heaters, Inc. Pick Heaters shall not be liable for losses or delays
resulting from damaged or defective parts. This warranty does not cover damage caused by
improper installation or adjustment, or by willful neglect of specified operation and maintenance
procedures.
Equipment not manufactured by Pick Heaters, Inc. which is supplied as a component is not
covered by this warranty. However, Pick Heaters, Inc. will pass on to the purchaser any
adjustment made by the supplier of any defective equipment.
Please read these instructions completely before installing or operating your Pick Heater.

PICK VARIABLE FLOW SERVICE MANUAL
4
This symbol is placed in this manual to call attention to safety precautions for the installation and
operation of this product. Observe ALL instructions accompanied by this symbol. This symbol
means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!
Be familiar with the varying degrees of hazard represented by the signal words CAUTION and
WARNING.
CAUTION indicates a need to be aware of situations or conditions which demand greater
attention to safety practices when operating or servicing the unit.
WARNING indicates a situation demanding full attention to safety precautions due to possible
hazards.
Segments of information preceded with the word “IMPORANT” should be noted, as damage
may occur to the unit or system if detailed instructions are not followed.
Note: Most Pick Variable Flow Heaters are used to heat water. However, these units also find
extensive service in processing a water-miscible products. Installation, maintenance and
troubleshooting procedures are not affected b the nature of the liquid being heated. (To avoid
complications, this manual uses “water” to refer to any liquid or slurry being heated.)

PICK VARIABLE FLOW SERVICE MANUAL
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TROUBLESHOOTING
Pick heaters rarely require troubleshooting or repair, thanks to the simplicity of design and
operation. Many apparent difficulties with heater operation are actually the result of a problem or
adverse condition in the steam supply system, or product supply and distribution lines.
The following pages are to direct the technician through a logical approach for system
troubleshooting. General problem are shown in the header of each table. Key physical
observations are listed in the OBSERVATION column. PROBABLE CAUSE is the likely cause
of the problem and ACTION indicates the suggested operation to resolve the problem. The PAGE
column directs the technician to additional service or repaid instructions for the suggested action,
if applicable.
If you are not able to solve a problem with your heater as described in these pages, or if your
problem is not cocered in this manual, please contact your local Pick representative or call Pick
Heaters at [phone]. (Outside the US and Canada, call 262-338-1191 or Fax 262-338-
8489.)
PROBLEM: Heater will not heat liquid to the desired temperature.
OBSERVATION PROBABLE CAUSE ACTION PAGE
Insufficient supply air
pressure
Check air supply, set
filter regulator at 20 psi
Temperature controller
problem
Check temperature
controller components
and air supply. See
separate manual for
optional temperature
controller.
21
Steam control valve is
FULL CLOSED
RTD failure, or polarity on
I-to-P Transducer (+/-) may
be reversed (optional
electronic controller only)
Check wiring for loose
connections, refer to
separate manuals for
wiring diagrams.
Improper controller
calibration
Increase controller
setting and re-calibrate
21
Inadequate air pressure Check air pressure
supplied, set filter
regulator at 20 psi
I-to-P tranducer calibration
(optional)
Calibrate I-to-P per
separate manual
Steam control valve is
PARTIALLY OPEN
Steam valve actuator spring
out of adjustment
Adjust actuator per
separate manual
20
Steam control valves
is FULL OPEN
Water flow is higher than
originally specified
Reduce water flow rate
Check specifications on
heater order, compare
to actual operating
conditions

PICK VARIABLE FLOW SERVICE MANUAL
6
Steam control valves
is FULL OPEN
(continued)
Temperature rise may be
greater than originally
specified
Adjust heater operating
demand to original
specifications. Consult
factory for upgrade to a
different heater or
steam valve if demand
can’t be altered
Plugged steam strainer
basket
Remove steam line
basket, empty debris,
flush basket and re-
install
22
Deposit accumulation on
injection tube
Clean injection tube.
Contact factory for
possible alternate
materials
14
Damaged injection tube Disassemble and
inspect injection tube.
Repair injection tube or
return to Pick Heaters
for complete re-
conditioning.
12-13
Steam boiler or pressure
reducing valve (PRV) set
lower than specified
Increase steam supply
pressure at boiler or
PRV. Consult Pick
Heaters for re-sizing of
steam valve.
23
Steam boiler undersized Confirm boiler output,
and overall steam
requirements.
Steam supply valve NOT
FULL OPEN
Confirm that all steam
supply valves are open
Steam supply piping or
components are undersized
or restricted
-Check for restrictions
in steam supply piping.
-Upgrade supply pipe
size (see “Steam
Supply” section for
steam line sizing
calculations)
See
Installation
Manual
22
Water pressure is too high
Supply pressure higher than
design
Water pressure reducing
valve is set too high
-Install pressure
reducing valve
-Consult factory
-Reduce setting
23
PROBLEM: Heater will not heat liquid to the desired temperature.
OBSERVATION PROBABLE CAUSE ACTION PAGE
Pump not circulating water Inspect and repair
pump as necessary
See parts list

