Instruction Manual

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DOUBLE SHELL & TUBE HEAT EXCHANGER

TABLE OF CONTENTS

INTRODUCTION .............................................................................................6

GENERAL NOTES AND WARNINGS ................................................................................................................................... 6

INSTALLATION AND OPERATION............................................................6

INSTALLATION ............................................................................................................................................................ 7

B. PIPE CONNECTIONS ......................................................................................................................................................... 7

ELECTRICAL CONNECTIONS .................................................................................................................................... 7

D. OPERATION OF NORMAL RECIRCULATION PUMP ................................................................................................... 8

E. OPERATION OF SECOND RECIRCULATION PUMP ..................................................................................................... 8

F. OPERATION OF SWITCH PANEL..................................................................................................................................... 9

G. OPERATION DUE TO OVER TEMPERATURE CONDITIONS ...................................................................................... 9

H. GENERAL SETUP AND OPERATION OF BLEND VALVE.......................................................................................... 10

GENERAL OPERATION OF HEAT EXCHANGERS................................................................................................. 11

J. GENERAL OPERATING PRINCIPLE............................................................................................................................... 11

STORAGE AND TRANSPORTATION................................................................................................................................ 12

STARTUP ........................................................................................................................................................................... 13

CLEANING......................................................................................................................................................................... 13

CERTIFICATION ............................................................................................................................................................... 14

GENERAL OPERATION OF RELIEF VALVE ........................................................................................................... 14

REPLACEMENT PARTS ..............................................................................14

A. RECIRCULATION PUMP................................................................................................................................................. 14

BLEND VALVE............................................................................................................................................................ 14

MAINTENANCE.............................................................................................15

TROUBLESHOOTING..................................................................................17

UNIT SEPARATION FOR INSTALLATION.............................................18

UNIT STARTUP AFTER INSTALLATION...............................................20

12501 Telecom Drive, Tampa Florida 33637

Installation, Operating and

Maintenance Instructions

Supplement

90/0.5.0

Rev. 5

Summary of content (25 pages)

