UK Exchangers UKE-8-50 Instruction Manual

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Instantaneous
Hot Water Heater
Operating & Instruction
Manual
Read these Instructions before unpacking,
installation and use of the equipment.
Important Notice:
UK Exchangers Ltd cannot accept any warranty claims if the equipment is not handled,
positioned, installed, or operated as per the general guide lines contained within this manual.
The actual running conditions should be checked against the specification sheets for the heat
exchanger.

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How it Works
The unit is designed to heat domestic hot water (DHW) using low temperature hot water (LTHW). The primary
circulating shunt pump mounted on the exchanger is for heat exchanger control only and is sized to pump the
correct volume of LTHW through the heat exchanger to ensure efficient operation.
When domestic hot water is required, the control valve modulates to allow LTHW to be pumped through the
exchanger. The required DHW outlet temperature can be set on the controller.
The temperature of the DHW is monitored by the strap-on sensor on the DHW outlet pipe. This sends a signal
to the controller in the panel that in turn modulates the control valve thereby maintaining the DHW outlet
temperature set on the controller.
If the DHW goes over temperature then an over heat stat shuts down primary circulating pump (and also the
secondary pump if fitted and controlled by the panel). The system can only be re-started when the temperature
has cooled down and after the high temperature re-set button has been pushed on the front of the panel.
To avoid the possibility of thermal siphoning back from the boiler return we recommend that non return valves
are incorporated into the pipe-work. Due to the high efficiency of the heat exchanger when there is no DHW
circulation it is possible to over heat the DHW and cause the stat to trip even when the primary shunt pump is
not running.
Time Clock / BMS Operation
As an additional option the unit can be supplied with either a time clock that is incorporated into the panel or
Building Management System interface signals.
During control times / schedules, the pump(s) run continuously.
When in AUTO control (by either BMS or time clock) only the operation of the pump(s) is controlled. The high
temperature over heat protection and the control of the modulating valve is independent of the auto pump
control operation.
Four port valves are fitted as standard to all of the models in the range. Advantages of a four port valve are
that it allows the LTHW circulation to be maintained to and from the unit at all times. This:
•avoids cold pipe work when exchanger not calling for heat
•allows any other boiler safety & control functions to continue (such as over runs, etc)
•enables the exchanger to be connected into the main primary loop rather than from a “tapping” into
the main primary flow and return.
Primary Pump Energy Saving Feature (if fitted)
As another additional option, the packaged unit can be fitted with an energy saving feature for the primary
shunt pump. In times of low demand, the pump shuts down, thus saving energy. As this corresponds to the
valve closing, then the boiler circuit is closed off as well, thus saving more energy from the primary heat
source. The pump shuts down when the actuator is less than 4% open, and the pump starts when the actuator
is more than 6% open.
The energy saving feature can be retro-fitted, but it does involve modifications to the actuator and the control
panel..
Commissioning – as with all plant equipment, it is recommended that some commissioning takes place in
order to set up the equipment correctly and to check the settings. Contact our Sales Office for commissioning
rates if required.

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4 PORT VALVE – Cast iron body type
Before use, or if the system has been drained down for a period of time, it is important to check the operation
of the valve – push the button slide forward on the side of the actuator – this frees the actuator drive from the
valve – then rotate the valve stem from left to right (or right to left – depending upon where the valve is
positioned), whilst continuing to hold the slide button forward (releasing the button locks the actuator drive
back to the stem, thus preventing manual rotation). The valve stem should rotate for about 90 degrees before
coming to a stop. The valve stem should move relatively easily – if not, then check that slide button is being
pushed forward enough, and try again. If the stem still cannot be rotated, then spray WD40 into where the
valve stem goes through the valve body. If still no movement, then contact the Sales Office.

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Control valve testing:
Once filled with water, and before use, or if the system has been drained down for a period of time, it is
important to check the operation of the valve – switch on the control panel and set the temperature to a high
level (temperature altered by raising the set point). This is done by:
•press which is too the right of the temperature display.
•The lower display will then show “SP” and the upper display will show the actual set point.
•Press or to change the set point to the required value.
•Finally, press to return to normal run mode.
The actuator should slowly rotate clock wise until the valve is at the “2 O’clock” position and then stop. Now
lower the temperature (below ambient), and the actuator should rotate anti-clockwise and stop at around the
“10 O’Clock” position. If the actuator does not move, or does not turn full travel, then switch off at the panel by
turning the isolation knob in the panel door. Pull out central knob of actuator slightly (this exposes orange
sleeve) – this frees the actuator drive from the valve – then rotate the knob from left to right (or right to left –
depending upon where the valve is positioned). The valve stem should rotate for about 90 degrees before
coming to a stop. The valve stem should move relatively easily. If the stem still cannot be rotated, then valve
has seized. Remove actuator and spray WD40 into where the valve stem goes through the valve body and
then try rotating valve using a suitable wrench on the end of the stem.. If still no movement, then contact the
Sales Office.
Re-setting actuator – the central knob can only be pushed back in when the valve and the actuator are exactly
in line – the valve has be rotated back to the same position it was in before the central knob was pulled out. If
this proves to be troublesome, remove actuator by un-screwing central set screw in the middle of the actuator
knob, switch on the panel, set temperature high to force the control system to rotate actuator to fully open
position, rotate valve to fully open position, install actuator and tighten screw (NOTE – ensure that the back of
the actuator locks into the locating dowel protruding from the valve body) and then tighten the central screw.
It should then be possible to push back in the central knob and so covering the orange sleeve. Once done,
return the control temperature back to the desired value.
Instantaneous Hot Water Systems
1. Installation
Lifting: Exercise extreme caution at all times when lifting
Do not lift with the secondary shunt pump attached.
Lift from underneath if still on a base (pallet).
Lift off pallet using the lifting hole on the top at the plate heat exchanger (UKE14 only), or by attaching slings
under or through the base plate – ensure unit is steadied during manoeuvring. It is possible to lift from the top
frame bar of the heat exchanger (UKE14 only) to steady the assembly – however, do not lift from the frame bar
without using the lifting hole / from the base, as well.
It is also possible to attach a strap or sling around the top flanged connection pipe at F1 location (goes out to
the control valve) for steadying purposes only – do not lift from this point – use only to steady the unit whilst
lifting from other areas.

