Spirax Sarco EasiHeat User manual

IM-P481-04 CTLS Issue 4 1
1. Safety information
2. General product information
3. Installation
4. Commissioning
5. Fault finding
6. Maintenance
© Copyright 2018
Printed in GB
4819050/4
Spirax EasiHeatTM
DHW Potable and Process Water Heating
Compact Heat Transfer Solution
Installation and Maintenance Instructions
IM-P481-04
CTLS Issue 4

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Copyright © Spirax Sarco Limited 2018
All rights reserved
Spirax Sarco Limited grants the legal user of this product (or device) the right
to use the Work(s) solely within the scope of the legitimate operation of the
product (or device). No other right is granted under this licence. In particular
and without prejudice to the generality of the foregoing, the Work(s) may not
be used, sold, licensed, transferred, copied or reproduced in whole or in part
or in any manner or form other than as expressly granted here without the
prior written consent of Spirax Sarco Limited.

IM-P481-04 CTLS Issue 4 3
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
Sarco 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 - Lifting
The Spirax Sarco EasiHeatTM 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 Sarco 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.
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.
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. 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. The Spirax Sarco
EasiHeatTM DHW potable and process water heating compact heat transfer unit complies with the
requirements of the Pressure Equipment Directive (PED) - F or any product specific PED
catagorisation that is required for this unit or products used in the make-up of the unit p lease
contact Spirax Sarco directly.
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 (PED).
The products’ use on other fluids may be possible but, if this is contemplated, Spirax
Sarco should be contacted to confirm the suitability of the product for the application
being considered.
ii) Check material suitability, pressure and temperature and their maximum and minimum
values. If the maximum operating limits of the product are lower than those of the
system in which it is being fitted, or if malfunction of the product could result in
a dangerous overpressure or overtemperature occurrence, ensure a safety device is
included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be
induced by any system to which they are fitted. It is the responsibility of the installer
to consider these stresses and take adequate precautions to minimise them.
v) Remove protection covers from all connections and protective film from all name-
plates, where appropriate, before installation on steam or other high temperature
applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded) before attempting
to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some previous time.
Consider: flammable materials, substances hazardous to health, extremes of temperature.
1.5 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.
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.
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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Fig. 1
Spirax Sarco EasiHeatTM
DHW heat transfer solution
A
B
DC
E
2.1 General information
The Spirax Sarco 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 Sarco EasiHeat™DHW system is expandable by the inclusion of additional items
such as steam pressure reduction, safety valve and safety high limit shut-o󰀨 should be selected separately.
The base unit of the Spirax Sarco 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 Sarco 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.
E - Lockable isolator
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 Sarco EasiHeat™DHW see the Technical
Information sheet TI-P481-02.
2. General product information

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2.2 Spirax Sarco EasiHeatTM DHW nomenclature
The product nomenclature is a reection of the core items and unit options that have been ordered and
supplied – See the table below:
Spirax Sarco EasiHeatTM DHW nomenclature example:
EHD 2 P EL ST -HL CV2 G1 W S - E R2 C2
Compulsory
selection
Domestic hot water EHD =Spirax Sarco EasiHeat™DHW EHD
CV size
1 = DN20
2
2 = DN25
3 = DN32
4 = DN40
5 = DN50
6 = DN65
Pressure vessel code P=PED P
Actuation EL =Electric EL
PN =Pneumatic
Condensate removal
ST =Steam trap
STPT =Pump trap
PTHC =Pump trap high capacity
Mechanical
options
High limit HL =Integrated high limit HL
IHL =Independent high limit
High limit actuation
(EL only)
B=Battery back-p C
C = Super capacitor
Isolation
V1 =Ball valve
V2V2 =BSA
V3 =DBB3
Gasket material G1 =EPDMPC G1
G2 =Heatseal
Extras W = Wheels W
S=EN 12828 safety option S
Panel options
Energy monitoring E=With energy monitoring E
R1 =Level 1 – SMS and E-mail
R2
Remote access R2 =Level 2 – Full web access
R3 =Level 3 – SMS + Remote
Communications
C1 =Modbus RTU
C2
C2 =BACnet
C3 =LonTalk (LonWorks)
C4 =DeviceNet
C5 =CANopen
C6 =Pronet
C7 =Probus

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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
Sarco 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 specied design pressure and temperature for
the unit. The Spirax Sarco 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 tted 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
3. Installation