PICK VARIABLE FLOW SERVICE MANUAL
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Malfunction in the pump
look check valve
Inspect and repair
check valve as
necessary
Capacity of heater is
exceeded
Consult Pick Heaters
for heater upgrade
information
Faulty temperature
controller
Repair or replace
controller
21
Boiler or supply not
adequately sized to provide
enough steam to
accommodate all demands
in the steam system
Check steam supply
sizing and boiler for
pressure fluctuations
22Steam inlet pressure
varies
Steam quality may be poor
(excess condensate
entrained in system)
Install a drip leg with a
steam trap upstream of
the strainer, to maintain
high quality steam at
the heater.
See
Installation
Manual
Steam valve packing gland
too tight
Adjust steam valve
stem packing gland
21 Steam valve has a
jerky motion
Air leak in the control line -Use Soap solution to
detect any leaks
-Repair leaks or replace
line
21
Optional temperature
controller not properly tuned
*(PID Parameters)
Tune the controller per
controller manual.
Injection tube problem
Stuck piston
Plugged Orifices
Broken spring
Refer to detailed
instructions for
disassembly and
inspection of the heater
and injection tube
12-14
Air or gas trapped in a high
point of the supply or the
discharge piping creating an
unstable condition
-Bleed air from the
system
-Remove surge tank
-Install automatic air
vent valve(s) at system
high points
23
Steam valve oscillates
*PID- Proportional
Integral Derivative,
the tuning parameters
on some electronic
and pneumatic
temperature
controllers
Water and steam pressures
too close together
Check operating
pressures
Reduce water pressure
or increase steam
pressure

PICK VARIABLE FLOW SERVICE MANUAL
8
PROBLEM: Noisy Heater Operation.
OBSERVATION PROBABLE CAUSE ACTION PAGE
Air trapped in a high point
of the cold water supply or
the hot water header,
creating an unstable
condition
Bleed air from the
water system
Install automatic air
vent valve(s)
23
Distribution branches not
connected to the top of
water headers
Check connection of
distribution branches,
re-pipe if necessary
or
Add automatic air
bleeds at system high
points
23
USE-POINT control valves
opening or closing too
rapidly
-Readjust rapid-acting
control valves
-Adjust or repair valves
as necessary to allow
smooth operation
-Eliminate sources of
water pressure spikes or
upsets
Cross-connection between
the hot water line and
another water line
-Visually trace all lines
to locate possible cross-
connections
-Eliminate the cross-
connection with
installation of check
valves or other valving
Water and steam pressures
too close together
-Check operating
pressures
-Reduce water pressure
or increase steam
pressure
23
Unstable water pressure
valve in system
-Observe operation of
all valves with steam to
the heater turned off
-Adjust or replace
faulty valves as
necessary
Shock absorber or pulsation
dampener device in the
system
Remove all shock
absorber devices (surge
tank)
Continued next page
Supply water pressure may
be unstable
-With steam off,
inspect water supply
system or pressure, and
correct as necessary
-Install water pressure
control valve if
required

PICK VARIABLE FLOW SERVICE MANUAL
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Steam quality may be poor
(excess condensate
entrained in steam
-Examine the steam
system, correcting any
deficiencies
-Install a drip leg with
steam trap, upstream of
the strainer, to maintain
high quality steam at
the heater
See
installation
manual
Steam control valve
positioned less than 20%
open (operating below
minimum turndown)
Check steam valve
travel when operating.
Valve must be open
more than 20% open.
Consult Pick Heaters
about a smaller or dual
steam valve
arrangement
21
Steam control valve moves
too fast (only with non-
standard or faulty
temperature controller)
The temperature
controller should be
tuned to allow 7-10
seconds for full valve
travel
Injection tube problem Refer to detailed
instructions for
disassembly and
inspection of the heater
and injection tube.
Replace piston, spring
or injection tube if
required
11-13
Crack or hole in steam flow Repair or replace inlet
house.
CONSULT FACTORY
Steam control valve moves
too fast due to use of valve
positioner(s)
Remove valve
positioner(s)
Steam valve opening
pressure out of adjustment
Adjust valve according
to steam valve
instruction manual
20
Valve packing gland too
tight
Adjust packing gland
according to valve
manual
21
Unstable steam pressure
reducing valve upstream of
the system
Examine reducing
valve, repair or replace
if necessary

PICK VARIABLE FLOW SERVICE MANUAL
10
PROBLEM: Low Water Flow Rate
OBSERVATION PROBABLE CAUSE ACTION PAGE
Supply failure from the
water source
Examine water supply
system, correct all
problems
Broken or plugged pipe
fittings, including check
valves, gate valves, strainer,
etc.
Inspect water supply
lines, replace plugged
or faulty components
Clean water strainer
basket (if applicable)
PROBLEM: Overheated water or steam discharge
OBSERVATION PROBABLE CAUSE ACTION PAGE
Temperature controller set
too high during initial setup,
or during a previous
operating session
Reset controller to the
desired temperature
-See installation
manual for calibration
procedure
Air pressure supplied to the
temperature controller too
high
Reset air pressure to 20
psi
Relief valve not functioning
properly
Inspect adjust or repair
as necessary
19-20
Particularly after
extended heater
shutdown
Lead in the steam control
valve
Inspect and repair as
necessary
20
PROBLEM: Temperature indicator doesn’t agree with controller setting
OBSERVATION PROBABLE CAUSE ACTION PAGE
Water temperature is
stable and satisfactory
Temperature controller not
properly calibrated
Re-calibrate
temperature controller
(See separate manual
for optional controllers)
21
PROBLEM: Discolored Water
OBSERVATION PROBABLE CAUSE ACTION PAGE
Problem in the supply water
system
Inspect water lines,
correct any deficiencies
Galvanic corrosion due to
dissimilar metals (between
heater and system piping)
Install dielectric unions
at all connections
between the heater and
copper piping
23
Problem in the steam supply
system
Examine the steam
supply system, correct
any deficiencies