Installation, Operation and Maintenance Instructions Thermaflow E Plate Heat Exchanger Package OM013

Transcription

1 Installation, Operation and Maintenance Instructions Thermaflow E Plate Heat Exchanger Package OM013 Calorifiers Heat Exchangers Pressurisation Units Sales Tel: Sales Fax: sales@gmsthermal.co.uk Riverside Works, Egmont Street, Mossley Ashton-Under-Lyne, OL5 9NE The operating and maintenance instructions contained within this package are for Thermaflow E Plate Heat Exchanger Package. Please refer to separate instructions for steam/water unit. Please note that an electronic version of these instructions is available from our website. Please contact our sales office for further information. Rev Date By Details C 01/07/2016 Natasha Bennett PED Code Updated Revision Details

2 Contents Contents Standard Unit Information & Description PED Information Installation Commissioning and Operation Maintenance End of Life Disassembly, Recycling & Disposal Recommended Spares...6 Page 1

3 1.0 Standard Unit Information & Description The ThermaFlow E range comprises water/water plate heat exchanger packages. These are mostly used in systems to heat domestic hot water. In the majority of applications the water is heated by LTHW (supplied at 82 C) although the heater can be used for primary temperatures up to 110 C if required. Other applications may also arise with different water temperatures and materials of construction. Primary Pipework Secondary Pipework Exchanger Plates Exchanger Gaskets (Other materials on request) Standard Material Schedule Carbon Steel Stainless Steel Stainless Steel EPDM Design Data Primary Secondary Maximum Working Pressure Refer to Unit Nameplate Refer to Unit Nameplate Hydraulic Test Pressure Refer to Unit Nameplate Refer to Unit Nameplate Design Temperature range Refer to Unit Nameplate Refer to Unit Nameplate Complies with PED (SEP) Page 2

4 2.0 PED Information The standard range of ThermaFlow E packages are designed in accordance with the requirements of the Pressure Equipment Directive 2014/68/EU. Units classed as SEP in the PED category are not supplied with a CE mark. Units in category 1 and above are CE marked and appropriate markings and certification is supplied with each unit. It is the responsibility of the user and/or installer to ensure that the unit is installed and operated safely, and in accordance with the instructions supplied within this manual. IMPORTANT NOTES 3.0 Installation Read and understand all the installation documents listed above. Keep them in a safe place near the unit. Bolting Down: To ensure stability during and after installation, the unit must be bolted to the floor. Separate instructions and a record of initial set-up are provided for the unit s digital controller and should be kept safe with these instructions and the unit wiring diagram by the unit operator for future reference. INSTALLATION The unit must be installed indoors, away from damp, frost and ambient temperatures exceeding 40 C and bolted to a firm base. Provide adequate space at sides and front for access for operation and servicing. The unit is supplied ready for connection to site services. Pipework considerations - The unit has as standard one in-built primary pump which draws water from a low loss header or similar arrangement and circulates the water through the unit. This pump cannot be used as the boiler circulation pump. As an option, the unit may be fitted with an additional backup primary pump. If the boiler circulation pump generates a high differential pressure (>10kPa) at the connections to the ThermaFlow E the differential pressure should be reduced by fitting a bypass. Unvented System considerations - If the ThermaFlow E is being installed in an unvented (sealed) system then special arrangements need to be made to ensure a safe installation. These are covered in separate instructions available from GMS. Buffer vessels: ThermaPak units are supplied with a buffer vessel to increase peak hot water flowrates. See the separate instructions for buffer vessels. Standard Units: Secondary water flows through the unit under its own pressure. ThermaPak units (for use with secondary buffer vessel): A secondary shunt pump is fitted which circulates water between plate heat exchanger and vessel. Ensure that pipework is adequately sized and supported. Page 3

