Spirax Sarco EasiHeat User manual

IM-P481-10-US 9/2017 1
1. Safety information
2. General product
information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
© Copyright 2017
Printed in USA
IM-P481-10-US September 2017
Spirax EasiHeat TM
HTG Steam Side Control Water Heating
Compact Heat Transfer Solution
Installation and Maintenance Instructions

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2
Copyright © Spirax-Sarco Limited 2017
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 EasiHeat TM 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 EasiHeat 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 EasiHeat TM 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.
1. Safety information

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Warning - Anti-legionella cycle:
The temperature set-point during the anti-legionella cycle will exceed normal
operating temperatures and could cause scalding if water is used during the cycle.
The cycle should only be initiated when it is safe to do so.
There must also be water drained from the circuit at the end of the cycle to assist in
reducing the water temperature.
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 lm 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.

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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.
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.
Warning: The temperature set-point during the anti-legionella cycle will exceed
normal operating temperatures and could cause scalding if water is used during the
cycle. The cycle should only be initiated when it is safe to do so.
The water must also be drawn from the system at the end of the cycle to assist in
reducing the water temperature trapped within the system.
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.

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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.

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2.1 General information
The Spirax EasiHeat HTG system uses steam to provide accurate heating of potable hot
water or hot water for processes. Systems are supplied fully assembled and pressure
tested ready for installation. and are supplied fully assembled and pressure tested ready
for installation.
The Spirax EasiHeat HTG unit consists of the following core items
(refer to Figure 1):
APlate heat exchanger.
BPneumatic or electrically actuated control valve and positioner.
CPLC controller.
DHigh limit isolation valve.
ECondensate removal.
2. General product information
Fig. 1
Spirax EasiHeat HTG TM 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.
2. For further technical information regarding the Spirax EasiHeat HTG see the Technical
Information sheet TI-P481-11.
A
B
D
C
E

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Spirax EasiHeat™ Heating Steam Side Control nomenclature
Compulsory
selection
Building
heating unit
EHHSC =Spirax EasiHeat™ Heating
Steam Side Control EHHSC
Control
valve size
1
1.2
2
2.2
3
3.2
4
5
6
=
=
=
=
=
=
=
=
=
1" reduced trim
Split range: 1" reduced trim & 1"
1"
Split range: 1" & 1½"
1½"
Split range: 1½" & 2"
2"
2½"
3"
2
Trim option L=Low Noise L
Pressure
vessel code A=ASME A
Actuation
EL4
EL3
PN
=
=
=
Electric (SIMS)
Electric (SX90)
Pneumatic
EL4
Condensate
removal
PT
PTHC
ST
=
=
=
Pump trap
Pump trap high capicity
Steam trap
PT
High limit HL
IHL
=
=
High limit (SIMS)
High limit (SX90) HL
Mechanical
options
High limit
actuation EL
only
B=Battery back-up B
Manual
isolation
valve
V1
V2
=
=
Ball valve
Gate valve V1
Gasket
material G1 =EPDM G1
Extras W=Wheels W

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Panel
options
Panel type
T6
P2
=
=
110V UL SIMS TOUCH
SCREEN
110V UL PROCESS
CONTROLLER
T6
Energy
monitoring E=With energy monitoring E
Remote
access
R1
R2
R3
=
=
=
Level 1 - SMS Text and E-mail
Level 2 - 3G web access
Level 3 - Both of the above
(R1+R2)
R2
Communication options
C1
C2
*C3
C4
C5
*C6
C7
=
=
=
=
=
=
=
Modbus RTU
BACnet MS/TP (RS485)
Modbus TCP/IP (Client)
Profinet
CanOPEN
BACnet TCP/IP (Client)
Profibus RS485
C2
Options
O1
O2
O3
=
=
=
Selected option 1
Selected option 2
Selected option 3
O1
* Note: not available when panel options R2 or R3 selected
How to order example
EHHSC 2 L A EL4 PT -HL BV1 G1 W - T6 ER2 C1 O1

