Spirax Sarco SpiraHeat User manual

IM-P661-02-US TES Issue 2 1
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Fault finding
6. Maintenance
© Copyright 2019
Printed in US
Spirax SpiraHeatTM Heating System
Process Controller Based
Compact Heat Transfer System
Installation and Maintenance Instructions
IM-P661-02-US
TES Issue 2

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Copyright © Spirax-Sarco Limited 2019
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.

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In addition to putting your personnel at risk of death or serious harm, failure to
comply with the instructions, recommendations and guidance set out in this document
may jeopardise your warranty rights. Further, use of the product(s) otherwise than
in accordance with this document will be undertaken entirely at your own risk. To
the fullest extent legally permitted, Spirax Sarco excludes all responsibility and
liability for any and all loss or damage caused in the event that the practices and
procedures detailed in this document have not been followed.
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 mechanical installation and commissioning of the
Spirax SpiraHeatTM packaged heat exchange system and should be used in conjunction with
the relevant IMIs for the other system components and supplementary safety information
for all the system components.
Warning - Lifting
The Spirax SpiraHeatTM unit should be lifted by a suitable forklift truck, from the base, placed
in position and securely bolted to the floor.
On no account is the Spirax SpiraHeatTM unit to be lifted by any other part, other than the
base.
Note: Sufficient space should be provided around the systems location to allow access for
maintenance.
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. Before any installation or maintenance procedure, always ensure that all primary steam
and condensate return lines and secondary water lines are isolated.
4. Ensure any residual internal pressure in the system or connecting pipework is carefully
relieved.
5. Allow hot parts to cool before commencing work, to avoid the risk of burns.
6. Always wear appropriate safety clothing before carrying out any installation or
maintenance work.
7. This product is not fitted with a high limit temperature or pressure switch. In the event
of a failure of the control system or components within the product, secondary side
water could be heated to temperatures above the set point. The risks associated with
this should be assessed during installation as part of the system’s integration. The hot
water system into which this product is installed should have appropriate safety systems
installed to mitigate any risk.
An independent high limit temperature safety device should be integral to the overall
system into which the SpiraHeat is installed. Electrical provisions have been made for
an appropriate control device to be connected to the product should this be required,
please see Section 3.5.
1. Safety information

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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
over-pressure or over-temperature 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.
1.5 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.

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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 and
consider whether protective clothing (including safety glasses) are required.
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.
1.13 Residual hazards
In normal use the external surface of the product may be very hot. If used at the maximum
permitted operating conditions the surface temperature of these products may reach
temperatures of 392°F (200°C).
These products are not self-draining. Take due care when working around, dismantling or
removing the product from an installation (refer to ‘Maintenance instructions’).

D
B
A
C
2.1 Description
The Spirax SpiraHeatTM system uses steam to provide accurate heating of low temperature hot water
for processes and heating. Systems are supplied fully assembled, configured and pressure tested
ready for installation.
2. General product information
The Spirax SpiraHeatTM unit consists of the following core items (refer to Figure 1 and 2):
A Heat exchanger.
BPneumatic or electrically actuated control valve and positioner.
C Process controller (available without, see section 2.3).
D Steam isolation valve (optional on steam side control).
Fig. 1
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2.2 Operating conditions
Operating ambient temperature 32°F to 131°F (0°C to 55°C)
Relative humidity 5 to 85% non-condensing
Atmosphere Not suitable for use above 6500ft or in explosive or corrosive atmospheres
IP rating IP54*
*Excluding some 'EL' option systems which are reduced to IP31
2.3 How to order
All systems are designed for the required heat load with controls to suit the application. The best
way of ensuring that we have all the necessary information for quotation and manufacture is to
contact your local Spirax supplier who will size the appropriate SpiraHeatTM.
Fig. 2
B
A
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3.1 Steam and condensate connections
It is important that the steam supply (and compressed air if pneumatic actuation is selected) to
the Spirax SpiraHeatTM unit is supplied as dry and as clean as possible, in accordance with good
steam engineering practice.
It should also be ensured that all connecting pipework is stress free and adequately supported.
The steam supply should always be maintained at the specified design pressure and temperature for
the unit. The Spirax SpiraHeatTM must not operate above the maximum steam pressure and temperature
indicated on the name-plate attached to the plate heat exchanger.
The installation of an appropriately sized safety valve, to protect any lower pressured equipment on
either the hot or cold side of the plate heat exchanger, is strongly recommended.
Spirax Sarco supplies a range of traps, strainers, separators, safety valves and pressure reducing
equipment.
3.2 Air supply
If a pneumatic control system is installed, connect a compressed air supply 20 to 85 psi g (1.4 to 6.0 bar g)
to the pressure regulator mounted on the control valve.
3.3 Electrical supply
All electrical wiring and connections should be carried out in accordance with National Regulations.
A means to isolate and lock the incoming power supply should be fitted adjacent to the unit.
Mains supply is directly connected to the primary side of the incoming control panel isolator and main
ground terminal as shown in Figure 4.
3. Installation
Fig. 4
Phase connection Neutral connection Ground connection
Q1
16A
PE
3L2 5L21L2
4T2 6T32T1

