Spirax Sarco EasiHeat User manual

1
IM-P565-09 TES Issue 1
EasiHeat
© Copyright 2023
6500851/1
EasiHeat
Installation and Maintenance Instructions
IM-P565-09
TES Issue 1
EasiHeat Dual Control System EasiHeat Steam Control System
EasiHeat Condensate Control System

IM-P565-09 TES Issue 1
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EasiHeat
1. Safety information 3
2. General product information
8
2.1 Description
3. Installation
13
3.1 Steam and condensate connections
3.2 Steam and condensate connections
3.3 Air supply
3.4 Electrical supply
3.5 Electrical specifications
4. Commissioning
4.1 Pre-commissioning inspection (initial start-up)
4.2 Commissioning procedure
4.3 Flow meter commissioning procedure
4.4 HMI commissioning
4.5 Start-up procedure
4.6 Shutdown
5. Fault finding
6. Maintenance
6.1 General
6.2 High-limit device testing
6.3 Scale formulation
6.4 Local isolator
6.5 Batteries/Maintenance
6.6 Functional test of safety compenents
6.7 Smart fuse
7. Component map
7.1 Component naming convention
7. 2 Component definitions
Contents
Page numbers to be updated when document is approved

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EasiHeat
1. Safety information
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 these products can be guaranteed only if they are properly installed, commissioned and maintained
by a qualified person (see Section 1.11) in compliance with the related operating instructions. General installation and
safety instructions for pipeline and plant construction and also the proper use of tools and safety equipment must also
be complied with.
General safety notes
This document refers only to the mechanical installation and commissioning of the EasiHeat system should be used in
conjunction with the relevant IMIs for the other system components and supplementary safety information for all the
system components.
Lifting
The EasiHeat system should be lifted by a suitable forklift truck, from the base, placed in position and securely bolted
to the floor when required.
The customer is responsible for the safe lifting of the EasiHeat system.
Caution
or
Warning
Do not lift the EasiHeat system by any other part except from the base.
Note: always leave sufficient space around the system for future maintenance operations.
Warnings
1. The unit is designed and constructed to withstand the intensity of work in ordinary use.
2. Use of the product for any other purpose, or failure to install the product in compliance with these Installation and
Maintenance Instructions, may damage the product and also cause serious injuries to operating personnel.
3. Before carrying out any installation and maintenance procedure, always check that all primary steam, condensate and
water return lines on the secondary have been isolated.
4. Make sure that residual pressure in the system and in pipework has been vented to atmospheric level.
5. To avoid the risk of burns, allow parts to cool before carrying out any type of operation.
6. Always wear suitable protective clothing before carrying out any installation or maintenance activity.

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EasiHeat
1.1 Intended use
Referring to the installation and maintenance instructions and the nameplate of the unit and the Technical Specifications,
check that the product is suitable for intended use/application.
EMEA - The EasiHeat heating system complies with the requirements of the EU Pressure Equipment Directive/UK Pressure
Equipment (Safety) Regulations and is / marked. For any product specific PED catagorisation that is required
for this unit or products used in the make-up of the unit please contact Spirax Sarco directly.
i) The product has been specifically designed for use on steam and water belonging to Group 2 of the above-mentioned
Pressure Equipment Directive.
ii) Check suitability of material, pressure and temperature and related maximum and minimum values. If the maximum
operating limits of the product are lower than those of the system in which it to be inserted, or if malfunction of the
product could generate dangerous overpressure or overtemperature, always insert a safety device in the system to
prevent exceeding of such limits.
iii) Determine the correct installation position and direction of flow of fluids.
iv) The product is not designed to withstand external stresses induced by the system in which it is fitted. The installer is
responsible for taking into account such stresses and for adopting adequate precautions to reduce these to a minimum.
v) Prior to installation, remove protective covers from all connections and and also protective film and packaging elements.
1.2 EU Pressure Equipment Directive/UK Pressure Equipment (Safety) Regulations
classification
The EasiHeat series are classified as assembly according the EU Pressure Equipment Directive/UK Pressure Equipment
(Safety) Regulations:
Product Fluid Group Category
EasiHeat DHW and HTG 2 I
EasiHeat DHW and HTG (T10 HEX with 46+ plates) 2II
For the category of bespoke units, refer to the “EC Declaration of Conformity” supplied with the product.
Other component parts of the assembly comply with the relevant European Directives, where necessary. Please refer to
specific component literature for further details.
1.3 Access
Ensure safe access and, if necessary, a safe working platform (suitably guarded) before attempting any work on the
product. Arrange suitable lifting gear if required.
1.4 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.5 Hazardous liquids or gases in the pipeline
Take into account what is currently in the pipeline or what may have been in the pipeline at some previous time. Consider:
flammable materials, substances hazardous to health, extreme temperatures.
1.6 Hazardous environment around the product
Consider: areas with a risk of explosion, lack of oxygen (e.g. tanks, pits), dangerous gases, extreme temperatures, hot
surfaces, fire hazards (e.g. during welding), excessive noise, moving machinery.
The place of installation of the assembly must be equipped with the fire-prevention devices required by current regulations.

