JFD WHE - 3, Operation And Maintenance Manual

Page 1: ...Operation and Maintenance Manual Water Heater Electric WHE 3 With Remote Panel Part Number KI40018 AA AB and AC Document Number KI OM 0591 Revision 3 ...

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Page 3: ...tions 9 2 3 Electrical Installation 10 2 4 Initial System Check 10 2 5 Start Up and Function Check Local Control 11 2 6 Start Up and Function Check Remote Control 13 3 Operations 14 3 1 General 14 3 2 Heating Requirement 14 3 3 Operator Controls 17 3 4 Operating Start Up Procedure 18 3 5 Shutdown Procedure 19 3 6 Drain System 19 4 Maintenance 20 4 1 Routine Maintenance 20 4 2 Periodic Maintenance ...

Page 4: ...v KI OM 0591 Rev 3 6 Part Identification 29 6 1 Hoses 33 6 2 Spare Parts List 35 Appendix A Temperature Controller Parameter Settings Appendix B Manufacturer Related Documents Appendix C System Drawings ...

Page 5: ...ecked A Bennett Mechanical Engineer Approved P Black Senior Mechanical Engineer Copyright Details 2017 JFD Copyright of this document is the property of JFD and it may not be copied used or otherwise disclosed in whole or in part except with prior written permission from JFD or if this document has been furnished under a contract with another party as expressly authorised under that contract Discl...

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Page 7: ...ent Their uses are as follows INFORMS THE READER OF AN OPERATION OR CONDITION WITCH MAY INVOLVE RISK TO LIFE INFORMS THE READER OF AN OPERATION OR STATE WITH POTENTIAL FOR PERSONNEL INJURY Informs the reader of an operation or state with potential for damage to equipment Note Informs the user of additional information for clarification or to assist with an operation ...

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Page 9: ...eawater and runs from a 440 3 phase 60 Hz or 380 3 phase 50 Hz power supply The output is heated seawater at pressures up to 68 bar and 45 litres min The remote control panel of the WHE 3 is a 19 rack mounted face plate comprising the following Fine Temperature Control Potentiometer Water Outlet Temperature Display Pump Run Indication General Fault Indication Emergency Stop Push Button The remote ...

Page 10: ...ºC The Temperature rise through the unit would be 49ºC The heater selection schedule shown in Table 3 indicates that heater banks 1 through to 5 should be used as this would provide a temperature rise of 47 50ºC through the unit Once the correct configuration of heater banks has been selected the temperature controller regulates the temperature of the outlet by adjusting the flow rate of water pas...

Page 11: ...resh water inlet tee and distributed to two separate inlet filters The filters may be isolated using hand valves on the inlet and outlet of each filter These filters clean input water of particulate matter down to 50 µm in order to protect the piston pump and umbilical coupling from being damaged and prevent clogging of the heating water tubes in the diver suits The inlet filters are each fitted w...

Page 12: ...S A HIGH VOLTAGE HIGH CURRENT SYSTEM AND ONLY TRAINED COMPETENT PERSONNEL SHOULD ATTEND TO INSTALLATION SERVICE AND MAINTENANCE REQUIREMENTS ALL RELEVANT SAFETY PROCEDURES MUST BE FOLLOWED The remote control panel requires cable connection to the WHE 3 unit and these connections are detailed in the electrical drawings provided in Appendix C The WHE 3 main panel and remote control panel are operate...

Page 13: ...ontrol circuit is used to control the contactors relays timer and the safety circuits in the system The contactors controlled by switches mounted in the control panel door switch the high voltage to the heaters and the pump The temperature of the output fluid is regulated by dumping excess capacity thereby increasing the flow rate of fluid through the heater tank and lowering the output temperatur...

Page 14: ... electrical schematics in Appendix C Refer to Table 2 and Figure 2 below for the control panel layout and part identification Figure 2 Control Panel Layout The following table identifies the major control components and outlines their function within the control circuit Refer to wiring diagrams in Appendix C for full wiring details Table 2 Control component identification Component Component ID Fu...