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Lifting Points to Avoid:
Avoid lifting from the stainless steel threaded connections, control panel, pump, valves, or any of the pipe work
and fittings not mentioned above.
Maintenance Space:
Leave a minimum of double the width of the exchanger, either side of the unit, to allow for access to the
exchanger tie bolts, and to allow for removal of the heat transfer plates.
Leakage:
Gasketed Plate Heat Exchangers do have the potential to leak at some time during their life. Therefore, to
avoid damage to plant room floor, electrical conduits etc., we recommend that a drip tray is placed underneath
the plate pack.
Safety:
If the unit is to operate near personnel, we recommend that a metal spray shield is located over the
gasketed plate pack in case of “blow out”. This would avoid scalding. The surfaces of the unit, pump, valve,
and pipe work become hot during operation – ensure that adequate consideration is given to personnel to
protect them from burns when deciding upon the location of the unit.
Pressure – it is essential that the exchanger, as with all pressure containers, is protected from the effects of
any over pressurisation should a fault in the operation of the system arise. Provision of suitable pressure relief
devices such as relief valves, or bursting disks should be considered – positioned local to the exchanger, with
no control, or isolating valves between the device and the exchanger to “block the pressure path”.
Welding:
Do not weld near to or on the heat exchanger or associated components.
Primary Shunt Pumps:
The pumps rely on water for cooling and lubrication. Damage will be caused if the pumps are run on a dry
system.
DHW Shunt Pump:
If a DHW pump is supplied loose, the direction of the pump must be so that the water flows into the top right
hand side connections (F2). Do not fit this pump until the unit has been installed in its final position. This pump
must be fitted with adequate supports so that no strain is put upon the heat exchanger connections.
Water Softener:
It is essential to treat / soften the DHW prior to heating to reduce the build up of scale in the heat exchanger.
Consult with a water softening specialist to determine the best method of treatment for the water in your area.
Water Connections:
Use two wrenches when attaching unions to the domestic water circuit threaded stub connections. One
wrench to be used to tighten the union & the other to prevent the stub end from rotating – this avoids damage
to the gasket inside the unit that seals against the back on the stub connection. Use a none hardening thread
sealant for best results. Threads are BS21 – taper, male. It is necessary to support the secondary pump and
the pipe work as the heat exchanger connections are not designed to accept any weight being imposed upon
them.

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Pipe-work:
To avoid damage to the unit, to prevent failure and to ease maintenance, we recommend the following:
•Pipe-work - fully support to avoid weight/forces acting upon the unit / connections.
•The fitting of flexible couplings if the pipe work is subject to vibration.
•The pipe work is completely flushed before attaching to exchanger. The exchanger acts as an
effective filter and will become blocked if pipe-work debris is allowed to enter the plate pack.
•The fitting of suitable vents, isolation valves & drains. To allow servicing of the package without
complete system draining appropriate isolation valves should be fitted.
•The fitting of non return valves where appropriate
•The fitting of suitable sized pressure relief valves in the pipe work on both circuits (essential safety
requirement).
Sensors:
There are two temperature sensors – one for control and the other for over heat protection.
Both sensors are the strap on type, they both need to be attached tightly to the pipe work. If steel pipe work is
used, then for best results we recommend that a section of steel pipe is replaced by copper, and the sensors
attached to this section of copper. Both sensors should be connected to the secondary flow pipe work going to
the services (flow from F3 connection). The control sensor needs to be attached to the pipe between 250 to
500 mm away from the exchanger, and the over heat located just after the control sensor. Route and clip the
wires as necessary – do not attach any wires near, or onto the tie bolts, or along the length of the top
horizontal frame bar of the heat exchanger.
Temperature sensors wires
Wires to both the sensor and the over heat stat can be extended - they are not any special wires - 2 core flex
for the sensor and 3 core for the over heat stat.
You shall loose accuracy of the temperature readings (by as much as 2 deg C), but it shall be consistent for all
readings recorded by the panel. This is due to additional resistance that the extended wires shall impose.
Remove the wires directly from the panel - add a junction box and then run you extended wires from the
respective junction boxes to then connect into the panel. If you cut the old wires, you shall have to add 2
junction boxes to increase the length and this shall add even more resistance - therefore, the use of one box is
the better way to do things.
Longer wires increase the resistance by 0.1 ohms per metre, hence the accuracy of the controller is reduced
(5 metres of wires = +/- 2 C accuracy)
The PT100 gives a resistance of 38 ohms
The wire = 0.1 ohms per metre
The controller compares the resistance between an internal resistor and the sensor loop, then subtracts the
one resistance from the other to come up with a reading. Therefore, if the wires are increased in length, this
comparison of resistances is different from the “expected” – hence a slightly different reading is recorded

