Spirax Sarco EasiHeat DHW User manual

IM-P481-04 CH Issue 1 1
Spirax EasiHeatTM
DHW Potable and Process Water Heating
Compact Heat Transfer Solution
Installation and Maintenance Instructions
1. Safety information
2. General
Product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
IM-P481-04
CH Issue 1
4819050/1
© Copyright 2012
Printed in the UK

IM-P481-04 CH Issue 1
2

IM-P481-04 CH Issue 1 3
Note: This document refers only to the mechanical installation and commissioning
of the Spirax EasiHeatTM DHW 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
This product is designed and constructed to withstand the forces encountered during
normal use.
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.
Before any installation or maintenance procedure, always ensure that all primary steam
and condensate return lines and secondary water lines are isolated.
Ensure any residual internal pressure in the system or connecting pipework is carefully
relieved.
Allow hot parts to cool before commencing work, to avoid the risk of burns.
Always wear appropriate safety clothing before carrying out any installation or
maintenance work.
Lifting
The Spirax EasiHeatTM unit should be lifted by a suitable forklift truck, from the base,
placed in position and securely bolted to the floor.
Warning:
On no account is the Spirax EasiHeatTM 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.
1. Safety information

IM-P481-04 CH Issue 1
4
Safe operation of these products can only be guaranteed if they are 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.
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. These products comply with the requirements of the European
Pressure Equipment Directive 97 / 23 / EC and fall within category 'SEP'. It should
be noted that products rated as 'SEP' are required by the Directive not to
carry the mark.
i) The product has been specifically designed for use on steam or water/
condensate which are in Group 2 of the above mentioned Pressure Equipment
Directive. 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.
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.

IM-P481-04 CH Issue 1 5
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.

IM-P481-04 CH Issue 1
6
2.1 General information
The Spirax EasiHeat™ DHW system uses steam to provide accurate heating of potable
hot water or hot water for processes. Systems can be sized for any heating duty from
50 kW to approximately 1.1 MW and are supplied fully assembled and pressure tested
ready for installation.
The standard Spirax EasiHeat™ DHW system is expandable by the inclusion of additional
items such as steam pressure reduction, safety valve and safety high limit shut-off should
be selected separately.
The base unit of the Spirax EasiHeat™ DHW provides the core of the system, while options
(see Sections 2.2) provide additional features such as: high limit package, stop valve
package and energy monitoring.
The Spirax EasiHeatTM DHW unit consists of the following core items
(refer to Figure 1):
A Plate heat exchanger.
B Pneumatic or electrically actuated control valve and positioner.
C PLC controller.
D Pipeline ancillaries.
2. General product information
Fig. 1 Spirax EasiHeatTM DHW heat transfer solution
Notes:
1. For additional information about any particular product used in the construction of this unit
see the relevent product specific Technical Information (TI) sheet.
2. For further technical information regarding the Spirax EasiHeat™DHW see the Technical
Information sheet TI-P481-02.
A
B
DC

IM-P481-04 CH Issue 1 7
2.2 Spirax EasiHeatTM DHW nomenclature
The product nomenclature is a reflection of the core items and unit options that have been
ordered and supplied – See the table below:
Spirax EasiHeatTM DHW nomenclature example:
EHD 2 P EL ST -HL CV2 G1 W S - E R2 C2
2
EHD
EL
P
HL
ST
V2
C
S
G1
E
R2
C2
W
Domestic hot water EHD = Spirax EasiHeat™DHW
1 = DN20
2 = DN25
3 = DN32
CV size 4 = DN40
5 = DN50
Compulsory 6 = DN65
selection Pressure vessel code P = PED
Actuation EL = Electric
PN = Pneumatic
ST = Steam trap
Condensate removal PT = Pump trap
PTHC = Pump trap high capacity
High limit HL = Integrated high limit
IHL = Independent high limit
High limit actuation B = Battery back-p
(EL only) C = Super capacitor
V1 = Ball valve
Mechanical Isolation V2 = BSA
options V3 = DBB3
Gasket material G1 = EPDMPC
G2 = Heatseal
Extras W = Wheels
S = EN 12828 safety option
Energy monitoring E = With energy monitoring
Panel options R1 = Level 1 – SMS and E-mail
Remote access R2 = Level 2 – Full web access
R3 = Level 3 – SMS + Remote
C1 = Modbus RTU
C2 = BACnet
C3 = LonTalk (LonWorks)
Communications C4 = DeviceNet
C5 = CANopen
  C6 = Pronet
  C7 = Probus

IM-P481-04 CH Issue 1
8
3. Installation
3.1 Steam and condensate connections
It is important that the steam supply (and compressed air if pneumatic actuation is selected)
to the Spirax EasiHeat™ DHW 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™ DHW 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 (4.5 to 8 bar g
(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 earth terminal as shown in Figure 2.
Fig. 2
Phase connection Neutral connection Earth connection
Q1
16A
PE
3L2 5L21L2
4T2 6T32T1