Page 15: ...e control circuit Pump Overload O L1 This overload trips if the pump draws excessive current The normally open contact of the overload supplies the pump run indication The normally closed contact of the overload is used in the safety circuit Fault Relay Over Temperature R1 Fault relay de energizes during fault when the over temperature relay R3 or the thermostat contacts are open The over temperat...

Page 16: ...function Switch Mushroom Emergency Stop S9 This switch contact de energizes the motor and heater control circuits The pump and heaters are switched off but the controller and safety circuits remain energized Switch Float S10 The float switch mounted in the level control tank is used to prevent the system function if the water level in the heater tank is low The contact is used to activate the de b...

Page 17: ...bar The WHE 3 outlet is a 3 4 NPT stainless steel penetrator This may supply a valve manifold or a single pipe connection depending on the installation requirements The plumbing used should be capable of withstanding the maximum working pressure of 68 bar All valves fittings tubing and manifolds connected to the hot water system must be capable of working at this pressure If the system is not requ...

Page 18: ...nput to the system should be fitted to the bottom right hand side of the stainless steel electrical enclosure The mains power cable should be installed through a suitable gland and correctly grounded to the armour Mains cable connections to the isolator terminals must be tightened and checked POWER CONNECTION ENSURE THAT THE POWER SUPPLY IS TURNED OFF BEFORE CONNECTING ANY WIRING After the mains p...

Page 19: ...g 5 Allow the water to run for 5 to 10 minutes in this mode 6 Confirm that the heater tank is full by opening the tank vent valve to purge any residual bubbles in the heater tank 7 To complete priming shut the vent valve and supply valve s 2 5 Start Up and Function Check Local Control After installation is complete the WHE 3 must be thoroughly checked prior to being put into service The following ...

Page 20: ...ilable 8 Pump Motor Start Push the pump Start button the pump will start running and system pressure will rise to balance the pressure drop down the length of umbilical The flow rate will be approximately 45 lit min 9 Pump Flow Rate The pump is a positive displacement type and the flow rate may only be limited by an under supply of water to the pump To check flow rate use an inline flow meter on t...

Page 21: ...p with the WHE 3 Activation of the remote emergency stop will remove power from the main control circuit stop the pump motor and de energize the heater banks The heater banks will remain selected as the rotary selector switches are not reset An alarm will be generated and the general fault on the remote panel will illuminate in addition to the indication on the local control panel 2 Remote Pump Ru...

Page 22: ...a set point is selected that is below the range of the heater element selection then the unit will fully open the temperature control valve and may control temperature to some extent but massive energy losses will be incurred due to excessive dumping of heated water 3 2 Heating Requirement Before running the unit the operator must determine the heating required for the divers The following steps o...

Page 23: ...ed Trise To determine the required temperature rise Trise through the unit subtract the inlet temperature Tin from the required total outlet temperature Tout calculated in step 3 5 Heater bank selection After calculating Trise use the table in Table 3 to determine the heater banks to be used Locate the temperature rise in the left column Read across to determine which heaters are required to achie...

Page 24: ...52ºC 95 30 125ºF The Temperature Controller set point SV should be set to the calculated Total Outlet Temperature Tout 52 C Trise Tout Tin 52 5 47ºC 125 40 85ºF As indicated in Table 3 for a 43 47ºC 77 85ºF temperature rise heater banks 2 3 4 and 5 should be switched on Heater on Temp Rise C F Heater 1 Heater 2 Heater 3 Heater 4 Heater 5 0 4 0 7 4 8 7 14 8 11 14 20 11 14 20 25 14 18 25 32 18 22 32...

Page 25: ...nd if required a higher heater selection may be used 3 3 Operator Controls Local operator control of the WHE 3 is achieved using the Temperature Controller keypad to change the set point and rotary switches for heater bank selection For remote control the WHE 3 operator will select the heater banks to be used and start the pump motor locally Once the controller has been set to use the remote set p...