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Electrical Installation:
Connect the supply cable to the panel using a suitable isolation switch protected by a fuse or MCB rated
at no more than 16 amps. The only connections required are the supply to the panel together with connection
of secondary pump(s) if applicable. When a secondary pump is supplied with the package, the pump control
cables are installed at the factory and clearly marked. They should be connected to the pump only after the
pump has been fitted to the pipe work. All other wiring is carried out at the factory. All wiring must be carried
out by suitably qualified personnel in line with current regulations.
Panel enclosure: IP 65 – takes 240 volts, or 415 volts if UKE-19
Controller: IP 54
Actuator: reduced to 24 Volts – cover IP41 rated
Pump terminal box: IP44 rating – takes full supply voltage from the control panel
Sensor: reduced to 24 volts – may be effected by moisture
Over heat stat: reduced to 24 volts – not designed for outside use as can rust internally.
Pipe-work Connections: - Fig 1: Connection location and function.

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2. Setting up the controller & Start-up:
Shock: It is essential that the exchanger is not subjected to thermal or mechanical shock as this could lead to
premature gasket failure.
Operation in automatic mode:
Once the pipe work and electrical connections have been made, all miniature circuit breakers (mcbs) located
in the panel should be set to “on” and the system filled and vented. The following procedure should then be
followed to start the unit:
1. The control panel should be switched on at the main isolator. The “controls healthy” lamp on the control
panel will be illuminated to indicate that the panel is live with the control voltage available.
2. Each pump is fitted with a “Hand/Off/Auto selector switch. If “Hand” is selected the relevant pump will run.
Similarly if “Off” is selected than the relevant pump will not run. If “Auto” is selected then the pump will run
under the control of the time clock/BMS interface.
3. The temperature controller is factory set at 10% proportional span and 5 sec integral time (auto reset).
These setting should give reasonable results with most systems but, depending on the thermal response
of the system, some adjustment may be needed. Any such adjustment should only be carried out by
competent persons. Full controller instructions are given in appendix 1.
4. Adjustment of the temperature set point can be done as follows:
•From the normal run mode press .
•The lower display will then show “SP” and the upper display will show the actual set point.
•Press or to change the set point to the required value.
•Finally, press to return to normal run mode.
5. The time clock (not fitted on BMS controlled panels) is factory set to the correct day and time. Should this
need alteration this can be done by pressing and holding the CLOCK key whilst pressing the DAY, HOUR
or MIN keys until the correct values are shown.
The time clock (if fitted) is also factory set to switch ON at 07.30 and OFF at 20.00 every day. Should this
need alteration this can be done as follows:
•Press TIMER key once to enter program mode, display will show “1 ON_:__C1”
•Press the DAY key to choose one of the 15 different day combinations (see table below) for the first
ON time of channel 1.
•Press the HOUR and MIN keys to select the desired first ON time for Channel 1
•Press TIMER key once. Display will show “1 OFF_:__C1”. Repeat previous steps to set the desired
first OFF time for channel 1.
•Repeat the entire sequence to set up to four different ON/OFF times for channel 1.
•When all required times are set press the CLOCK key to return to run mode.
NOTE: On panels fitted with a time clock, twin head pump(s), and auto head change over, channel two on
the time clock is used within the panel to rotate the duty pump and should not be altered from factory
settings. Should this inadvertently be done then it must be re-programmed as follows:
•Set the times for channel 1 as described above, once this is complete press the TIMER key so the
display shows “1ON_:__C2”.
•Press the DAY key until 14 is selected.
•Set the ON time to 00.01 using the HOUR and MIN keys.
•Press the TIMER key so display shows “1OFF_:__C2”.
•Set the OFF time to 23.59.
•Press CLOCK key to return to run mode.