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1.7 The system
Consider the effect of the work to be carried out on the entire system. Consider whether the action proposed (e.g. closing
of isolating valves, electrical isolation) may put any other part of the system or personnel at risk.
Hazards may include isolation of vents or protective devices or the rendering ineffective of controls or alarms. Ensure
isolating valves are opened and closed gradually to avoid shocks to the system.
1.8 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and locking or labelling of closed valves. Do not
assume that the system has depressurised even when the pressure gauge indicates zero.
1.9 Temperature
Allow time for temperature to normalise after isolation to avoid the risk of burns and consider whether
protective clothing (including safety glasses) is required.
If there is a possibility of heated water coming directly/indirectly in contact with personnel, a high limit
must be fitted to mitigate the risk of scalding and appropriate risk assessment conducted
1.10 Hard water
Water supplied to the EasiHeat is recommended to be less than (<) 200ppm
1.11 Protective bonding
The EasiHeat system and nearby metallic items within 2.5m meters should be all connected to the
same common earth.
1.12 Electrical Hazard
The EasiHeat system's panel contains hazardous voltages. Some maintenence operations may require
the panel being energized and open. These maintenence actions may only be undertaken by a suitably
qualified and competent person.
1.13 Legionella
Legionella bacteria presents a risk in any hot water system, appropriate measures should be taken in
line with national guidance to manage this risk. Features are available with this product to enable
monitoring to reduce the risk.
1.14 Tools and consumables
Before starting work, make sure you have suitable tools and/or consumables on hand. Use only genuine Spirax Sarco
replacement parts.
1.15 Protective clothing
Consider whether you and/or others require protective clothing to protect against hazards, such as chemicals, high/low
temperatures, radiation, noise, falling objects and danger to eyes and face.
1.16 Permits to work
All work must be carried out or supervised by a suitably competent person. Installation and operating personnel should
be trained in correct use of the product according to the Installation and Maintenance Instructions. Any formal work
permit system adopted must be complied with. Where no such system is applied, a person responsible should be informed
of progress of the work and, where necessary, an assistant with primary responsibility for safety should be appointed.
Post "warning signs" if necessary.
1.17 Handling
Manual handling of large and /or heavy products may involve a risk of injury. Lifting, pushing, pulling, carrying or
supporting a load by bodily force may 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 appropriate handling methods according to the circumstances of the work to be carried out.
Note: if it is necessary to use slings for lifting, it is good practice to fit these around the plate of the base unit to avoid
damage to the unit.

