Installation. Keltech S194 Series. Tankless Water Heating Solutions. Table of Contents

Transcription

1 Keltech S194 Series Tankless Water Heating Solutions Table of Contents Pre- Information...2 Supplies Required for...3 Pre- Storage Instructions...3 System Mounting Plumbing Connections....6 Electrical Connections....7 Controller Operation Operation Test Optional Features...12 Preventive Maintenance and Troubleshooting Field Wiring Schematic (Appendix A) Rev. B; ECN Bradley Page 1 of 16 12/5/2012 P.O. Box 309, Menomonee Falls, WI USA PHONE 800.BRADLEY ( ) FAX bradleycorp.com

2 R Date Datum Date Signe Date Date S194 Series IMPORTANT P.O. Box 309, Menomonee Falls, WI TEST THIS UNIT EACH WEEK DIESES GERÄT 1ST WÖCHENTLICH ZU PRÜFEN. ESSAI HEBDOMADAIRE Test-operate valve(s) each week and sign below. Report any malfunctions immediately. Ventil(e) wöchentlich im Testbetrieb prüfen, bestätigt durch Unterschrift. Jegliche Störung sofort melden. Test le fonctionnement des valves chaque semaine et signe en bas. S'il y à quelque chose qui ne va pas fait un rapport immédiatement. Signed Date Signed Unterschrift Signed Signed THIS SIDE UP Packing List Read this installation manual completely to ensure proper installation, then file it with the owner or maintenance department. Compliance and conformity to drain requirements and other local codes and ordinances is the responsibility of the installer. Separate parts from packaging and make sure all parts are accounted for before discarding any packaging material. If any parts are missing, do not begin installation until you obtain the missing parts. Flush the water supply lines before beginning installation and after installation is complete. Test the unit for leaks and adequate water flow. Main water supply to the emergency fixture should be ON at all times. Provisions shall be made to prevent unauthorized shutoff. Please refer to the enclosed instructions for flushing the unit prior to use. The ANSI Z358.1 standard requires an uninterrupted supply of flushing fluid. Bradley plumbed emergency fixtures require a minimum of 30 PSI (0.21 MPa) flowing pressure. Flushing fluid should be tepid per ANSI Z The inspection and testing results of this equipment should be recorded weekly to verify proper operation. This equipment should be inspected annually to ensure compliance with ANSI Z For questions regarding the operation, installation or maintenance of this product, visit bradleycorp.com or call 800.BRADLEY ( ). Product warranties and parts information may also be found under Products on our web site at bradleycorp.com. and maintenance of this system must be completed by a qualified plumber and electrician according to the information contained in this installation manual and in compliance with all national and local codes. When making electrical connections be sure to follow all lockout tagout safety procedures. It is recommended that all water supply and electrical connections be made at temperatures above freezing (32 F (0 C). Failure to do so may result in major product and/or property damage. 2 12/5/2012 Bradley Rev. B; ECN

3 S194 Series Supplies Required for : (3) Unions 1" NPT Pressure and Temperature Relief Valve 1" NPT Y-Strainer (100 mesh) 1" NPT Drain Pipe (copper) 1" NPT (2) Gate or Ball Type Valves (Isolation) 1" Conduit Inlet Fitting Pre- Storage Information Keep units stored in original packaging until installation. Care should be taken to minimize excessive on-site transport reducing risk of shock and impact damage. Temperature for storage must exceed 35ºF at all times (indoor storage is recommended). Units kept in their original crates will withstand outdoor elements for a brief period (about one month in most climates). For units stored outdoors, take precautions to protect the units from rain or falling precipitation from tarps or other waterproof material. Avoid runoff and/or accumulation of groundwater (from any source) that may exceed one inch. Uninstalled units ordered without ENHT freeze protection option may not be stored in environments where temperature will fall below 35 F. For ENHT supplied heaters, if unit was stored where the temperature could fall below 45 F, the unit must be powered immediately after hydraulic testing in order to ensure internal freeze protection components are activated. Once the unit is installed and the on-site plumbing has been hydraulically tested, the power supply must remain constant until the risk of freeze is eliminated. Packaging Crates are made of ¾ AC plywood and the dimensions are approximately 82" x 48" x 24". Crated units must be stacked evenly and placed no more than two crates high. All crates and packaging should be considered "Fragile" and transported accordingly. Standard safety procedures for forklift transport and large items less than 1000 lbs should be followed at all times. Support for crates stored on an elevated industrial capacity rack or shelf must be provided for the entire length and width of the crates. Bradley Rev. B; ECN /5/2012 3