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Once all times are set the clock must be put into AUTO mode by repeatedly pressing the CH A MANUAL
key and CH B MANUAL key until the indicator bar on the display is above the word AUTO for both
channels.
Reviewing the existing program can be done be done by repeated pressing of the TIMER key. When done,
press the CLOCK key to return to run mode.
Timed operation can be overridden by pressing the MANUAL key to move the indicator bar on the display
to the desired position (ON, OFF or AUTO). Timed operation will not resume until the indicator bar is
repositioned above the word AUTO.
All time clock adjustment can be done with the panel turned off.
Table showing on days for DAY key settings (X=on)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Mon X X X X X X
Tue X X X X X X
Wed X X X X X X
Thur X X X X X
Fri X X X X X
Sat X X X X X
Sun X X X
3. Shutting down the Exchanger for Maintenance:
Shut down: Switch panel “OFF” at main isolator.
Allow unit to cool, close isolation valves, and drain heat exchanger.
Tools: Ratchet spanners and ring or open-ended spanners, plus light machine oil. M24 (36mm
across flats)
Procedure:•Ensure the control panel is isolated and all isolation valves on the pipe work are closed.
•Allow unit to cool, and drain exchanger.
•Release all pressure from inside of exchanger.
•Lightly oil the tie bolt threads down either side of the exchanger.
•Undo the clamping bolts uniformly - keep the frame plates as parallel as possible during this
operation.
•Push / pull back the mobile frame plate away from plates pack & secure if necessary.
•Separate heat transfer plates carefully, avoiding damage to gaskets.
Use gloves to handle the plates - the edges can be sharp.
4. Cleaning of the plates:
Safety: Wear gloves & eye goggles when using cleaning detergents.
Brushing: Use nylon or other types of “soft” scrubbing brushes with detergent. Never use a metal
brush, steel wool, or sand/glass paper.
Detergents: Consult a cleaning specialist for a suitable choice of detergent. Ensure that all detergents
used are compatible with the plate and gasket material before use.
Plate material: 316 stainless steel
Gasket material: Nitrile rubber, or EPDM

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5. Assembly:
•Refer to the Plate Sequence Sheet to determine the order of the plates, & the type required.
•Fit the start plate (see illustration on next page), ensuring the plate pattern is pointing in the
correct direction as indicated on the plate sequence sheet.
•Fit plates in the correct order according to the Plate Sequence Sheet.
•Ensure all gaskets face towards the fixed / head frame plate (connection end).
•Alternate between left & right handed plates - if the plate edges form a regular honeycomb
pattern, then the left / right hand sequence is correct (see illustration below for herringbone
pattern example)
Assembly diagrams:
6: Tightening of the plate pack:
Procedure:•Lightly oil tie bolt threads.
•Evenly tighten all bolts. We recommend the use of ratchet / friction spanners.
•Ensure clamping is as uniform as possible, thus keeping the frames plates parallel throughout
the operation. Avoid skewing the frame plates by more than 10mm
•Tightening is complete when the distance between the inside faces of the two frame plates is
within the compression length maximum and minimum dimensions as given on the plate pack
sequence sheet.
•Finally check that all bolts are in tension, and clean any spilt oil off the frame plates.
•On completion, the unit can be pressure tested at no more than 6 bar g.

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Examples of Gasket and Plate types:

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7. Trouble Shooting:
Heat Exchanger Plate Pack Assembly:
1) Nuts tight to turn: insufficient oil on threads
2) Plates move out of alignment: remove plates & degrease, then dry.
inspect plate hanging system for damage.
Excessive pressure drops:
1) Liquid flows higher than design: Check & adjust
2) Plate channels blocked: Back flush, C.I.P., or dismantle to clean.
3) Inaccurate measurement: Check pressure gauge for accuracy
ensure measurement does not include any
bend, valve / fitting, & pipe run losses.
4) Liquid temp. below design: Viscous media generate higher resistance to
flow at lower temperatures.
5) Media used not as per design: The addition of glycol or other additives can
increase the pressure drop.
Leakage: 1) leakage near connection: First heat transfer plate gasket damaged – dismantle
heat exchanger plate pack, and check condition. If
the threaded connections are rotated when in situ,
damage can occur to the backing O-rings. Refer to
connection tightening section of the manual.
Flange gaskets leaking – check / replace.
Crack in weld at joint – Dye Pen. Check and repair
(remove plates out of heat exchanger before
welding).
2) cross contamination: Check all plates for cracks and / or holes.
3) leakage from plate pack: Check tightening dimension
Check condition of the gaskets.
Check that all gaskets are seated correctly.
For nearly all leakage problems, it is necessary to dismantle the plate pack before any attempts to rectify the
fault can be made. Mark the area(s) from where the leaks are occurring before taking apart the exchanger to
assist in fault finding once plates are taken out of exchanger.
Decrease in the performance:
1) plate surfaces require cleaning or de-scaling.
2) pumps or associated controls have failed.
3) liquid flows not as per the design specification.
4) associated boiler under sized.
5) primary temperature lower than design figures.
6) Sensors faulty (check first that they are securely fastened around pipe work).
7) plate pack has been assembly incorrectly.
8) unit running in co-current flow, instead of counter current - check with contract
drawing and alter pipe work if necessary., and check direction of pump flows.
9) air lock has developed in the plate pack.