Page 26: ...tor are switched to the on position Emergency switch Check that the switch is de activated 2 Open the sea water supply valve and allow water to flow through the system Note If the indicated pressure drop across the inlet filters exceeds 1 bar the filter cartridge may need to be changed to maintain optimum performance 3 Check the inlet water temperature and determine the required temperature rise a...

Page 27: ...system with fresh water for at least 15 to 20 minutes after each usage This will flush out the heating system plumbing valves umbilical and most important the breathing gas heat exchanger and the hot water suit If required run the pump to ensure adequate flushing of the system pipework with fresh water 5 During the flushing process ensure that the entire system is flushed out by momentarily openin...

Page 28: ... normal working conditions the filters should be changed when the pressure drop across the filter units rises about 1 bar The pressure drop across the filters is deduced by subtracting the outlet pressure indicated on the filter gauge from the inlet pressure gauge The two filters are arranged with valves to allow the isolation of each filter for service The unit is designed to run using a single f...

Page 29: ...ctions from JFD Items authorised for return must be shipped with freight prepaid A full description of the operating conditions medium being used and full details of the problem with the pump 4 3 5 Filter Inspection The most common cause of low pump pressure is damage due to foreign matter carried in the fluid being pumped Small abrasive particles in the fluid may damage the pump valves valve seat...

Page 30: ...rn parts Inlet filter clogged or improperly size Clean Use 50 micron filter element Check more frequently Worn packing Abrasives in pumped fluid or severe cavitation Inadequate water supply Install proper filter Check fluid supply available to the pump Low Pressure Fouled or dirty inlet or discharge valves Clean inlet and discharge valve assemblies Worn inlet or discharge valves Replace worn valve...

Page 31: ...plug o ring Oil leaking from drain plug Loose drain plug or worn drain plug o ring Tighten drain plug or replace o ring Loud knocking noise in pump Pulley loose on crankshaft Check key and tighten set screw Broken or worn bearing Replacing bearings Frequent or premature failure of the inlet manifold seals Scored plungers Replace plungers Over pressure to inlet manifold Reduce inlet pressure 2 5 ba...

Page 32: ...the flow rate will be maintained Water will not heat Circuit breakers tripped in heating circuits Switch off reset breaker s If breaker s trip again when switched on investigate cause In an emergency faulty element may be switched off leaving other banks operational Manual over board dump valve open Close manual overboard dump valve Temperature control valve is stuck in the fully open position due...

Page 33: ...malfunction Clean regulator and reassemble If unit will not regulate pressure on pump to 2 5 bar replace or repair regulator Emergency Corrective Action Bypassing the regulator will allow operation in an emergency but this is not recommended as this will put increased load and water on pump as well as causing seals to leak and allow water into crankcase Refer to Pump Troubleshooting 5 1 and 0 Sea ...

Page 34: ...perature switch Determine which over temperature switch is open circuited and replace The over temperature switches in system are TC 1 1 and TC 1 2 System will not run pump overload fault light on Pump overload relay has tripped Possible low voltage single phase of incorrect frequency Check the input voltage and frequency Measure the current on the pump motor to see if it s within rating Reset ove...

Page 35: ...rn switch on Control circuit breaker tripped Check reset If faulty replace Faulty main power contactor Replace Pump turns on and off rapidly Faulty overload relay Replace Motor shorted Replace Pump will not run for long periods of time without overloading Low voltage to system Check voltage If voltage is not a minimum of 420 V pump will overload Pump is corroded or jammed inside and very difficult...

Page 36: ...nd the remote display Refer to the Appendix B section for the controller for manual and details on the controller parameter settings Remote analog dial not calibrated to controller If there is incorrect scaling between the remote potentiometer and the temperature controller the pointer knob may be loose or incorrectly aligned Remove the pointer re align and refit If the analogue range scale is inc...

