Spirax Sarco Universal Lite Control Panel User manual

IM-P481-15 CTLS Issue 3 1
Universal Lite Control Panel incorporating SIMSTM
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Fault finding
6. Maintenance
Universal Lite Control Panel
incorporating SIMSTM
Installation and Maintenance Instructions
IM-P481-15
CTLS Issue 3
© Copyright 2020
Printed in GB

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IM-P481-15 CTLS Issue 3
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Universal Lite Control Panel incorporating SIMSTM
Copyright © Spirax-Sarco Limited 2020
All rights reserved
Spirax-Sarco Limited grants the legal user of this product (or device) the right to use the
Work(s) solely within the scope of the legitimate operation of the product (or device). No
other right is granted under this licence. In particular and without prejudice to the generality
of the foregoing, the Work(s) may not be used, sold, licensed, transferred, copied or
reproduced in whole or in part or in any manner or form other than as expressly granted
here without the prior written consent of Spirax-Sarco Limited.

IM-P481-15 CTLS Issue 3 3
Universal Lite Control Panel incorporating SIMSTM
Safe operation of this product can only be guaranteed if it is properly installed, commissioned,
used and maintained by qualified personnel (see Section 1.11) in compliance with the operating
instructions. General installation and safety instructions for pipeline and plant construction, as
well as the proper use of tools and safety equipment must also be complied with.
Note: This document refers only to the electrical connection and operation of the control system
within the Universal Lite control panel. Please refer to the relevant IMIs for the systems components
and supplementary safety information.
Warnings - General:
1. This product is designed and constructed to withstand the forces encountered during normal
use.
2. Use of the product for any purpose other than its intended use could cause damage to the
product and may cause injury or fatality to personnel.
3. Always wear appropriate safety clothing before carrying out any installation or maintenance
work.
1.1 Intended use
Referring to the Installation and Maintenance Instructions, name-plate and Technical Information
Sheet, check that the product is suitable for the intended use/application.
i) The product has been specifically designed for use on steam or water/condensate. The
products’ use on other fluids may be possible but, if this is contemplated, Spirax Sarco should
be contacted to confirm the suitability of the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and minimum values.
If the maximum operating limits of the product are lower than those of the system in which it
is being fitted, or if malfunction of the product could result in a dangerous overpressure or
overtemperature occurrence, ensure a safety device is included in the system to prevent such
over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be induced by
any system to which they are fitted. It is the responsibility of the installer to consider these
stresses and take adequate precautions to minimise them.
v) Remove protection covers from all connections and protective film from all name-plates, where
appropriate, before installation on steam or other high temperature applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1. Safety information

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Universal Lite Control Panel incorporating SIMSTM
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases, extremes of
temperature, hot surfaces, fire hazard (e.g. during welding), excessive noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed action (e.g.
closing isolation valves, electrical isolation) put any other part of the system or any personnel
at risk?
Dangers might include isolation of vents or protective devices or the rendering ineffective of
controls or alarms. Ensure isolation valves are turned on and off in a gradual way to avoid system
shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure. Consider double
isolation (double block and bleed) and the locking or labelling of closed valves. Do not assume
that the system has depressurised even when the pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns.
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and/or consumables available. Use only
genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and/or others in the vicinity require any protective clothing to protect against
the hazards of, for example, chemicals, high/low temperature, radiation, noise, falling objects, and
dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.Installation and
operating personnel should be trained in the correct use of the product according to the Installation
and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where there is no such
system, it is recommended that a responsible person should know what work is going on and, where
necessary, arrange to have an assistant whose primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting, pushing,
pulling, carrying or supporting a load by bodily force can cause injury particularly to the back.
You are advised to assess the risks taking into account the task, the individual, the load and the
working environment and use the appropriate handling method depending on the circumstances
of the work being done.
Please note that if lifting straps are required we would recommend that they be fitted around the
baffle plate legs to prevent damage to the unit.
1.13 Transport
Transportation and storage temperatures within a range of –25 °C to +55 °C and for short periods
not exceeding 24 h at up to +70 °C. Suitable means shall be provided to prevent damage from
humidity, vibration, and shock.