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Trouble Shooting – continued:
No Secondary Flow:
Possible Causes:
a) Electrical Fault
b) Pump Tripped (Trip Lamp illuminated on control panel)
c) High Limit Shut Down (High Temp. Lamp illuminated on control panel facia)
d) Air Lock in system
e) Not in correct mode of operation.
Remedies: a) Check electrical supply to control panel together with the mcbs fitted within the panel
b) Reset overload within the control panel using the blue reset button fitted on the relevant
overload F112 is for primary pump 1
F132 is for primary pump 2 (only if fitted)
F152 is for secondary pump 1 (only if fitted)
F172 is for secondary pump 2 (only if fitted)
Should the pump fail to restart, a problem may exist elsewhere in the system and advice
should be sought from the installer/supplier. For a twin headed pump, switch the control
dial to “manual” – this changes over the pump head that is currently in operation.
c) The system will need to be reset after high limit shut down. Wait for a few minutes to allow
the temperature to cool slightly and then press the manual re-set button. Should the
problem fail to reset or frequently reoccur, advice should be sought from the
installer/supplier.
d) Vent air from system.
e) Check Main Control Switch/Time clock.
Secondary Water Temperature too High / Low , or unit cuts out on over heat
Possible Causes:-
a) Wrong set point on controller.
b) Air Lock in pipe work.
c) Primary water temperature too high or too low.
d) Primary water flow too high / too low, or secondary flow not correct.
e) Fault in temperature sensor.
f) Actuator fault – the valve does not modulate, or move during operation..
g) Control valve seized or binding
h) Primary circuit pressure feeding PHE too high
Remedies:- a) Adjust Controller – see relevant section in manual
b) Vent System
c) Ensure that boiler or source of primary temperature water is functioning correctly & rectify
as required.
d) Ensure that primary and/or secondary water pump(s) / source is / are performing correctly
& rectify as required.
e) Electrician required – the sensor and the wires need to be checked. Isolate panel, then
disconnect the temperature sensor wires (not the over heat stat) out of the panel and
measure the resistance. The resistance should be around 110 ohms (depending on
temperature. If a reading of “infinite” is shown then there is an open circuit, and the most
likely cause is that the wires leading to and from the sensor are broken. If the reading is
zero, then there is a short circuit in the circuit. Check / replace the wires/sensor.
f) Actuator failed – remove from valve (see actuator replacement section). Alter set point to
low temperature and check to see if actuator drive turns to fully closed position, and then
alter set point to a high temperature and check to see if drive rotates a full 90 degrees
from fully closed position. If no, or in-sufficient travel of the drive is observed, then
actuator requires replacement.

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Trouble Shooting – continued:
g ) Check for binding / seizure – remove actuator (see actuator removal section) and then try to
rotate valve stem – you can use grips on the end of the stem as an aid but make sure that
the stem is protected from damage from the grips. The valve should rotate freely through out
the range of travel. Sediment build up can block the action of the valve and this rotating action
can some times be enough to free the component. If binding persists then isolate the unit,
shut down, and drain primary circuit. The inner parts of the valve can be removed without
taking the complete valve off the pipe work:
Cast iron valve type – loosen the 4 bolts on the side of the valve body and pull body back
the side panel. This may require a lever, but try to avoid damage to the sealing face.
Inspect, clean and lubricate or replace with new components. If it looks as though the
paddle is binding against the valve body then the paddle then any “proud” / high points
can be shaved down by the use of wet and dry, or emery, paper.
Brass valve type, rotate the silver disk until the lugs on the disk are no longer underneath
the brass noggins and then pull out the stem and valve paddle – there is a sealing O-ring
which needs to be protected from damage. If the paddle is tight to remove then replace the
central bolt into the stem and use the bolt to aid in pulling out the paddle part of the valve.
If it looks as though the paddle is binding against the valve body then the paddle then any
“proud” / high points can be shaved down by the use of wet and dry, or emery, paper.
A possible remedy without taking out valve inners may be to spray lubricant (such as
WD40) onto valve shaft bearing (see section on control valve in Section 1 at beginning of
manual) and then locate the stem a few times to work in the lubricant. If the pressure of the
primary circuit is too high then it can be greater than what the primary shunt pump on the
exchanger control loop can pump against. If this is the case, the primary shunt pump fails to
pump back into the return loop of the main primary circuit as it is effectively “fighting” against
the pressure of the primary circuit. The primary circuit pressure must be reduced to allow to
the shunt pump to circulate water through the exchanger.
Primary or secondary Pump(s) fails to operate:
Possible Causes:-
a) Circuit breaker tripped or set to “off” - Check circuit breakers inside panel .
b) If pump tripped out of a fault then this could indicate a too high a Current – if the unit is new
then check the direction of the pump rotation and check to see if the pipe work has been
connected correctly – the over load setting can be adjusted – contact an electrician to
undertake this work. The wiring diagram can be referred too to find the location of the overload
and the factory setting. There is a scaled dial on the overload which can be rotated to
increase/decrease the overload current – caution – too high an over load setting reduces the
protection on the pump.
c) Pump motor burnt out or faulty – contact the Sales Office for replacement parts.