Page 37: ...KI OM 0591 Rev 3 29 Part Identification 6 Part Identification Figure 6 General Arrangement Front View Figure 7 Inlet Outlet and Pressure Relief Valve ...

Page 38: ...ched pair AA and AC DO03077 Belts Matched pair AB DO04356 13 Motor Pulley Taper Lock Bush Part No DO02831 DO02830 14 Pump Pulley Taper Lock Bush Part No DO02829 DO02828 15 Filter Gauge DOPBBA63BB02QJ2A 16 Filter Inlet Valve 3 4 VB36265 17 Check Valve DO02780 18 Fresh Water Inlet Valve 3 4 VB36265 19 Inlet Pressure Gauge DOPBBA63BB02QJ2A 20 Inlet Manifold Block DO05902 21 Salt Water Inlet Valve 3 4...

Page 39: ...KI OM 0591 Rev 3 31 Part Identification Figure 8 General Assembly Rear Side View 30 Front Dump Manifold DO05900 Item Description JFD Part No ...

Page 40: ... Tank 4 0 kW AB DO39912 32 Heater Element Inside Heater Tank 4 5 kW AA and AC DO02776 SPARE Heater Element Inside Heater Tank 4 5 kW AB DO39113 33 Pump CAT 1057 DO02722 34 Motor DO02777 35 Pressure Reducing Valve Set to 2 bar DO02359 36 Filter Housing DO04768 37 Filter Element Inside Housing 10 50 µm DO04793 38 Level Float Switch DO02779 39 Mechanical Safety Thermostat DO02374 40 Relief Valve Tank...

Page 41: ...Cert 3 2 Cert Heater Tank Relief Valve to Dump Manifold HP621 HM047 Manual Temperature Control Valve to Dump Manifold DO801 3 4 HM045 Motorised Temperature Control Valve to Dump Manifold DO801 3 4 HM045 Heater Tank to Pump DO801 3 4 HM048 Heater Tank Outlet open end HP621 HM049 Pump Discharge to Hot Water Outlet KI6069 DO06069 Item Description JFD Part No 45 Remote Panel Face Plate DO06499 46 Remo...

Page 42: ...3 Part Identification 47 Remote Set Point Signal Generator DO04798 48 Remote Pump Running Indication DO04990 49 Remote General Fault Indication DO04992 50 Remote Emergency Stop Button DO03260 Item Description JFD Part No ...

Page 43: ...r AB DO04356 Filter Gauge DOPBBA63BB02QJ2A Filter Inlet Valve 3 4 NPT VB36265 Check Valve 3 4 BSP DO02780 Fresh Water Inlet Valve 3 4 NPT VB36265 Salt Water Inlet Valve 3 4 NPT VB36265 Inlet Temperature Gauge DO05836 Outlet Pressure Gauge DOPSBA63BB02QJ3A Outlet Temperature Gauge DO05836 Pump Outlet Hose DO06069 Filter Housing DO04768 Filter Element In Filter Housing 10 50 µm DO04793 Level Float S...

Page 44: ...ket Flange WHE 3 DO04692 Lamp Filament BA9s 24 Vdc 2 W DO03912 Lamp Holder for Start Stop Switch DO04823 DO04921 Module Diode Plug In 6 220 Vdc DO03910 Neoprene Gasket 2 mm thick 364 mm Diameter DO02760 Oil JFD Cat Pump Lube SAE 40 DO03764 Overload Thermal 3 Pole 9 14 A DO02904 Pocket Thermostat 1 1 4 BSP brass Boss DO03961 Power Supply 340 550 V 24 Vdc 5 A DO03904 Relay Base Socket Din Rail Mount...