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1.18 Storage
Note: If the EasiHeat cannot be installed and put into operation immediately upon receipt at the jobsite, certain precautions
are necessary to prevent deterioration during storage.
Responsibility for integrity of the heat exchangers must be assumed by the user. Spirax Sarco will not be responsible
for damage, corrosion or other deterioration of heat exchanger equipment during transit and storage.
The following suggested practices are provided solely as a convenience to the user, who shall make their own decision
on whether to use all or any of them.
-On receipt of the EasiHeat, inspect for shipping damage to all protective covers. If damage is evident, inspect for
possible contamination and replace protective covers as required. If damage is extensive, notify the carrier immediately
and Spirax Sarco.
-If the EasiHeat is not to be placed in immediate service, take precautions to prevent rusting or contamination.
-Store under cover in a heated area, if possible. The ideal storage environment for EasiHeat and accessories is indoors,
above grade, in a dry, low humidity atmosphere which is sealed to prevent entry of blowing dust, rain or snow. Maintain
temperatures between 0 °C and 40 °C (32 °F and 104 °F) and humidity at 40% relative humidity or lower.
Note: Ambient temperature of the place where the unit will be installed must be above 0 °C (32 °F) and below 40 °C (104 °F).
1.19 Freezing
Precautions must be taken to protect products that are not self-draining against frost damage in environments where
they may be exposed to temperatures below freezing point.
1.20 Disposal
As the product may contain PTFE and Viton, particular precautions must be adopted to avoid potential risks for health
caused by decomposition or combustion of such materials. Unless otherwise indicated in the installation and maintenance
instructions with regard to the materials of the seals, this product can be recycled and it is considered that no
environmental risk exists deriving from disposal thereof provided that suitable precautions are adopted. However, its
components can be checked to verify the possibility of safe disposal.
PTFE:
- This material can be disposed of only using approved systems and never in incinerators.
- PTFE waste to be disposed of must be stocked in separate containers, must never be mixed with other waste and must
be sent directly to a landfill.
Viton:
- VITON waste can be sent directly to landfills when permitted and accepted by local and national regulations.
- VITON components may also be incinerated but a scrubber must be used to remove the hydrogen fluoride developed
by the product, carrying out this procedure in accordance with local and national regulations.
The components are insoluble in aquatic media.
Electrical:
Unless otherwise stated, the electrical components within this product are recyclable and no ecological hazard is
anticipated with its disposal providing due care is taken. The product should be recycled in line with local legislation.
An overview of the structure of the control panel is availible in the supplied wiring diagram.
Please visit the Spirax Sarco product compliance web pages
https://www.spiraxsarco.com/product-compliance
for up to date information on any substances of concern that may be contained within this product.
Where no additional information is provided on the Spirax Sarco product compliance web page, this product may be
safely recycled and/or disposed providing due care is taken.
Always check your local recycling and disposal regulations.

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1.21 Return of products
Customers and stockists are reminded that, under EC Health, Safety and Environment Law, when returning products to
Spirax Sarco, they must provide information regarding any hazards and precautions to be taken due to contamination
residues or mechanical damage which may represent a risk to health, safety or the environmental. This information must
be provided in writing, including Health and Safety datasheets relating to any substances identified as hazardous or
potentially hazardous.
Notes:
For additional information about any particular product used in the construction of this unit see the relevent product
specific Technical Information (TI-P565-08) sheet.
Copyright © Spirax-Sarco Limited 2023
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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EasiHeat
2.1 Description
EasiHeat systems use steam to provide accurate heating of low temperature hot water (HTG), domestic hot water (DHW) or hot water
for processes. Systems can be sized for any heating duty from 70 kW to approximately 3.5 MW and are supplied fully assembled
and pressure tested, ready for installation.
The core Easiheat system is available in 3 different basic configurations:
- Steam Control
- Condensate Control
- Dual Control
The innovative dual control system allows control of temperature and pressure within the heat exchanger to allow more of the available
energy to be transferred to the heated media.
Additional feature and options are available for each core configuration, such as high limit valves, isolation and metering options.
These options are detailed in section 2.2.
The EasiHeat unit consists of the following core items (refer to Figure 1):
ASteam plate heat exchanger, type T6-P, TS6-M, T8-M, or T10-M
BPneumatically or Electrically actuated steam control valve and positioner
CPLC Controller and sensors
DCondensate removal solution
EPipeline ancillaries
FLockable Isolator
For a detailed list of equipment and specifications, refer to the PandID and documentation provided.
For additional information about any particular product used in the construction of these units see the relevent product specific Technical
Information (TI) sheet.
For further technical information regarding the EasiHeat system please refer to TI-P565-08 and IM-P565-10.
2. General product information
Fig. 1a EasiHeat Dual Control System
A
F
E
D
CB

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Fig. 1b EasiHeat Steam Control System
Fig. 1c EasiHeat Condensate Control system
A
F
E
D
CB
A
F
E
D
C