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Actuator Replacement:
a) Switch off panel
b) Un-do central bolt holding actuator to valve stem, and pull off complete actuator assembly.
c) Remove small cross head screw holding actuator cover, remove cover, remove wire plug, and
note position of the 3 (some times 4) small dip switches on the printed circuit board.
d) Spray WD 40 or similar into valve stem bearing to lubricate valve and rotate a few times from left
to right.
e) Remove cover on new actuator, and set the dip switches the same as the old unit, plug in wires,
and refit actuator cover
f) Rotate control valve stem fully clockwise until it stops.
g) Switch on the panel, set temperature high to force the control system to rotate actuator to fully
open position, install actuator and tighten screw (NOTE – ensure that the back of the actuator
locks into the locating dowel protruding from the valve body) and then tighten the central screw.
Do not over tighten, and ensure that pointer is to the right (valve fully open), and that the actuator
knob is fully pushed in.
h) Alter the control Set Point to a low temperature – actuator should move until stops at fully closed
position. Then alter the control Set Point to a high temperature – actuator should move to fully
open position. If all OK then re-set control temperature to desired value.
8. Maintenance:
Time interval: Once a year as a minimum.
Performance: Check temperatures and flows against commissioning data.
Plate pack: Check the tightening dimension, and look for any signs of leakage from heat
exchanger.
Nozzles: Check general condition, and for any signs of leakage.
Frame: wipe clean all painted parts, and check surfaces for signs of damage - “touch up” if
necessary.
Bolts & bars: Check for rust, and clean. Lightly coat threaded parts with molybdenum grease, or a
corrosion inhibitor (ensure that no grease, etc. falls onto the plate gaskets).
Electrical: Check the security of all electrical connections and inspect the wiring for damage.
Actuator/valve: Spray WD40 or similar into valve spindle where it enters the valve..
9. Spare Parts:
To help identify the unit, it is necessary to quote the serial number as given on the nameplate. Replacement
parts and other information can be obtained from:
UK Exchangers Ltd
Unit 55, Stilebrook Road, Olney, Buckinghamshire, MK46 5EA
Tel : [phone] Fax : [phone]
E-mail: [e-mail] Web: www.uk-exchangers.com

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Appendix 1:
Parameter listing for Temperature Controller (For commissioning Engineers use only)
1/16 DIN PROCESS CONTROLLERS
CONCISE PRODUCT MANUAL
CAUTION: Installation should be only performed by technically
competent personnel. Local Regulations regarding electrical
installation & safety must be observed.
SELECT MODE
Select mode is used to access the configuration and operation menu functions.
It can be accessed at any time by holding down and pressing .
In select mode, press or to choose the required mode, press to enter. An unlock
code is required to prevent unauthorised entry to Configuration & Setup modes. Press or
to enter the unlock code, then press to proceed.
Mode Upper
Display
Lower
Display
Description
Default
Unlock
Codes
Operator   Normal operation None
Set Up   Tailor settings to the application 
Configuration   Configure the instrument for use 
Product Info   Check manufacturing information None
Auto
-Tuning   Invoke Pre-Tune or Self-Tune 
Note: The instrument will always return automatically to Operator mode if there is no key
activity for 2 minutes.
CONFIGURATION MODE
First select Configuration mode from Select mode (refer to section 2).
Press to scroll through the parameters, then press or to set the required value.
Press
to accept the change, otherwise parameter will revert to previous value. To exit from
Configuration mode, hold down and press to return to Select mode.
Note: Parameters displayed depends on how instrument has been configured. Refer to
user guide (available from your supplier) for further details. Parameters marked * are
repeated in Setup Mode.
Parameter Lower
Display
Upper
Display
Adjustment range & Description Default
Value
Input Range/Type  PT100 sensor 
Scale Range Upper
Limit  Scale Range Lower Limit +100
to Range Maximum 100
Scale Range Lower
Limit  Range Minimum to
Scale Range Upper Limit -100 0
Decimal point
position  0=XXXX, 1=XXX.X, 2=XX.XX, 3=X.XXX
(non-temperature ranges only) 1
Control Type

 Primary only

 Primary & Secondary
(e.g. heat & cool)
Primary Output
Control Action   Reverse Acting 
 Direct Acting
Alarm 1Type 
 Process High Alarm

 Process Low Alarm
 Deviation Alarm
 Band Alarm
 No alarm
High Alarm 1
value*  Range Minimum to Range Maximum in display
units
Range Max
Low Alarm 1
value*  Range Min
Band Alarm 1
value*  1LSD to span from setpoint in display units 
Dev. Alarm 1
value*  +/- Span from setpoint in display units 
Alarm 1
Hysteresis*  1LSD to full span in display units 
Alarm 2 Type*  Options as for alarm 1 
High Alarm 2
value*  Range Max
Low Alarm 2
value*  Range Min
Band Alarm 2
value*  
Dev. Alarm 2
Value* 
Options as for alarm 1

Alarm 2
Hysteresis*  
Loop Alarm   (disabled) or  (enabled) 
Loop Alarm Time*  1sec to 99 mins. 59secs .
Alarm Inhibit

 No alarms Inhibited

 Alarm 1 inhibited
 Alarm 2 inhibited
 Alarm 1 and alarm 2 inhibited
Output 1 Usage 
 Primary Power

 Secondary Power
 Alarm 1, Direct
 Alarm 1, Reverse
 Alarm 2, Direct
 Alarm 2, Reverse
 Loop Alarm, Direct
 Loop Alarm, Reverse
 Logical Alarm 1 OR 2, Direct
 Logical Alarm 1 OR 2, Reverse
 Logical Alarm 1 AND 2, Direct
 Logical Alarm 1 AND 2, Reverse
 Retransmit SP Output
 Retransmit PV Output
Linear Output 1
Range 
 0to 5 V DC output

