UK Exchangers UKE-8-50, Operating Instructions Manual

Page 1: ...d 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 ...

Page 2: ...me 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...

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Page 4: ...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 c...

Page 5: ...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 temp...

Page 6: ...idered 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...

Page 7: ... 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 a...

Page 8: ...cted 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 th...

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Page 10: ...t 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 ...

Page 11: ...tion 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 cl...

Page 12: ...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 comp...

Page 13: ... 13 Examples of Gasket and Plate types ...

Page 14: ...askets 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 befor...

Page 15: ...t 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 ...

Page 16: ...dle 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...

Page 17: ...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 sign...

Page 18: ...Type 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 1 LSD to span from setpoint in display units Dev Alarm 1 value Span from setpoint in display units Alarm 1 Hysteresis 1 LSD to full span in display units Alarm 2 Type Options as for alarm 1 High Ala...

Page 19: ...it 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 1 LSD to span from setpoint Alarm 1 Hysteresis 1 LSD to full span in display units High Alarm 2 value Range Minimum to R...

Page 20: ... 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 Dis...