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3. Installation
3.1 Steam and condensate connections
It is impor tant that the steam supply (and compressed air if pneumatic actuation is selected)
to the Spirax EasiHeat TM 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 EasiHeat TM 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 (65 to 116 psi 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 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
(shown with the IP2X cover removed) and main ground terminal as shown in Figure 2.
Fig. 2
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
110 Vac / 60 Hz
240 Vac / 50 Hz
Control panel load requirements Internally fused at 5 amps
Electrical control actuator
24 Vac
4 - 20 mA control
Pneumatic control actuator
-
4 - 20 mA control
High limit isolation valve 24 Vac
PT100 temperature sensors 3 wire
Note: Power supply 10 - 16 A
3.5 Electrical connections
The following are available for customer connection to the Spirax EasiHeat system if
required:
Volt free contacts
Terminal designation Description Type
X14 Enabled / running signal
1 x N/O contact
1 x N/C contact
X15 High Limit alarm
1 x N/O contact
1 x N/C contact
X16 Band Alarm
1 x N/O contact
1 x N/C contact
Fig. 3 VOLT F REE
ENABLE SIGNAL
K1
/ 7.2
ENABLE
REL AY
21
K2
/ 7.3
HIGH
LIMIT
REL AY
K3
/ 7.4
BAND
REL AY
24 22
21 3 21 3 21 3
131
132
133
141
142
143
151
152
153
21
24 22
11
14 12
VOLT F REE
HIGH LIMIT ALARM
VOLT F REE
BAND ALARM
X15 X16X14

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Remote operation and retransmission connections
Terminal designation Description Type
X7 Remote set point 4-20 mA input
X17 Remote enable 24 Vdc signal
X9 Retransmission value 4-20 mA output
Fig. 4
CHANNEL 13
4-20mA
REMOTE PID
LOOP SETPOINT
X7 21 3 21 3 21 3
001+ 001-
X17 X9
24.3
162
REMOTE SYSTEM
ENABLE
CHANNEL 0
RETRANSMISSION
OF PV OR VALVE
POSITION

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Terminal layout overview
Terminal layout detailed
Note: for detailed wiring schematic options please refer to the 'Operations manual'.
1. Basic
2. Independent high limit
3. Independent high limit with safety
4. American standard
X1 -Water temperature IN
X2 -Water temperature OUT
X3 -Make up water
X4 -Return water
X5 -High limit temperature
Group X6 to X10A
X6 -Linear actuator feedback
X7 -Remote PID loop set point
X8 -Steam meter
X9 -Retransmission value
X10A -Linear actuator control position
Fig. 5
X1 - X5
PT100
inputs
X6 - X8
4 - 20 mA
inputs
X9 - X10A
4 - 20 mA
outputs
X10B – 10G
actuator
signals
X11
Bypass
pump
X14 - X16
volt free
signals
X17
remote
enable
X12
Bypass
valve
X13A- C
High limit
valve
Group X10B to X13C
X10B -Linear actuator closed signal
X10C -Linear actuator supply voltage
(Linear actuator A - Electric
actuator only)
X10D -Linear actuator B supply
X10F -Positioner A DC supply
X10G -Positioner B DC supply
X11 -Bypass pump
X12 -Bypass valve
X13 -High limit valve
X13A -High limit valve control output
signal
X13B -High limit valve supply voltage
(electric actuator only)
X13C -High limit valve battery signal
Group X14 to X17
X14 -Volt free signal for enabled
X15 -Volt free high limit
X16 -Volt free band alarm
X17 -Remote enable signal

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4. Commissioning
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 EasiHeat is isolated.
- Double check that all steam, condensate and water connections are correctly
connected to the Spirax EasiHeat.
- 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 2).
- 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).
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 87 psi 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).
Fig. 6
Handwheel
Travel
indicator
Travel
indicator
Air inlet
Fig. 7

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- Open the secondary (cold side) isolating valves downstream of the Spirax EasiHeat.
- Start the main secondary water circulating pump(s) if fitted.
- Check and confirm there is secondary water circulation through the Spirax EasiHeat.
- If the circulation is okay, switch on the main power to the control panel (local isolator).
- Turn the control panel isolation switch to ‘ON’.
- Follow the quick star t-up guide (Section 4.2) before opening the steam isolations valves.
4.2 TVA quick commissioning:
The TVA flowmeter is factory set to display data in metric units (changeable to imperial if
required by following the flow chart, Figure 10, or the individual product Installation and
Maintenance Instructions (IMI)).
All commissioning of the TVA is through the arrow buttons located on the front display
see Figure 8.
Fig. 8
Fig. 9
ENtER
PASS 7452
Followed by:
LCD
display
5 button
keypad
4 screws
Press and hold down the 'OK' button and hold for 3 seconds, then enter the default pass
code.
Use the up and down arrows to set the number then press OK to confirm your selection,
repeat until all numbers are entered.