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2501 Telecom Drive, Tampa Florida 33637 Installation, Operating and Maintenance Instructions Supplement 90/0.5.0 Rev. 5 DOUBLE SHELL & TUBE HEAT EXCHANGER TABLE OF CONTENTS INTRODUCTION ............................................................................................. 6 GENERAL NOTES AND WARNINGS ................................................................................................................................... 6 INSTALLATION AND OPERATION......................................
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LIST OF ILLUSTRATION FIGURE 1 - TYPICAL HEATER ILLUSTRATION ..............................................................................................................................................3 FIGURE 2 – CONTROL BOX .........................................................................................................................................................................4 FIGURE 3 - SWITCH BOX ............................................................................................
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Figure 1 - Typical Heater Illustration Page 3 of 25
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Figure 2 – Control Box Page 4 of 25
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Figure 3 - Switch Box Page 5 of 25
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For information concerning warranties, or for questions pertaining to installation, operation or maintenance of Leslie products, contact: Leslie Controls Inc. 12501 Telecom Drive Tampa, FL 33637 USA Phone: (813) 978-1000 USA Fax: (813) 978-0984 www.LesleiControls.com WARNING! Injury or death can occur due to failure to completely isolate component from all sources of pressure before beginning disassembly.
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A. INSTALLATION NYCHA150 After connecting inlet cold water, outlet hot water, Steam inlet, re-circulation inlet, safety relief valve drains and condensate piping, lag unit to concrete floor. Inlet Steam Outlet Condensate Inlet water Outlet Hot water Inlet Steam Outlet Condensate 4” RF ¾”F NPT 2” F NPT 2” F NPT 4” RF ¾”F NPT CAUTION! Safety Relief valves and condensate drain must be connected properly to drainage, to insure no hot water can contact people. C.
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Schematic Component Descriptions 1. Power on Light: • Indicates that power is being supplied to system. • Fuse F1 blown, burnt out light or disconnection of power will cause light to go out. 2. No flow light: • Will light red when pressure switch (PS1) senses no pressure across pumps. 3. Reset Switch: • This switch is only used if unit was set up so that it will not automatically reset.
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pump should fail then Red light for “NO_FLOW” will light. Follow instructions for isolating this pump and starting primary pump or shutting down system. No. 1 Heater Over Temp Hot water is off. Red No. 2 Heater Over Temp Hot water is off. Red When disassembling a gasketed joint, always use a new gasket upon reassembly. NEVER RE-USE OLD GASKETS.
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Second switch = 130 degrees F Should an over temperature condition occur a temperature switch in first or second stage of one or both sides of the unit will recognize this and switch the relay in the control box. Relay will: 1. Cause solenoid supplying hot water to shut off supply of hot water to output of system. 2. Cause three way valve (101) to rotate and divert condensate water away from condensate cooler and send it directly to drain. 3. Cause “RESET”, “NO. 1 HEATER OVER TEMPERATURE “NO.
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I. GENERAL OPERATION OF HEAT EXCHANGERS Heat exchangers are designed to transfer heat between steam and water at various temperatures, fluid flows, and pressures. WARNING! exchangers are most common type of heat exchangers. These heat exchangers are counter flow units, which from a thermodynamic point of view extract more heat from a given fluid stream than order common types of heat exchangers. Heating medium flows through tubes. Thermal energy is transferred through tube walls.
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Shell Tube 422°F 422°F (217°C) (217°C) OPERATING PRECAUTIONS In order to achieve maximum performance from heat exchanger, following must be strictly followed: Heat exchangers should be used according to specification given. Pressures and temperatures should not exceed limits set forth in Operating Parameters and Selection of Heat Exchangers Section. Initial start up should be done according to Start up Section. Heat exchangers should be free of any debris existing in fluid.
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rain). During transportation, ensure that they are not exposed to mechanical damages. STARTUP To prepare heat exchanger for operation, it should initially be: Mounted properly Filled with working fluids Deaerated All connections checked for leaks During startup, first open valves, then start pump of heated medium followed by opening cycle of heating medium. Valves should be opened gradually in order to achieve a steady increase in flow and pressure.
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- Accepted for use in food processing industries (if applicable) Removes scale, slag, tarnishes, and hard water deposits Easily rinsed out of system No objectionable or corrosive fumes CERTIFICATION Heat exchangers are designed and fabricated in accordance with ASME Code Sec. VIII, Div.1 for symbols “U” and “UM”. Heat exchangers are CSA approved and have obtained CRN in Canadian provinces. Copies of above certificates are available upon request. 1.
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Service Parts For Model BO Ref Part No Description No 3 9585L001 Seat, Bolted-In 4 1182 Sleeve 5 11132L050 Capscrew 6 11133 Lockwasher 7 1183 Element O-Ring, Buna-N 8 1096X(TEMP) Element Assembly 9 761 O-Ring MAINTENANCE WARNING! Warranty will be void if heat exchanger tubes are not flushed every six months. Reports on this maintenance by Heater Serial number must be provided to Leslie after each flushing. These reports are to be sent to sales@lesliecontrols.
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SOLENOID VALVES (Ref ASCO Form number V6297R2) See ASCO solenoid instruction set for Installation, Operation and Maintenance Instructions. 12. 13. RECIRCULATION PUMPS (Ref Bell and Gossett manual P81884 Rev C) WARNING! Be certain electrical power is not present at motor leads before continuing. Failure to follow these instructions could result in serious personal injury or death WARNING! 14. Pressure may be present in the pump body.
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Valve Listing and Functions (refer to assembly drawing for particular size heater) Item No. ON OFF 15 Flow diverter, primary flow to Pump 1, no flow to No flow to pump 1, flow to pump 2 pump 2 16 Emergency pressure relief, flow to drain No flow to drain 37 Hand Op Ball, re-circulation water to Cold inlet No re-circulation water to Cold inlet water water 39 Gain Adjuster Valves Adjust cold water flow to insure constant temperature over the range of flow. 41 Hand Op.
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Water temperature fluctuates or is colder than required Water temperature can not be maintained at 120 F Pump 1 or Pump 2 Light is lit and No Flow light is on. Can see Pump is turning and water is recirculating. Blockage in condensate line causing condensate to back up into heat exchangers. Gain adjusters not adjusted correctly Check the temperature of heat exchanger outside casing. If top is hot and bottom is warm or cold, shut unit off and check draining of condensate.
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5. Undo steam side unions and remove condensate drain line between steam traps and condensate cooler. 6. Remove bottom rail bolts from frame. 4. Remove output water copper tubing section and put it aside.
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7. Remove center rail bolts from frame. Frame is ready to be split in two sections. 3. Ensure output hot water connection is tight. Outlet 4. Connect emergency relief valve to drain. CAUTION! Never lift or push in any place but frame of unit. Damage to piping and or components can occur if pressure is applied to them. UNIT STARTUP AFTER INSTALLATION 1. Lag the frame to the floor. 2. Insure input cold water connection is tight. 5. Connect steam supply to flange.
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6. Set condensate drain valves such that the condensate flow passes through cooler. 7. Open up both steam gate valves to full open.
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8. Open all other valves. Open cold water supply valves to heat exchangers before opening valves to second blend valves.
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9. Set three way diverting valve for pump to be used. 10. Plug in the electronic control box and make sure the correct re-circulation pump is on. 11. Loosen connection to differential pressure switch and make sure the lines are free of air and filled with water.
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12. Set the front and back aquastat thermal switches for proper temperature setting. GAIN VALVE SETTING PROCEDURE 1. 13. Supply proper steam pressure to the unit. 14. Wait until the system stabilizes and then run procedure to set Page 24 of 25 Ensure all connections are made and unit is running at specified maximum flow. 2. Turn off supply of water to one side. Half of specified maximum flow is now being delivered. 3. Check outlet water temperature and ensure it is 120 degrees F. 4.
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It is solely responsibility of system designer and user to select products and materials suitable for their specific application requirements and to ensure proper installation, operation and maintenance of these products. Assistance shall be afforded with selection of materials based on technical information supplied to Leslie Controls Inc.; however, system designer and user retain final responsibility.