4 S194 Series System Mounting WARNING! To prevent high voltage shock, disconnect the power supply before performing any work inside the system enclosure. If the system use is infrequent and mounted in an area where freezing can occur between uses, drain water from the heat exchanger through the two drain plugs located at the bottom of the heat exchanger. An optional enclosure heating system may also be purchased to keep the system from freezing. Connecting pipe to the male threads on the outside of the bulkhead will cause leaking or other damage to the system. The best location for mounting the tankless system is central or close to the points of use. Long pipe runs are not recommended due to heat loss of up to 1 F for every 10 feet of uninsulated pipe. Position the units as close as possible to the fixture to reduce delivery times of tepid water. When determining location, consider the possibility that start-up verification and testing may be performed with the service door open. Placement outside the splash zone or partitioned from any fixture and its direct runoff is recommended. 1. Set the system in a vertical, upright position with the outlet located at the top. 2. Bolt the two legs to the floor. 4 12/5/2012 Bradley Rev. B; ECN

5 S194 Series System Mounting A B C 4" 1" NPTF D Outlet 27" E Dump Outlet F G Suggested Region For Power Entrance. Entrance Holes To Be Provided By Installer. 1" NPTF Dim. "A" Dim. "B" Dim. "C" Dim. "D" Dim. "E" Dim. "F" Dim. "G" 63kW 24" 3.4" 11³ ₁₆" 16" 31¼" 72" 60" 72kW 30" 3.8" 11³ ₁₆" 22" 39¾" 60" 48" 108kW 30" 3.8" 11³ ₁₆" 22" 39¾" 60" 48" 126kW 30" 3.8" 11³ ₁₆" 22" 39¾" 72" 60" 144kW 30" 3.8" 11³ ₁₆" 22" 39¾" 72" 60" +6" for fuse disconnect and freeze protection options +2" for fuse disconnect and freeze protection options Bradley Rev. B; ECN /5/2012 5

6 S194 Series Plumbing Connections Use gate or ball type valves to reduce restrictions caused by other valve types. Plumbing connections are 1" female National Pipe Thread (NPT). 1. Install the pressure and temperature relief valve onto the union on the HOT water outlet. The valve must empty into a well-located drain. The dump should also empty into this drain. 2. Install the shutoff valve above the union on the inlet connection. Use 1" hard copper tubing for the hot water outlet connection. 3. Connect the pressure and temperature relief valve (150 psi and 210 F) to the plumbing on the water outlet side of system, and drain. Make sure there is no valve or restriction between the relief valve and the system. 4. Install the shutoff valve onto the pressure and temperature relief valve on the hot water outlet. To avoid water damage, install a drain pipe from the pressure relief valve and the dump outlet to a welllocated drain. 5. Install a 100 mesh Y-strainer between the inlet shutoff valves and the system. To eliminate trapped air: If the end use fixture is not at the highest point in the plumbing configuration, then an automatic air vent valve must be added at the highest point in the system or at any drop. 6 12/5/2012 Bradley Rev. B; ECN

7 S194 Series Electrical Connections Install system according to national and local electrical codes. Follow all lockout/tagout procedures when performing and wiring to the system. To prevent damage to the electronics or internal wiring, do not perform any brazing or sweat soldering inside the enclosure box. 1. Open the enclosure door. 2. Make an appropriate size hole in the enclosure at the appropriate location for the conduit inlet fitting (supplied by installer) as shown on page Install an appropriate conduit connector. 4. Route the grounded electrical supply through the fitting in the enclosure. 5. Route the wires through the conduit. 6. Connect the wires to the system terminal block inside the enclosure. Set-Up 1. Make sure the 3-pole circuit breaker is OFF and that all connections have been properly made. 2. Turn ON the water supply. 3. Turn ON the water outlet valve. 4. Turn ON the hot water faucet valve to bleed off trapped air in the heat exchanger. Failure to bleed air properly will damage elements and cause system malfunction. 5. Turn OFF the hot water faucet and check for plumbing leaks. Before turning on the power, close the electrical box. 6. Pull out the Emergency Stop button. On all S194 series model systems, the preprogrammed digital temperature controller is mounted through the enclosure door. The controller will not be powered and the display will be blank until water is flowing through the heater. Refer to the Controller Operation section for more information. Electrical Specifications Model Voltage Amps Kilowatts Min. Wire Size (based on Amperage rating of THHN wires) S194G6FS AWG S194G6GS AWG S194G6HS AWG S194G6JS AWG S194G6K /0 AWG S194G4AS AWG S194G4BS AWG S194G4CS AWG S194G4DS /0 AWG S194G4ES /0 AWG Bradley Rev. B; ECN /5/2012 7