 0to 10 V DC output
 2to 10 V DC output
 0to 20 mA DC output
 4to 20 mA DC output
Retransmit Output
1Scale maximum 
-1999 to 9999
(display value at which output
will be maximum)
Range max
Retransmit Output
1Scale minimum 
-1999 to 9999
(display value at which output
will be minimum)
Range min
Output 2 Usage  As for output 1 Sec or Al2
Linear Output 2
Range  As for output 1 
Retransmit Output
2Scale maximum 
-1999 to 9999
(display value at which output
will be maximum)
Range max
Retransmit Output
2Scale minimum 
-1999 to 9999
(display value at which output
will be minimum)
Range min
Output 3 Usage  As for output 1 
Linear Output 3
Range  As for output 1 
Retransmit Output
3Scale maximum 
-1999 to 9999
(display value at which output
will be maximum)
Range max
Display Strategy  ,,,,or (refer to section 8) 
Serial
Communications
Protocol

 ASCII
Mm
Mm Modbus with no parity
Mm Modbus with Even Parity
Mm Modbus with Odd Parity
Serial
Communications
Bit Rate

.1.2 kbps
.
.2.4 kbps
.4.8 kbps
.9.6 kbps
 .19.2 kbps
Comms Address  1to 255 (Modbus), 1 to 99 (ASCII) 
Comms Write  Ww Read/Write Ww
 Read only
Digital Input 1
Usage   Setpoint 1 / Setpoint 2 select* 
 Automatic / Manual select
Digital Input 2   Setpoint 1 / Setpoint 2 select* 

-19-
Usage  Automatic / Manual select
 Remote / Local setpoint select
Remote Setpoint
Input Range 
 0to 20 mA DC input

 4to 20 mA DC input
 0to 10 V DC input
 2to 10 V DC input
 0to 5 V DC input
 1to 5 V DC input
 0to 100mV DC input Available on
full RSP (Slot
B) only
 Potentiometer
(2Kminimum)
RSP Upper Limit  -1999 to 9999 Range max
RSP Lower Limit  -1999 to 9999 Range min
RSP Offset  Constrained within Scale Range Upper & Scale
Range Lower limits 
Configuration Lock
Code  0to 9999 
SETUP MODE
Note: Configuration must be completed before adjusting Setup parameters.
First select Setup mode from Select mode (refer to section 2). The MAN LED will
light while in Setup mode. Press to scroll through the parameters, then press or
to set the required value.
To exit from Setup mode, hold down and press to return to Select mode.
Note: Parameters displayed depends on how instrument has been configured.
Parameter Lower
Display
Upper Display Adjustment Range &
Description
Default
Value
Input Filter Time Constant  OFF or 0.5 to 100.0 secs .
Process Variable Offset  ±Span of controller 
Primary Power Ww Current power levels (read only) N/A
Secondary Power Ww
Primary Proportional Band  0.0% (ON/OFF) and 0.5% to 999.9%
of input span .
Secondary Proportional Band 
Automatic Reset
(Integral Time)  1sec to 99 mins 59 secs and OFF .
Rate (Derivative Time)  00 secs to 99 mins 59 secs .
Overlap/Deadband  -20 to +20% of Primary and
Secondary Proportional Band 
Manual Reset (Bias)  0%(-100% if dual control) to 100% 
Primary ON/OFF Differential  0.1% to 10.0% of input span
centered about the setpoint.
(Entered as a percentage
of span)
.
Secondary ON/OFF Diff. 
Prim. & Sec. ON/OFF
Differential 
Setpoint Upper Limit  Current Setpoint to Range max R/max
Setpoint Lower limit  Range min to Current Setpoint R/min
Primary Output Power Limit  0% to 100% of full power 
Output 1 Cycle Time 
0.5, 1, 2, 4, 8, 16, 32, 64, 128,
256 or 512 secs. 
Output 2 Cycle Time 
Output 3 Cycle Time 
High Alarm 1 value  Range Minimum to Range Maximum R/max
Low Alarm 1 value  R/min
Deviation Alarm 1 Value  ±Span from SP in display units 
Band Alarm 1 value  1LSD to span from setpoint 
Alarm 1 Hysteresis  1LSD to full span in display units 
High Alarm 2 value  Range Minimum to Range Maximum R/max
Low Alarm 2 value  R/min
Deviation Alarm 2 Value  ±Span from SP in display units 
Band Alarm 2 value  1LSD to span from setpoint 
Alarm 2 Hysteresis  1LSD to full span in display units 
Loop Alarm Time  1LSD to full span in display units .
Auto Pre-tune  
(disabled) or

Auto/manual Control
selection   (enabled)
Setpoint Select shown in
Operator Mode 
Setpoint ramp adjustment
shown in Operator Mode 
SPRamp Rate Value  1to 9999 units/hour or Off (blank)
Off
Setpoint Value Scale range upper to lower limits.
(when dual or remote setpoint options
are used,
 is replaced by
 &  or 
or *before the legend indicates
the currently active SP)
Scale
Range
Minimum
Local Setpoint Value 
Setpoint 1 Value 
Setpoint 2 Value 
Setup Lock Code  0to 9999 
AUTOMATIC TUNING
MODE
First select Automatic tuning mode from Select mode (refer to section 2).
Press toscroll through the modes, then press ortoset the required value.
To exit from Automatic tuning mode, hold down and press , to return to Select mode.
Pre-tune is a single-shot routine and is thus self-disengaging when complete.
If  in Setup mode = ,Pre-tune will attempt to run at every power up*.
Refer to the full user guide (available from your supplier) for details on controller tuning.
Parameter Lower
Display
Upper Display
Default
Value
Pre-Tune   or .Indication remains  if automatic
tuning cannot be used at this time* Off
Self-Tune 
Tune Lock  0to 9999 
Note: Automatic tuning will not engage if either proportional band = 0.
Also, Pre
-tune will not engage if setpoint is ramping, or the PV is less than 5% of input
span from the setpoint.