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EasiHeat
3. Installation
Metric Maximum dimensions
(mm)
Piping connections
Type Valve actuation H L W Steam Water Condensate
EHDSC EL or PN 1760 1950 850 DN65 DN65 DN25
EHDDC EL or PN 1760 2320 950 DN65 DN65 DN15
EHHCC (T6) EL or PN 1760 1480 870 DN50 DN50 DN15
EHHCC (T8) EL or PN 1760 1950 850 DN80 DN80 DN20
EHHCC (T10) EL or PN 1760 1760 870 DN100 DN100 DN25
Imperial Maximum dimensions
(inches)
Piping connections
Type Valve actuation H L W Steam Water Condensate
EHDSC EL or PN 70 77 34 2½" 2½" 1"
EHDDC EL or PN 70 92 38 2½" 2½" ½"
EHHCC (T6) EL or PN 70 59 35 2" 2" ½"
EHHCC (T8) EL or PN 70 77 34 3" 3" ¾"
EHHCC (T10) EL or PN 70 70 35 4" 4" 1"
* EHHDC has the same dimensions as the EHHCC versions
Options selected may impact overall dimensions.
3.1 Dimensions (approximate)
L
W
H

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3.2 Steam and condensate connections
It is important that the steam supply (and compressed air if pneumatic actuation is selected) to the EasiHeat 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 EasiHeat 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 the pressure equipment on either the hot or cold side of the plate heat
exchanger, should be fitted if required.
Spirax Sarco supplies a range of traps, strainers, separators, safety valves and pressure reducing equipment.
3.3 Air Supply
If a pneumatic control system is installed, connect a compressed air supply 2 to 6 bar g (29 psi g to 87 psi g) to the pressure regulator
mounted on the control valve.
If the PN3000 actuator has been fitted the maximum air pressure is 3 bar g.
Please refer to documentation for the pneumatic control valve when lifting.
During lifting, take into account the high centre of gravity of the unit and adopt all the necessary
precautions to avoid accidental tipping over of the unit.
3.4 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 earth terminal as shown in Figure 2.
Fig. 2
Live and neutral
Supply into M20 gland
Earth

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3.5 Electrical specifications
3.5.1 Power supply
Electrical supply requirements
110 Vac/60 Hz
230 Vac/50Hz
Power consumption 400 W
Maximum supply conductor
dimensions 16 mm2
Maximum current draw 1.6A
Fuses
Panel Fan (F1) 0.5A (Slow blow)
PLC/HMI/Comms (F3) 3A (quick blow)
Steam Control Valve (F4) and Split range steam control valve/
Condensate control valve analog position feedback (F5) 5A (slow blow)
F6 24V 4-20 mA 0.5A (Slow blow)
The following are available for customer connection to the EasiHeat system if required:
3.5.2 Customer connections
Volt free contacts
Terminal designation Description Type
RHL E-stop circuit alarm N/O volt-free contact
RRM Run BMS contact N/O volt-free contact
RBX4 TA21 Water outlet temperature retransmission 4-20 mA Analog Input
Fig. 3

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Remote operation and retransmission connections
Terminal designation Description Type
RDX1 Remote stop request 24 Vdc coil
RDX2 Remote start request 24 Vdc coil
RDX2 Remote start request 24 Vdc coil
RBX1 VB31 steam control valve retransmission 4-20 mA Analog Input
RBX2 VB32 auxiliary control valve/VB41 condensate control valve retransmission 4-20 mA Analog Input
RBX3 Hot Water setpoint transmission 4-20 mA Analog Input
RBX4 TA21 Water outlet temperature retransmission 4-20 mA Analog Input
Fig. 4

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M12 Sensor/Component connector layout
Fig. 5