8 S194 Series Controller Operation To prevent damage to the system, do not attempt to program your controller. The following information assists the customer with understanding and use of the digital controller: Upper Lower Description Display Display Function EZ Key Setpoint Up button Setpoint Down button Toggles output on/off Increases output temperature Decreases output temperature Infinity Key H2O Temp-Out Setpoint Back to Home page Advance Key Outputs Active (L1-L5) indicators Setpoint Temperature Display (Lower Display) Output Temperature Display (Upper Display) Advances through parameter prompts Auto, Man, Off C.r71 - Turns Control Loop On/Manual/Off XX.X% h.pr1 - Heater Power % no AUt1 - Autotune (Contact Factory) C or F C_F1 - Change Temperature Units from F to C Indicate when output 1,2,3,4 or 5 are active Displays: - Setpoint - Percent Power - Temperature units F or C - Menu prompt name - Alarm code Displays: - Actual process temp. of outgoing water - Prompt parameter value - Error code Feature Disabled 8 12/5/2012 Bradley Rev. B; ECN

9 S194 Series Controller Operation ON FLOW & HEATING OFF NO FLOW Bradley Rev. B; ECN /5/2012 9

10 S194 Series Performing Operation Test #1 Test the System 1. Close the enclosure door. 2. Pull out the Emergency Stop button. 3. Set the 3-pole switch or circuit breaker to the ON position. Heater will perform a dump cycle. Wait for dump cycle to complete. 4. Activate the shower or eyewash. When the flow rate reaches approximately 1.5 gpm, the flow switch activates. When the Flow Switch Activates If water flow exceeds the system's maximum heating capacity, the water temperature at the outlet will be lower than the temperature on the controller. Refer to the Temperature Rise Capabilities table shown below to determine maximum temperature rise capabilities. Systems installed into pump-and-well supplied water systems may require an operating pressure adjustment to a differential pressure of approximately 10 psi. For example, if the high limit pressure is 40 psi, adjust the low limit pressure to 30 psi with the pressure switch located on the supply pump. Heating elements energize via the solid-state relays. Bank ready lights illuminate on the front bezel. This verifies power supply connection to the heating elements. Red power light continues to be illuminated. Digital temperature controller displays output temperature. Additional programming is not required. When Modulation Begins Phase indicator lights flash in unison. Located on the panel are one (36kW or 54kW) or two (72kW 144kW) green ready lights. When illuminated, the safety circuit is engaged and ready for use. Green ready lights may not be present on older system models. 5. Test the water temperature and stability at the outlet by viewing the display. Controller displays the temperature of water exiting the system. 6. Turn OFF the shower or eyewash. The flow switch will deactivate and remove power from the elements and controller so that the display is blank and bank lights are off. Power light stays on. The system will not energize heating elements if the inlet water temperature is equal to or greater than the temperature set on the LED controller. temperature rise Capabilities (Temperature Rise vs. Flow) Gallons per Minute / Temperature Rise by kw Model kw S194G6FS0000 S194G4AS0000 S194G6GS0000 S194G4BS0000 S194G6HS0000 S194G4CS0000 S194G6JS0000 S194G4DS0000 S194G6KS0000 S194G4ES /5/2012 Bradley Rev. B; ECN

11 S194 Series Performing Operation Test #1 Safety Shower Operation When a Low Flow Condition Occurs When a low flow condition (less than 15 gpm) occurs, such as operation of the eyewash system, only two (2) or four (4) elements energize depending on the geographical location of the installation. One set of PID values is selected on the controller for accurate temperature control at low flow conditions. When the System Detects High Flow Conditions When the system detects high flow conditions (greater than 15 gpm), all elements energize. A second set of PID values is selected on the controller for accurate temperature calibrations at high flow conditions. When the System Shuts Down When the system shuts down or switches from a high to low flow condition, the dump valve opens and purges the system of latent heat. This ensures safe water temperatures at both the eyewash and shower stations. This system also provides anti-scald for applications where environmental temperatures are above 95 F. Bradley Rev. B; ECN /5/