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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 (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 Sarco 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 R EE
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 F R EE
BAND ALARM
X15 X16X14
Note:
Power supply 10 - 16 A

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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
CH A NNEL 0
RETRANSMISSION
OF PV OR VALVE
POSITION

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Terminal layout overview
Fig. 5
Terminal layout detailed
Note: for detailed wiring schematic options please refer to the 'Operations manual'.
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
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 (requires
4-20mA input)
X8 -Steam ow
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

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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 ush 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
Sarco EasiHeatTM is isolated.
- Double check that all steam, condensate and
water connections are correctly connected to
the Spirax Sarco EasiHeatTM.
- Check all ange bolts are tight.
Fig. 6 Handwheel
Travel
indicator
Travel indicator
Air inlet
Fig. 7
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 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).
- Open the secondary (cold side) isolating valves
downstream of the Spirax Sarco EasiHeatTM.
- Start the main secondary water circulating
pump(s) if tted.
- Check and conrm there is secondary
water circulation through the Spirax Sarco
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. Commissioning

IM-P481-04 CTLS Issue 4 13
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 conrm your selection, repeat until all
numbers are entered.
4.2 TVA quick commissioning:
The TVA owmeter is factory set to display data in metric units (changeable to imperial if required by
following the ow 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.

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Default = 7452 but
user settable.
Fig. 10 TVA configuration displays
4.3 TVA flowmeter commissioning chart
To navigate around the rst level menu use the up and down arrows, to enter any sub menu use the right arrow.
(test display) VER x.x Total high ENTER PASS
Tot al low
Flow
Power
Pressure
Temp. °C °C or °F
bar g or psi g, depending
if metric or imperial units
are selected.
kW or kBtu/h
kg/h or lb /h
(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 on sequence; turn
on all segments, then show
the software version no.
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 interrupted POWER OUt
No signal from sensor NO SIGNL The 4-20 mA alarm can also be activated
Signal from sensor constant SENSR CONST The 4-20 mA alarm can also be activated
Flow above maximum HIGH FLOW Shows when flow i / p exceeds MAX A

IM-P481-04 CTLS Issue 4 15
Configuration
sub-menus
xxxx BASIC dAtA
MEtER
OUtPUtS
4-20 mA SORCE FLOW
POWER
SEt 4 mA xxxxx
CHECK 4 mA OP = 4mA
CHECK 20 mA OP = 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.
SEt 20 mA xxxxx

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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.
Fig. 11
Fig. 12
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 owmeter suitable for integration with the HMI.
The next menu Sorce will need FLOW to be selected.
Obtain the correct ow data from the Spirax Sarco EasiHeatTM specication sheet supplied for accuracy,
thereafter navigate down the menu and input:
Minimum ow = 4 mA
Maximum ow = 20 mA
OUtPUtS 4-20 mA
PULSE
OUtPUtS
4-20 mA SORCE FLOW
POWER
SEt 4 mA xxxxx
CHECK 4 mA OP = 4mA
CHECK 20 mA OP = 20 mA
SEt 20 mA xxxxx

IM-P481-04 CTLS Issue 4 17
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.
Fig. 13
When ready the above screen will appear, touch the screen. If the unit has not been congured for previous
use following page will appear.
To be able to move to next page the unlock code is essential, after entering the proper code (found on the
software authentication document), the lock and the continue button will appear which will transfer you to
the time/date setting page.
Fig. 14

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Fig. 16
Fig. 18
After unlocking the system (by using the unlock code) and setting the time and date or
if the unit has been returned to factory default one of the following four pages will appear (pre-con gured
for designated region):
By choosing the relevant  ag 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 4.5.3).
Fig. 15
Fig. 17
Fig. 19

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The system will advance automatically to allow the selection of the relevant Spirax Sarco EasiHeatTM unit -
The type of Spirax Sarco EasiHeatTM unit that is available is dependent on the ag selection.
The next screen (Figure 20) requires conrmation of the system to be congured.
Fig. 20
The selection shall be conrmed by the icon becoming highlighted with a red surround and a continue
button shall be revealed.
Press the continue button to advance to the system conguration menu.

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Fig. 21
The system conguration is now required to be entered on this page; again a selection is highlighted by a blue
surround around the icon.
Fig. 22
System conguration should match the mechanical conguration of the Spirax Sarco EasiHeatTM and
control system of the plant, proper conguration will show or hide options available after conguration.
Some of the screens may contain additional options which with specied conguration may be hidden; all
the options are described in this document.