IM-P481-04 CH Issue 1 9
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 (optional) 24 Vac
Steam flowmeter TVA (optional) 4 - 20 mA control
PT100 temperature sensors 3 wire
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 FREE
ENABLE SIGNAL
K1
/ 7.2
ENABLE
RELAY
21
K2
/ 7.3
HIGH
LIMIT
RELAY
K3
/ 7.4
BAND
RELAY
24 22
21 3 21 3 21 3
131
132
133
141
142
143
151
152
153
21
24 22
11
14 12
VOLT FREE
HIGH LIMIT
ALARM
VOLT FREE
BAND ALARM
X15 X16X14

IM-P481-04 CH Issue 1
10
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

IM-P481-04 CH Issue 1 11
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 - Steam temperature
X4 - Condensate temperature
X5 - High limit temperature
Group X6 to X10A
X6 - Linear actuator feedback
X7 - Remote PID loop set point
X8 - Steam flow
X9 - Retransmission value
X10A - Linear actuator control position
Group X10B to X11
X10B - Linear actuator closed signal
X10C - Linear actuator supply voltage (Electric actuator only)
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
Fig. 5
X1 - X5
PT100
inputs
X6 - X8
4 - 20 mA
inputs
X9 - X10A
4 - 20 mA
outputs
X10B - 10C
actuator
signals
X11
Bypass
pump
X14 - X16
volt free
signals
X17
remote
enable
X12
Bypass
valve
X13A-C
High limit
valve

IM-P481-04 CH Issue 1
12
4. Commissioning
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.
4.1 Mechanical commissioning procedure:
- Check all 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).
Fig. 6
Handwheel
Travel indicator
Travel indicator
Air inlet
Fig. 7
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 6 bar g (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).

IM-P481-04 CH Issue 1 13
- Open the secondary (cold side) isolating valves downstream of the Spirax EasiHeatTM.
- Start the main secondary water circulating pump(s) if fitted.
- Check and confirm there is secondary water circulation through the Spirax EasiHeatTM.
- 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 start-up guide (Section 4.4) 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
3 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.

IM-P481-04 CH Issue 1
14
(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 = 8888
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 will also
be activated
Shows when
owi/p
exceeds MAX A
No
signal from
sensor
The 4-20 mA
alarm will 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

IM-P481-04 CH Issue 1 15
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

IM-P481-04 CH Issue 1
16
4.4 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
Fig. 14 Fig. 15
Fig. 16 Fig. 17
Choose the relevant flag for your Country, common default engineering units and language
are automatically selected. These can be readjusted if required by revisiting the settings
page a little later.
The system shall then advance automatically to allow you to make a selection on the Type
of Spirax EasiHeatTM unit.
When ready the above screen will appear, touch the screen. If the unit has not been
configured for previous use; or if it has been returned to factory default one of the following
four pages (Figures 14 to 17) will appear (configured for a designated region).

IM-P481-04 CH Issue 1 17
The next screen (Figure 18) requires confirmation of the system to be configured.
Fig. 19
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.
Select the DHW 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.

IM-P481-04 CH Issue 1
18
The system configuration should match the mechanical configuration of the Spirax
EasiHeatTM and control system of the plant Spirax EasiHeatTM plant and are detailed as
follows:-
Fig. 20 High limit selection
Fig. 21 High limit valve selection
Fig. 22 Linear Actuator Selection and configuration
Fig. 23 Enable control selection
Fig. 24 TVA flowmeter selection
Not
installed
PLC
controlled
Independently
controlled
Electrical Pneumatic
Local Remote
Not
installed
Installed
BVA PSA Valves
4-20mA
control
only
4-20mA
control and
feedback

IM-P481-04 CH Issue 1 19
4.5 TVA not installed
If the Spirax EasiHeatTM unit is not fitted with a TVA flowmeter then the system configuration
is now complete and the global navigation buttons at the base of the screen can be used
to navigate around the system.
Fig. 25
4.6 TVA installed
On TVA flowmeter selection a data entry point shall be displayed in order for effective
scaling of the flowmeter - This is the full engineering range for the 4 - 20 mA signal input
to the Spirax EasiHeatTM system.
The full range values entered at this point should match exactly those that are programmed
in the TVA flowmeter parameters (refer to Section 4.3 TVA commissioning).
Fig. 26
A new global screen navigation button shall be displayed allowing navigation to the logged
energy data for the Spirax EasiHeatTM system.

IM-P481-04 CH Issue 1
20
Press the energy button to navigate to the energy set-up page (Figure 27):
Fig. 27
Upon completion of the above data all of the other global navigation buttons that are
displayed in Figure 29 (along the base of the screen) are available for use.
Accurately enter the specific energy data to ensure that the valid energy data can be
calculated.
Boiler fuel properties - Selected via the drop down menu
Boiler feedwater temperature
Boiler efficiency
Cost per unit of fuel
n
$
Fig. 28