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3.4 Electrical specifications
Electrical supply: Refer to the name-plate on the unit
Control panel supply voltage
115 Vac/60 Hz
230 Vac/50 Hz
Control panel load requirements Internally fused at 5 amps
Electrical control actuator (output)
24 Vac
4 - 20 mA control
Pneumatic control actuator
-
4 - 20 mA control
High limit isolation valve (output) 24 Vac
PT100 temperature sensors 3 wire
3.5 Electrical connections
The following are available for customer connection to the Spirax SpiraHeatTM system if required:
Volt free contacts
Terminal designation Description Type
X4 External temperature/pressure limits 1 x N/C contact
X5 External temperature/pressure limits 1 x N/C contact
X6 External temperature/pressure limits 1 x N/C contact
X7 External temperature/pressure limits 1 x N/C contact
LIMIT SWITCHES' CONNECTIONS
IF FITTED REMOVE THE LINKS/BRIDGES
Fig. 5

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We strongly 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 SpiraHeatTM is isolated.
- Double check that all steam, condensate and water connections are correctly connected to
the Spirax SpiraHeatTM.
- Check all flange bolts are tight.
4.1 Mechanical commissioning procedure:
- Check that all of the electrical connections
are secure and as per the wiring diagram
(Section 3.3, Figure 4).
- Dry commissioning valve stroke check - An
initial valve stroke check should be carried out
to ensure free movement of the valve stem.
1. For the electric actuated control valve, use
the manual override on top of the actuator
to raise and lower the actuator spindle
between the two travel indicators located
on the side of the pillar (Figure 6). Siemens
electric valves can be manually opened
by pressing and turning the handwheel
clockwise.
2. For the pneumatic actuated control valve,
remove the existing air supply and connect
an independent air supply to the actuator
(pressure not to exceed 85 psi g (6 bar g),
allow the valve to fully open, remove the air
supply from the actuator allowing the valve
to close. Reconnect the original pipework
(Figure 7).
- Open the secondary (cold side) isolating
valves downstream of the Spirax SpiraHeatTM.
- Start the main secondary water circulating
pump(s), if tted.
- Check and conrm there is secondary water
circulation through the Spirax SpiraHeatTM.
- Once circulation is conrmed, switch on
the main power to the control panel (local
isolator).
- Turn the control panel isolation switch to ‘ON’.
4. Commissioning
Travel
indicator
Handwheel
Travel
indicator
Air inlet
Fig. 6
Fig. 7

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4.2 EPC3008 commissioning
The EPC3008 is factory set to the correct conguration required for the Spirax SpiraHeatTM. Please
refer to the EPC3008 installation manual for detailed instructions and congurations.
4.2.1. Equipment and software requirements
4.2.1.1. CPI Clip-on connector and driver
The CPI Clip-on connector must be purchased separately to the controller. It has the following order
code: “ITOOLS/NONE/USB/////XXXXX”.
Fig. 8 CPI Clip-on connector
To be able to use the CPI Clip-on connector its driver must be installed. The driver can be downloaded
by navigating to the link: https://www.eurotherm.com/usbcpi
4.2.1.2. EPC3008 controller
Make sure that the controller has the right hardware configuration by comparing the code on its left
side with the following order code:
“EPC3008 CC/VH/R2/D1/XX/XX/XX/E4/BS/XX/XXX/ST/XXXXX/XXXXXX”.
Fig. 9 Order code of the EPC3008 controller