-20-
PRODUCT INFORMATION
First select Product information mode from Select mode (refer to section 2).
Press to view each parameter. To exit from Product Information mode, hold down
and
press to return to Select mode.
Parameter Lower
Display
Upper
Display
Description
Input type   Universal input
Option 1 module type fitted 
 No option fitted
 Relay output
 SSR drive output
 Triac output
 Linear DC voltage / current output
Option 2 module type fitted  As Option 1
Option 3 module type fitted 
 No option fitted
 Relay output
 SSR drive output
 Linear DC voltage / current output
 Transmitter power supply
Auxiliary Option A module
type fitted 
 No option fitted
 RS485 communications
 Digital Input*
 Remote Setpoint Input (basic)*
Auxiliary Option B
module type fitted 
 No option fitted
 Remote Setpoint Input (full)
and Digital Input 2*
Firmware type  Value displayed is firmware type number
Firmware issue  Value displayed is firmware issue number
Product Revision Level  Value displayed is Product Revision level
Date of manufacture Mm Manufacturing date code (mmyy)
Serial number 1  First four digits of serial number
Serial number 2  Middle four digits of serial number
Serial number 3  Last four digits of serial number
Messages & ERROR
INDICATIONS
These messages indicate that an error has occurred or there is a problem with the process
variable signal or its wiring.
Caution: Do not continue with the process until the issue is resolved.
Parameter Upper
Display
Lower
Display
Description
Instrument
parameters are in
default conditions
 
Configuration & Setup required. This screen is
seen at first turn on, or if hardware
configuration has been changed. Press
to
enter the Configuration Mode, next press
or
to enter the unlock code number, then
press to proceed
Input Over Range  Normal Process variable input > 5% over-range
Input Under Range  Normal Process variable input > 5% under-range
Input Sensor Break  Normal
Break detected in process variable input sensor or
wiring
RSP Over Range Normal  ** RSP input over-range ** also seen
wherever RSP
value would be
displayed
RSP Under Range Normal  ** RSP input under-range
RSP Break Normal  ** Break detected in RSP
input signal
Option 1 Error

 Option 1 module fault
Option 2 Error  Option 2 module fault
Option 3 Error  Option 3 module fault
Option A Error  Option A module fault or RSP in both A & B
Option B Error  Option B module fault
OPERATOR MODE
This mode is entered at power on, or accessed from Select mode (see section 2).
Note: All Configuration mode and Setup mode parameters must be set as required before
starting normal operations.
Press to scroll through the parameters, then press or to set the required value.
Note: All Operator Mode parameters in Display strategy 6 are read only (see  in
configuration mode), they can only be adjusted via Setup mode.
Upper Display Lower
Display
Display Strategy and
When Visible
Description
PV Value
Active SP
Value 1&2(initial screen)
PV and target value of selected SP
Local Setpoints are adjustable in
Strategy 2
PV Value
Actual SP
Value 3&6(initial screen) PV and actual value of selected SP
(e.g. ramping SP value).
Read only
PVValue (Blank) 4(initial screen) Process variable only
Read only
Active SP
Value (Blank) 5(initial screen)
Target value of selected setpoint
only.
Read only
SP Value 
1, 3, 4, 5 & 6 if digital
input is not  and
RSP not fitted
Target value of SP
Adjustable except in Strategy 6
SP1 Value  Digital input = .
_lit if active SP = SP1
Target value of SP1
Adjustable except in Strategy 6
SP2 Value  Digital input = .
lit if active SP = SP2
Target value of SP2
Adjustable except in Strategy 6
Local SP
Value 
RSP fitted.
or *lit if the
active SP = 
Target value of local setpoint
Adjustable except in Strategy 6
Remote SP
Value 
RSP fitted.
or *lit if the
active SP = 
Target value of remote setpoint
Read only
,
 or  
RSP is fitted, digital
input is not  and
 is enabled in
Setup mode
Selects local/remote active setpoint
 = local SP,  = remote SP
 = selection via digital input (if
configured). Note: selecting 
or
 will override digital input, active
SP indication changes to *
Adjustable except in Strategy 6
Actual SP
Value   is not blank Actual (ramping) value of
selected SP. Read only
Ramp Rate   enabled in
Setup mode
SP ramping rate, in units per hour
Adjustable except in Strategy 6
Manual Control
If  is set to  in Setup mode, manual control can be selected/de-selected by
pressing the key in Operator mode, or by changing the status of a digital input if  or
 have been configured for  in Configuration mode.
While in Manual Control mode, the indicator will flash and the lower display will show
xxx (where xxx is the current manual power level). Switching to/from manual mode is via
Bumpless Transfer. Press or to set the required output power.
Caution: Manual power level is not restricted by the  power limit.