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Universal Lite Control Panel incorporating SIMSTM
2.1 General information
The Universal Lite Control panel has built in flexibility to be fitted to any heating (HTG) or domestic hot water
package (DHW) utilising a selection of different heat exchanger technologies.
The flexibility offered by the control panel includes steam side control, condensate control and bypass
options. With advance control logic that can suit packages for retro-fit or new designs.
The Spirax Package shown below is fitted with a plate and frame heat exchanger
as an example (refer to Figure 1):
APlate heat exchanger.
BPneumatic or electrically actuated control valve and positioner.
CUniversal Lite Control panel.
DPipeline ancillaries.
Fig. 1 DHW heat transfer solution
Notes:
1. For additional information about any particular product used in the construction of this unit see the
relevent product specic Technical Information (TI) sheet.
A
B
DC
2. General product information

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Universal Lite Control Panel incorporating SIMSTM
3.1 Electrical supply
All electrical wiring and connections should be carried out in accordance with National Regulations.
A lockable isolator/switch disconnect should be fitted adjacent to the unit.
Mains supply is directly connected to the primary side of the incoming control panel isolator and main earth
terminal.
3.2 Electrical specifications
Electrical supply: Refer to the name-plate on the unit
Control panel supply voltage
100 - 240 Vac
50 - 60 Hz
Control panel load requirements Internally fused at 5 amps
Electrical control actuator
24 Vdc (Asia)
240 Vac (Korea)
4 - 20 mA control
Pneumatic control actuator 4 - 20 mA control
High Limit isolation valve (optional)
24 Vdc (Asia)
240 Vac (Korea)
Steam flowmeter TVA (optional) 4 - 20 mA control
Temperature sensor 4 - 20 mA 2 wire
Ambient temperature 0 °C (32 °F) - 50 °C (122 °F)
IP rating IP54
3. Installation

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Universal Lite Control Panel incorporating SIMSTM
Fig. 2
Phase connection Neutral connection Earth connection
Q1
16A
PE
3L2 5L21L2
4T2 6T32T1
3.3 Electrical connections
The following are available for customer connection to the Spirax EasiHeat™ system if required:
Volt free contacts
Terminal Designation Description Type
X2 Enabled/Running Signal
1x N/O Contact
1x N/C Contact
X3 Volt Free High Limit Alarm
1x N/O Contact
1x N/C Contact
X4 Volt Free Common Alarm
1x N/O Contact
1x N/C Contact
Remote operation and re-transmission connections
Terminal Designation Description Type
X15
Remote Set Point
(Not Available if
EHHCC +Bypass)
4-20 mA Input
X5 Remote Enable 24 V dc Signal
X17 Retransmission Valve 4-20 mA Output

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Universal Lite Control Panel incorporating SIMSTM
-XC1
-Q1
OT16F3
-Q1
-K1
-K2
-K3
-K4
-K5
-K6
-K7
-X1
-X2
-X3
-X4
-X5
-X6
-X7
-X8
-X9
-X10
-X11
-X12
-X13
-X14
-X15
-X16
-X17
-0 -0 -0 -0
-OF7 -OF6 -OF5 -OF4 -OF3 -OF2 -OF1
-F4 -F3 -F2 -F1
-N3 -N4
-PSU
CPE-24 / 2.5
FAN
FILTER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Fig. 3
3.4.1 Terminal layout detailed
Note: for detailed wiring schematic options please refer to the wiring diagrams supplied with the control panel.
1. Asia
2. Korea
1X1 – Supply for Bypass Pump
X1 - Bypass Pump for EHD
3.4 Terminal layout overview
1
FILTER
FAN

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Universal Lite Control Panel incorporating SIMSTM
2
Group X2 to X5 – Volt Free
X2
X3
X4
X5
- Enabled/Running Signal
- Volt Free High Limit Alarm
- Volt Free Common Alarm
- Remote System Enable
3
Group X6 to X9 – Valve Controls
X6
X7
X8
X9
- EHD Bypass Valve (Mains AC for Korea, 24 V dc For Asia)
- High Limit Valve (Mains AC for Korea, 24 V dc For Asia)
- High Limit Valve Supply (Mains AC for Korea, 24 V dc For Asia)
- Linear Actuator Supply (Mains AC for Korea, 24 V dc For Asia)
-XC1
-Q1
OT16F3
-Q1
-K1
-K2
-K3
-K4
-K5
-K6
-K7
-X1
-X2
-X3
-X4
-X5
-X6
-X7
-X8
-X9
-X10
-X11
-X12
-X13
-X14
-X15
-X16
-X17
-0 -0 -0 -0
-OF7 -OF6 -OF5 -OF4 -OF3 -OF2 -OF1
-F4 -F3 -F2 -F1
-N3 -N4
-PSU
CPE-24 / 2.5
FAN
FILTER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Fig. 4
2
3
2
3.4 Terminal layout overview (continued)
FILTER
FAN