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4.2.1.3. Software – iTools software package
To communicate with the EPC3008, the iTools software package from Eurotherm has to be downloaded
and installed on a PC. It can be downloaded from the link below:
https://www.eurotherm.com/products/temperature-controllers/config-software/eurotherm-itools
4.2.2. Communicating with the controller using the CPI Clip-on connector
4.2.2.1. Connect the EPC3008 to the PC using the CPI clip-on USB cable. The clip-on port is located
on the bottom left side of the controller. To access it the bottom plastic holder has to be
removed.
Fig. 10 Plastic holder to be removed
Fig. 11 Connection point of the CPI Clip-on connector

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Fig. 12 Controller with connected clip-on connector
4.2.2.2. When you connect the cable to the controller it should power up. Open the iClone software
and select scan from the toolbar.
Fig. 13. iClone software icon
Fig. 14 Scan button in the iClone interface

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4.2.2.3. The enable background scan window will appear. Set it up as follows and click OK.
Fig. 15 Enable background Scan
4.2.2.4. A connection with the controller should be established and the controller’s ID should appear
in the main window of iClone.
Fig. 16 iClone interface with connected controller

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4.2.3. Uploading the software configuration using iClone
To configure the EPC3008 controller, obtain the latest .uic configuration file for SpiraHeat heating
from your local Spirax Sarco branch.
After following the instructions in section 4, follow the steps below in order to upload the configuration
file:
4.2.3.1. Select Load from the main toolbar and navigate to the .uic file on your PC.
Fig. 17 Opening the configuration file
4.2.3.2. Acknowledge the warning and make sure that controller is disconnected from all of its
processes. Then click Yes to start the upload.
Fig. 18 Warning confirmation
4.2.3.3. The upload file pop-up window will be visible with a message log. A correct file transfer to
the controller will be confirmed by the message below:

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Fig. 19 Successful file upload
4.2.3.4. Close the log and iClone interface. The controller is now ready to use.
Note: The controller’s parameters have to be adjusted further depending on the system’s behaviour
during commissioning. This software is an initial configuration file.
4.2.4. General operation
To set other settings through controller’s control panel if necessary, follow the user guide provided
for EPC3008 from the page below:
https://www.eurotherm.com/products/temperature-controllers/single-loop/epc3000-programmable-
controllers
4.3. Timers settings
The T1 timer starts when the SpiraHeatTM is set to run. The T1 timer relay opens the main isolation
valve prior to starting the EPC3008 controller. This allows the control valve to warm up and reduces
the risk of water hammer.
T1 must be set to a value below T2. By default this is set to 50 seconds.
The T2 timer starts when the SpiraHeatTM is set to run. The EPC3008 will close the isolation valve
when the control signal to the control valve is below the Alarm Control Point, A1.HI (default 1%). The
T2 timer relay allows the control valve to open over the Alarm Control Point before returning control
of the isolation valve to the EPC3008.
T2 must be set to a value above T1. By default this is set to 60 seconds.

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Fault Possible cause Remedial action
Unit does not power up
Loss of incoming supply Check incoming supply
Internal circuit breaker tripped Check Q2
Loss of 24 Vac Internal fuse blown Check fuse F1
PT100 signal not
reading correctly
Field wiring fault Check termination of 3 wire PT100
terminals and PT100 head
Faulty PT100 Check compensated resistance
No hot water
Isolation valve failed closed Refer to the IMI for the isolation
valve and actuator
Control valve failed closed Refer to the IMI for the control
valve and actuator
Steam trap failed closed Refer to the IMI for the steam trap
5. Fault finding

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Note: Before starting any maintenance observe the 'Safety information' in Section 1.
6.1 General
For maintenance of the individual components that make up the system, please see the relevant
product specific IMIs for the components concerned.
6.2 Scale formulation
Within open systems, where there is continual make-up water, there is a risk of scale formation. The
extent of the scale will depend largely upon the water quality, which varies greatly from area to area.
A test, conducted by a water treatment specialist, is recommended to determine the local water quality
and whether problems are foreseen.
After extended service, the heat exchanger should be inspected for cleaning. If scale becomes a
persistent problem, regular chemical cleaning should be considered.
6. Maintenance

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