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For correct commissioning, we recommend the service and support of a Spirax Sarco engineer. Please contact your local Spirax Sarco
representative for more details.
4.1 Pre-commissioning inspection (initial start-up)
-Ensure all bolts and fasteners have been correctly tightened before commissioning.
- Most of the new installations during the construction of pipelines and the installation of the system, may inadvertently collect dirt
particles inside the pipes. It is essential to carefully remove any residual impurities and dirt in them before starting the commissioning.
- Check that all the manual isolating valves (on primary steam, on condensate removal, on water side are closed.
- Clean the filters upstream of the regulation valves.
- Check that the steam and water design conditions do not exceed the rated values of the unit.
- Check that the supply steam line is properly pressurised and has been drained/ vented.
- Make a double check to verify that all connections to steam, condensate and water lines have been made correctly.
- Check the air supply of the filters/reducers of the valves (actuated pneumatically where established) and that it complies with the
system requirements.
4.2 Commissioning procedure
1. Dry commissioning valve stroke check - An initial valve stroke check should be carried out to ensure free movement of the valve
stem.
- For the electric actuated control valve, please see IM-P713-01.
- For the pneumatic actuated control valve, please see IM-P706-05
2. Open the secondary (cold side) isolating valves downstream of the EasiHeat.
3. Start the main secondary water circulating pump(s) if fitted.
4. Check and confirm there is secondary water circulation through the EasiHeat.
5. If the circulation is okay, switch on the main power to the control panel (local isolator).
6. Turn the control panel isolation switch to 'ON'.
7. Commission the flowmeter (if fitted) see section 4.3.
8. To finalise the mechanical commissioning of the EasiHeat system:
8.1. Open all condensate drain valves
8.2. Slowly open steam inlet valve
8.3. Monitor the process temperature to ensure that it is within the acceptable limits
4. Commissioning

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4.3 Flow meter commissioning procedure
4.3.1 Operating and display elements
1 Switching status LED for OUT1
2Switching status LED for OUT2
3 Process value in the indicated unit of measurement *
4 4-digit alphanumeric display
5 Keys for changing views and parameter setting
6 Enter button for entering settings.
1, 2, 3 Indicator LED's
LED 1 = switching status OUT1 (lights if output 1 is switched)
LED 2 = process value in the indicated unit of measurment (%, m/s, l/min, m3/h, C, 103))
LED 3 = switching status OUT2 (lights if output 2 is switched)
4: Alphanumeric display, 4 digits
Indication of the current process values in red or green characters
Display of the parameters and parameter values
5: Buttons up [up arrrow] and down [down arrow]
Select parameter
Change of parameter value (hold button pressed)
Change of the display unit in the normal operating mode (Run mode)
Lock / Unlock (buttons pressed simultaneously > 10 seconds)
6: Button [circle] = Enter
Change from the RUN mode to the main menu
Change to settings mode
Acknowledge the set parameter value
4.3.1 Operating modes
The device provides three selectable operating modes for flow measurement. The operating mode must be selected at the beginning
of the parameter setting
The selected operating mode has no effect on the temperature measurement, only absolute values in °C (°F) are indicated
Operating mode [ModE] Medium Display unit
REL liquids, air % of the taught range
LIQU liquids m/s; l/min m3/h
(fps, gpm, cfm)
GAS air
Note : A change of the operating mode leads to a restart of the device. The parameter settings are saved in the respective operating
mode, i.e. when the operating mode is changed, the settings are not lost
4
231
6
5
Fig. 6

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4.3.2 Parameter setting via the device keys: Operating mode
1. Open the [INI] menu.
2. Select [ModE] and define the operating mode: [LIQU]
3. The device carries out a reboot.
Note : Operating mode [LIQU] must be selected on all EasiHeat packages.
4.3.3 Parameter setting via the device keys: Internal pipe diameter
1. Open the [INI] menu.
2. Select [diA] and define the internal pipe diameter
Note : [diA] is only available if the [GAS] or [LIQU] mode is selected.
DN Diameter (mm)
DN50 54.8
DN80 66.9
DN100 108.2
The measurements above are taken in accordance with BS1600 : 1991
Commisioning of the flow meter is now complete.
4.3.4 Flowmeter orientation
If for any reason the flow meter has been or needs to be removed from the EasiHeat system it is important to understand the following:;
To achieve the optimum measuring accuracy, mount the sensor in a way that the flow goes to the larger of the two key surfaces and
do not go beyond the end stop."
1
2
Fig. 7

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4. Select language
4.4 HMI commissioning
Ensure that section 4.2 has been completed before continuing.
Note :
1. This stage may have been completed from factory.
2. For comprehensive detail on the start-up/running of the EasiHeat please see IM-P565-10.
3. Tap welcome screen

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5. Select engineering units, set date and time
6. Insert product nomenclature from product documentation pack

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7. Select controls
9. Complete commissioning by selecting green tick
8. Select operating conditions