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Universal Lite Control Panel incorporating SIMSTM
-XC1
-Q1
OT16F3
-Q1
-K1
-K2
-K3
-K4
-K5
-K6
-K7
-X1
-X2
-X3
-X4
-X5
-X6
-X7
-X8
-X9
-X10
-X11
-X12
-X13
-X14
-X15
-X16
-X17
-0 -0 -0 -0
-OF7 -OF6 -OF5 -OF4 -OF3 -OF2 -OF1
-F4 -F3 -F2 -F1
-N3 -N4
-PSU
CPE-24 / 2.5
FAN
FILTER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Fig. 5
45
5
6
4
Group X10 to X11 - Digital Inputs
X10
X11
- Linear actuator closed signal
- High Limit Valve Battery Healthy (Valves Only)
5
Group X12 to X15 - Analog Inputs
X12
X13
X14
X15
- T1 – Return Water Temperature
- T2 – Output Water Temperature
- T4 – Condensate Temperature/Pre-Blended Water Temperature
- Remote Setpoint/T6 – Pre Blended Water Temperature
6
Group X16 to X17 – Analog Outputs
X16
X17
- Linear Actuator Request Position
- Re-Transmission Of PV
3.4 Terminal layout overview (continued)
FILTER
FAN

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Universal Lite Control Panel incorporating SIMSTM
We recommend that you use the service and support of a Spirax Sarco commissioning engineer. Details of
this service can be found by contacting Spirax Sarco.
Note: Pre commissioning requirements:
- In most new installations, dirt collects in the steam pipeline during construction of the system. It is
essential to flush this out prior to commissioning.
- Ensure the secondary (cold side) of the system is charged and all air is bled from the system.
- Ensure that all main isolation valves for both steam and water are isolated.
- Ensure that the electrical supply to the Spirax EasiHeatTM is isolated.
- Double check that all steam, condensate and water connections are correctly connected to the
Spirax EasiHeatTM.
- Check all flange bolts are tight.
4. Commissioning

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Universal Lite Control Panel incorporating SIMSTM
Once you touch the screen for the first time this will move you Language selection screen with flag selection.
After making a selection proceed to the next screen using the arrow symbol in the bottom right hand side
of the screen.
By choosing the relevant flag for your Country the common default engineering units and language will
automatically be selected for that region. These values can be changed after the initial commissioning set-
up procedure has been completed.
4.1 HMI quick start commissioning procedure:
The HMI display is a 7" touch screen, and the following procedures detail a basic set-up of the control system
from initial power up. For a more detailed commissioning need then contact Spirax Sarco.
Fig. 8
Fig. 9

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Universal Lite Control Panel incorporating SIMSTM
Fig. 10
Fig. 11
The next screen (Figure 12) requires confirmation of the heat exchanger installed.

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Universal Lite Control Panel incorporating SIMSTM
Fig. 12
Select the appropriate heat exchanger as installed on the package. The selection shall be confirmed by the
icon becoming highlighted with a red surround and a continue button shall be revealed.
Press the continue button to advance to the system configuration menu.
Fig. 13
System configuration is required on this page. Selections are highlighted by a red surround to the icons.

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Universal Lite Control Panel incorporating SIMSTM
Fig. 14
System configuration should match the mechanical configuration of the package and control system of the
plant, proper configuration will show or hide options available after configuration. Some of the screens may
contain additional options which with specified configuration may be hidden; all the options are described
in this document.

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Universal Lite Control Panel incorporating SIMSTM
Spirax heat exchange package mechanical and control system configuration options are detailed as follows:
Fig. 15 High Limit Selection
Not Installed PLC Controlled
Fig. 16 ¼ turn actuator selection
BVA PSA VALPES Dump valve
Fig. 17 Linear actuator selection
Electrical Pneumatic
Fig. 18 Enable control selection
Local Remote Modbus
Fig. 19 PID Set point selection
Local Remote Modbus

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Universal Lite Control Panel incorporating SIMSTM
4.2 Global navigation buttons
!
Home
mimic
PID set
points
Settings
menu
Alarms
menu
Historical
trends
Service
menu
4.2.1 Home mimic
This button will always navigate you back to the overview of the Spirax package system that has been
selected and configured.
From this home screen the overall status and control of the Spirax package systems operation can be
performed, depending on the security level access.
Fig. 20

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Universal Lite Control Panel incorporating SIMSTM
Images shown below are dialogue pages that are only available for engineers access (level 2), which allow
control over the valves and pumps, it is possible to enter those dialogs by pressing the screen surface
at one of the unit devices (valves or pump). We are able to set the operation mode AUTO or MANUAL in
which we are able to start/stop the pump or open/close the valves.
Fig. 21
Automatic mode
Manual mode
The light indicator shows what mode is selected.
V1 dialogue page contains two value fields, the top one shows the actual valve position, and the bottom one
can be used to move the valve to requested position in manual mode.
Open/Start
Close/Stop

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Universal Lite Control Panel incorporating SIMSTM
PID set point
Fig. 22
Local temperature set point
MODBUS temperature set point
(DHW or SRDHW only) remote
Ramp-up temperature set point
Ramp-down temperature set point

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Universal Lite Control Panel incorporating SIMSTM
Fig. 23
If a bypass system is supplied then there are two set points required to ensure accurate temperature control.