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(test
display) VER x.x ENTER
PASS xxxx
Temp. °C
Power
Flow
Pressure
kg /h or lb /h
bar g or psi g, depending if
metric or imperial units are
selected.
°C or °F
BASIC
dAtA
kW or kBtu /h
Default = 7452
but user
settable.
Conguration
sub-menus
Total
high
Total
low
(Shows the total high 5 digits
for 10 s, then the low 5 digits.
In Kg or lb, kWh or kBTU)
Normal run mode
display sequence
POWER
OUt
NO
SIGNL
SENSR
CONST
HIGH
FLOW
The 4-20 mA
alarm can also
be activated
Shows when
ow i / p
exceeds MAX A
No
signal from
sensor
The 4-20 mA
alarm can also
be activated
Power
interrupted
Flow
above
maximum
Signal
from sensor
constant
Error Messages
These alternate with the normal run mode display.
They will be prioritised and will be latched when
they occur.
Pressing the 'OK' button will cancel the displayed
alarm and allow the next one to be viewed.
A continuous alarm will re-occur on the display 2
seconds after it has been cancelled.
Power on sequence;
turn on all segments,
then show the
software version no.
OUt
PUtS
MEtER
4-20 mA
CHECK
4 mA
CHECK
20 mA
SEt 4 mA
SORCE
SEt.20 mA
Connect a DVM
and use the up
and down keys
to set 4 or 20 mA
in kg /h or lb /h,
kW or Btu /h.
FLOW
POWER
OP = 4 mA
xxxxx
xxxxx
OP = 20 mA
Fig. 10 TVA conguration displays
To navigate around the first level menu use the up and down arrows, to enter any sub menu
use the right arrow.
TVA flowmeter commissioning chart

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From the Basic dAtA menu navigate to OUtPUts and press the right arrow to enter the sub
menu of 4 - 20 mA.
OUt
PUtS
4-20 mA
PULSE
Fig. 11
CHECK
4 mA
CHECK
20 mA
SEt 4 mA
SORCE
SEt.20 mA
FLOW
POWER
OP = 4 mA
xxxx
xxxx
OP = 20 mA
xxx
Fig. 12
OUt
PUtS
After this data has been input, continually press the left arrow button to take you back to
the run mode.
This completes the basic requirement for scaling of the TVA flowmeter suitable for integration
with the HMI.
The next menu Sorce will need FLOW to be selected.
Obtain the correct flow data from the Spirax EasiHeatTM specification sheet supplied for
accuracy, thereafter navigate down the menu and input: -
Minimum flow = 4 mA
Maximum flow = 20 mA

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4.3 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. A more detailed description of each individual
feature can be found in the full operation and maintenance manual.
Fig. 13
When ready the above screen will appear, touch the screen. If the unit has not been
configured for previous use following page will appear.
To be able to move to next page the unlock code is essential, which can be found on the
authentification certificate supplied with the panel. After entering the proper code, the lock and
the continue button will appear when pressed and transfer you to the time / date setting page.
Fig. 14

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Fig. 16
After and setting the time and date or if the unit has been returned to factory default the
following four pages will appear (pre-configured for designated region):
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 (see Section 4.3.3).
The system will advance automatically to allow the selection of the relevant Spirax EasiHeat
unit - The type of Spirax EasiHeat unit that is available is dependent on the flag selection.
Fig. 15

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The next screen (Figure 17) requires confirmation of the system to be configured.
Fig. 17
Select the EHHSC option, the selection shall be confirmed by the icon becoming highlighted
with a blue surround and a continue button shall be revealed.
Press the continue button to advance to the system configuration menu.
Fig. 18
The system configuration is now required to be entered on this page; again a selection is
highlighted by a blue surround around the icon.
Note: dependant on selected configurable requirements some of the icons shown above
will not be available.