Page 45: ...02723 PT100 Temperature Probe DO04564 Outlet Manifold Block DO05901 Front Dump Manifold DO05900 Pump CAT 1057 NAB Head DO02722 Motor DO02777 Pressure Reducing Valve DO02359 Accumulator CAT S S 6031 70 bar M O P DO02724 Valve Relief 1 2 MNPT 3 50 psi Brass DO02304 Remote Set Point Signal Generator DO04798 Remote Temperature Display DO06034 Heater Element In Heater Tank 4 0 kW 440 Vac DO02798 SPARE ...

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Page 47: ... at which event occurs EV2 Event 2 set value 50 Value at which event occurs EV3 Event 3 set value 50 Unused EV4 Event 4 set value 50 Unused LbA Control loop break alarm 210 Unused Ldb LBA deadband 0 0 Unused P Proportional band heat side 32 Set during AT I Integral time heat side 105 Set during AT d Derivative time heat side 26 Set during AT rPT Control response parameter 2 Pc Proportional band co...

Page 48: ... determination point 2 30 Unused HbH2 Heater melting determination point 2 30 Unused Pb PV Bias 0 Range Sensitivity of PV scale dF PV Digital filter 0 off Pr PV Ratio 1 Rotation of PV scale PLC PV Low input cut off 0 Unused rb RS Bias 30 0 Range Sensitivity of RS scale lncrease lncrease of range dF2 RS Digital filter 0 off rr RS Ratio 0 330 Rotation of RS scale increase anticlock T Proportional cy...

Page 49: ...Function Block Parameter Spec Value Description Code Description F10 SPCH Stop display 1 dE Bar graph display 1 dEUT Bar graph display resolution 100 dSoP PV Flashing display at input error 1 F11 Fn1 Direct key 1 1 AIM Transfer Type 1 and 2 Fn2 Direct key 2 1 Type 1 MON I Type 2 RIL Transfer Fn3 Direct key 3 1 Type 1 AREA Type 2 RIL RUN STOP Fn Direct key type 1 Selects the type of action of direc...

Page 50: ...Low limit of output to display F41 ES1 Event 1 type 0 MV1 High Heat Side Eho1 Event 1 hold action 0 Off EIL1 Event 1 interlock 0 Unused EH1 Event 1 differential gap 2 Prevents chattering of event output EVT Event 1 delay timer 0 Delay of action of event after trigger EEo1 Event 1 action at input error 0000 F42 ES2 Event 2 type 0 MV1 High Cool Side Eho2 Event 2 hold action 0 Off EIL2 Event 2 interl...

Page 51: ...timer 0 Delay of action of event after trigger EEo4 Event 4 action at input error 0000 F45 CTr1 CT1 ratio 800 CTA1 CT1 assignment 1 HbS1 Heater break alarm 1 HBA1 type 1 HbC1 Number of heater break alarm 1 HBA 1 delay times 5 F46 CTr2 CT2 ratio 800 CTA2 CT2 assignment 0 HbS2 Heater break alarm 2 HBA2 type 0 HbC2 Number of heater break alarm 2 HBA2 delay times 5 F50 Pd Hot Cold start 0 Hot start 1 ...

Page 52: ...ut change rate limiter down MV1 0 0 oLH Output limiter high MV1 105 0 Limits the max opening angle of actuator 1 oLL Output limiter low MV1 5 0 Limits the min opening angle of actuator 1 orU2 Output change rate limiter up MV2 0 0 ord2 Output change rate limiter down MV2 0 0 oLH2 Output limiter high MV2 105 0 Limits the max opening angle of actuator 2 oLL2 Output limiter low MV2 5 0 Limits the min ...

Page 53: ... limiter high cool side 100 PcLL Proportional band limiter low cool side 0 lcLH Integral time limiter high cool side 3600 IcLL Integral time limiter low cool side 0 DcLH Derivative time limiter high cool side 3600 DcLL Derivative time limiter low cool side 0 PAJ Proportional band adjustment factor heat side 1 00 IAJ Integral time adjusting factor heat side 1 00 dAJ Derivative time limiter low cool...