5 Fit isolating valves and make provision for air venting, draining and thermal expansion of both pipework and water. Fit strainers in the incoming pipework to prevent heat exchanger blockage by debris. Electrical - Electrical connection should be done by a competent person. Make electrical connections in accordance with the wiring diagram supplied with the unit and all applicable electrical regulations. METHOD OF OPERATION 4.0 Commissioning and Operation General: The plate heat exchanger transfers heat from the primary water (LTHW) to the secondary water (DHW). The controller measures DHW temperature at the outlet from the plate heat exchanger. If an adjustment is needed to obtain the required temperature then the controller s output signal voltage will alter accordingly. The primary pump speed and the position of the three/four port primary control valve are adjusted according to the controller s output signal. If the three/four port valve becomes fully closed (registered by limit switch) the control panel shuts down the LTHW pump until the valve opens again. Accessing the control panel interior: A door interlock isolator prevents door opening when in ON position. In OFF position it isolates main power. NOTE: Other inputs (e.g. to volt free contacts in the panel) MAY STILL BE LIVE! Isolate this elsewhere. When door interlock isolator is ON and LOCAL/STAND-BY/REMOTE switch is at STAND-BY the control circuit is energised but pump(s) will not run. The pump(s) can be switched on by turning the switch to LOCAL Single primary pump units: Primary pump (and secondary pump if fitted) will start Twin primary pump units: The two pumps communicate with each other and rotate from duty to standby on a regular basis. If one pump stops because of a fault the fault is signalled to the panel, a volt-free contact opens and a lamp shows. If the unit is switched to REMOTE the control circuit will be energised and the pump(s) will start only when the REMOTE START signal (from an external source) is present. Fault Conditions: Pump Trip: Light comes on and Pump Trip VFC opens. On twin primary pump units the back-up pump is automatically switched on if the other pump trips. High Temperature: Light comes on, Pump(s) stop, Control Valve closes, Hi Temp. Limit Volt Free Contact opens. Requires manual re-set. Power Failure: Volt Free Contact s open. Units self-reset on restoration of power. COMMISSIONING Fill the secondary water side first. Fill the unit slowly, avoiding water hammer. Switch on any external secondary water recirculation pump. Page 4

6 Fill the primary side slowly, avoiding water hammer. The unit is designed to vent air to the primary pipework. Vent the pumps in accordance with the instructions specific to them. INITIAL OPERATION Commission the unit first as above. Ensure that the Control Panel door is closed Turn LOCAL/STAND-BY/REMOTE switch to STAND-BY Turn DOOR INTERLOCK ISOLATOR to ON Turn LOCAL/STAND-BY/REMOTE switch to LOCAL Set High Limit Thermostat to approximately 10 C above Control set-point temperature. (The high limit thermostat is not a precision device and is only there to shut the unit down in the event of main controller or control valve failure. Further adjustment of this may be required in the first day or so of operation to prevent nuisance shut-down) All units with Variable Speed Primary Pumps The primary pumps have their own built-in inverters and controllers. The pump controllers are pre-set before leaving GMS for operation with the ThermaFlow units. The pumps contain their own fault control systems see pump specific instructions for details. ThermaPak units The secondary shunt pump runs when the primary pump runs. A thermostat in the vessel base turns the pumps off after the vessel is fully heated and turns them back on when there is a demand (registered by the thermostat sensing cold water at the base of the vessel) The unit is pre-set for a temperature of 60 to 65 C depending on order requirements. This can be altered on the digital temperature controller if required. In hard water areas 60 C may be desirable to minimise potential for scale deposition. The instructions for the digital temperature controller should be consulted before attempting to change settings, these are available on request from the GMS Technical Team. Please contact a member of our team on It is advisable to familiarise yourself with these instructions. The unit can now be left running. 5.0 Maintenance Pump(s) and control valve should be maintained in accordance with the instructions specific to them. The plate heat exchanger plates may occasionally require cleaning or de-scaling. To do this the heat exchanger plates must be removed from the frame by un-bolting the heat exchanger: See separate instruction sheet OM10 available from the GMS website. Page 5

7 6.0 End of Life Disassembly, Recycling & Disposal Please consult the general assembly drawing and product data sheets of the supplied unit for specific information regarding the materials used. Dispose of all material responsibly and in accordance with all local regulations. For further information, please contact the GMS Technical Team on Recommended Spares The recommended spares for the ThermaFlow E package are; - Plate & Gasket Set - Control Valve Actuator - Pump Seals Kit - Thermostats - Digital Controller - Control Panel Lamps Please contact our sales department for recommended spares prices and availability. Page 6