12 S194 Series Optional Features Portable Shower Station Ideal for situations where chemical injury at a location is a temporary risk. The portable shower station offers a complete safety shower/eyewash station all in one compact, portable package. Place the shower unit near or over the floor drain, connect the water and power supply, and the S194 Shower Station is ready for use. Ground Fault Provides equipment electrical protection to ground. After installation of water and power, test the ground fault. 1. Press the GF Test button. Watch for the ground fault light to illuminate and Bank Ready light(s) to shut off. The Ground Fault system is active and working properly. 2. Press the GF Reset button to reset the ground fault. If a trip occurs under normal operation, DO NOT RESET the Ground Fault without first evaluating and servicing the unit. Normal state is Ground Fault light OFF, Bank Ready lights ON. Freeze Protection (ENHT) Protects system and internal components in sub-freezing conditions. Allows unit to function at -23 F with an 11 mph wind. With this option, three phase power must be continuously applied to the SN heater for the internal freeze protection heater to operate. If three phase power cannot be continuously applied, the heat exchanger must be completely drained of water and electrically locked out and tagged or freezing may occur. Use start up procedure previously outlined to restart this equipment. This option does not require a separate electrical circuit. Freeze Protection (ENHT 30) Protects system and internal components in sub-freezing conditions. Allows unit to function at -30 F with a 50 mph wind. All freeze protected SN heaters are equipped with a temperature sensor that can provide a signal to a remote device when temperature inside the cabinet falls below 40 F (refer to the schematics for more information). Internal Fuse Disconnect Eliminates the need to run a separate box. NEMA 4X Corrosion-proof enclosure made of stainless steel which is ideal for harsh environments. Explosion Proof Purge System Electrical components installed in a NEMA 4 enclosure allow the system to be pressurized by clean instrument air or inert gas. The purge process removes flammable gases and/or prevents the accumulation of ignitable dusts within the protected enclosure. Heat, moisture, dust and corrosion are eliminated by a slow, continuous flow of inert gas or dry compressed air. This type of system conforms to Class 1, Division 2 hazardous area standards. Other Class and Division ratings may be available /5/2012 Bradley Rev. B; ECN

13 S194 Series Preventive Maintenance For your system to work properly and have protection from freezing, keep the system dry inside the enclosure. Moisture inside an enclosure increases the humidity inside, which condenses on cooler surfaces of the enclosure. This causes electrical problems and reduces the efficiency of enclosure insulation. WARNING! Monitor heater performance at each weekly shower check. Preventive Maintenance 1. Dry out the enclosures. 2. Seal any weeping leaks in seals or walls. 3. Replace missing plugs on the back of the enclosure. 4. Check seals monthly when temperatures rise above 32 F and weekly when temperatures fall below 32 F. 5. Check to make sure the following lights illuminate with activation of the shower or eyewash: Bank Ready, Controller, Load R, S, and T, and Power Light (remains illuminated) 6. Check to make sure the shower heater activates the dump port and dumps water whenever the shower is turned OFF. If the lights do not illuminate properly or if the shower does not properly activate the dump port, evaluate the causes and service the unit as necessary. 7. Check the performance of the internal freeze protection system for proper performance prior to the first seasonal freeze. Check weekly during temperatures below 32 F. Refer to the "Optional Features" section for additional information on freeze protection. 8. The manual reset safety overheats on the heat exchangers may trip when temperatures fall below 32 F. The overheats are set to trip at 100 F. Heat trace installed on piping can heat water to temperatures above 100 F. This causes the overheats to trip. Reset the overheats and lower the heat trace temperature to below 100 F. If systems are sealed and checked at the frequency outlined above during weekly OSHA Shower Checks, the system will provide years of reliable service. Preventive measures to correct small problems that may arise over the years will prevent more costly failures or catastrophic freeze failures in the future. Troubleshooting If the System Is Not Working or Works Intermittently 1. Check the following: Flow switch works properly. Emergency Stop button is pulled out. Enclosure door is latched. Water flow through the system is adequate to activate the flow switch at 1.5 gpm. System is wired with the proper breaker and wire size. Refer to the Electrical Connections section for proper requirements. Unit is receiving voltage from all three phases of the power source. A load voltage reading is also helpful. Control timers and relays are properly seated. 2. Refer to the schematics and check the following for continuity: Emergency stop switch. Door guard. High temperature bimetals (high temperature cut-offs). 3. Record Ohm reading: Before recording any Ohm readings, turn OFF the power. Insert test leads of the volt-ohm meter at flow switch test leads in terminal blocks 1 and 2. The switch should read an OPEN circuit without flow and CLOSED circuit with flow. If the flow switch is always in the CLOSED position: Disassemble flow switch and check to make sure there is no debris lodged in the switch. Clean and adjust the flow switch as necessary. Bradley Rev. B; ECN /5/

14 S194 Series Appendix A - Unit Schematic 14 12/5/2012 Bradley Rev. B; ECN

15 S194 Series Bradley Rev. B; ECN /5/

16 S194 Series 16 12/5/2012 Bradley Rev. B; ECN