Page 54: ...roup 0 rSG RUN STOP group 0 CHrd Automatic temperature rise dead time 10 0 CHrT Automatic temperature rise gradient data 1 0 F60 CMP1 Communication protocol1 0 CMP2 Communication protocol2 2 F70 SVrT Setting change rate limiter unit time 60 STdP Soak time unit 1 F71 SLH Setting limiter high 100 Sets the value at max input from signal generator SLL Setting limiter low 0 Sets the value at min input ...

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Page 57: ...rol Circuit With Remote Sheet 1 of 2 C 4 Sheet 2 of 2 C 5 WHE 3 Electrical Schematic 440 V Heater Circuit With Remote C 6 WHE 3 Electrical Schematic With Remote Busbar Manufacturing Detail C 7 Schematic Water Heater Electric WHE 3 Upgrade With PV S 3 1 Cert Sheet 1 of 2 C 8 Sheet 2 of 2 C 9 Schematic Water Heater Electric WHE 3 Upgrade With PV S 3 2 Cert Sheet 1 of 2 C 10 Sheet 2 of 2 C 11 ...

Page 58: ...25 25 1 35 6685 EDU 72 0 7 5 2 216758 7 21 670 73 25 48 9 78 670 3 7 670 25 1 5 7 5 0 17 67 1 66 67 2 3 57 8 7 75 7 21 72 P 75 9 3 2 5 7 75 6 0 187 27 25 2 1 5 1 250 7 21 211 7 21 0 16 216 P 1 780 127 6 0 16 216 5 5 1 21 6 6 826 6 7 5 5 9 352 8 7 352 7 1R 3 57 12 5 1 12 6 7 5 7 5 75 9 5 176 7 7 2 5 9 1 7 87 6 5 37 21 2 127 6 5 1 7 2 0 3 21 0 3 0 7 5 1 6 0 16 216 5 1 PP 826 0 16 216 25 3 7 1 826 5 ...

Page 59: ... 75 9 5 176 7 7 2 5 9 1 7 87 6 5 37 21 2 127 6 5 1 7 2 0 3 21 0 3 0 7 5 1 6 0 16 216 5 1 PP 826 0 16 216 25 3 7 1 826 5 029 6 53 6 1 8556 12 0 3 1 1 5 7 21 72 5 1 0 1 1 72 5 1 1 8 5 72 5 1 127 6 127 6 1 6 0 7 7 6 5 9 6 21 2 16 7 23 5 7 2 7 6 2 80 17 1 1 6 1 5 7 5 1 7 6 6833 1 21 1 1 0867 127 86 25 1 385326 27 5 7 1 7 7 25 7 6 6833 1 0867 127 5 352 8 7 287 3 50 66 21 1 5 7 1 520 7 2 1 56 7 5 1 352 ...

Page 60: ...C 4 KI OM 0591 Rev 3 WWHE 3 Electrical Schematic 24 VDC Control Circuit With Remote Sheet 1 of 2 ...

Page 61: ...KI OM 0591 Rev 3 C 5 Sheet 2 of 2 ...

Page 62: ...C 6 KI OM 0591 Rev 3 WHE 3 Electrical Schematic 440 V Heater Circuit With Remote ...

Page 63: ...KI OM 0591 Rev 3 C 7 WHE 3 Electrical Schematic With Remote Busbar Manufacturing Detail ...

Page 64: ...C 8 KI OM 0591 Rev 3 Schematic Water Heater Electric WHE 3 Upgrade With PV S 3 1 Cert Sheet 1 of 2 ...

Page 65: ...KI OM 0591 Rev 3 C 9 Sheet 2 of 2 ...

Page 66: ...C 10 KI OM 0591 Rev 3 Schematic Water Heater Electric WHE 3 Upgrade With PV S 3 2 Cert Sheet 1 of 2 ...

Page 67: ...KI OM 0591 Rev 3 C 11 Sheet 2 of 2 ...

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