pick variable flow service manual
Contents
1. ee 11 Heater Disassembly noro n uama te EET a RES RE ERE IT 13 Models 6X10 through 6 500 13 Model 6X it valent oed ee slot aaa E teta ese qd bars wats 13 Injection FubeCleanntmg L unas a e petas Ese pusqa E REM EET A 14 Injection Tube Disassembly 00 0 cece cece eee cee nen eee 22 14 Omen ed 16 18 Reassembly Installation of Injection 2 22 2 2 19 Heater medios eee oett uuo 19 Pump SerylCe ee te ete bad exeat a oA saq Sun a peg bray tes 20 Relief ET HR 20 Steam Control Val Ve mG Meda Forte HU tI RARI OR eU eod 2 Steam Valve Opening Pressure 0 0 0 2 2 2 21 Packing Gland Adjustment oroo eet ee Put VR 22 Temperature Controller Adjustment and 2 2 22 23 Other Troubleshooting 5 22 2 222 2 9 24 gt o teet ete bip NEA d ds 25 The Pick Heater Warranty Every Pick heater is warranted to perform at its2. VARIABLE FLOW SERVICE MANUAL TM EL heaters Inc INSTANTANEOUS STEAM INJECTION VARIABLE FLOW HEATER SERVICE MANUAL VARIABLE FLOW SERVICE MANUAL DO NOT DISPOSE OF THIS MANUAL The information on the following pages will be useful after installation Please direct this manual to personnel responsible for the ongoing maintenance and operator of the Pick Heater IMPORTANT DO NOT OPERATE THE PICK HEATER SYSTEM IN PARALLEL WITH ANY OTHER HEATING SYSTEM INCLUDING SECOND PICK HEATER SYSTEM CAUTION NEVER USE HANDS OR OTHER PARTS OF THE BODY TO SEARCH FOR WATER OR STEAM LEAKS IN THE SYSTEM HIGH VELOCITY LIQUIDS OR STEAM COULD PENETRATE THE SKIN AND CAUSE SERIOUS INJURY Any questions about the installation or operation of your Pick Heaters should be directed to your local Pick Heater representative or Pick Heaters at 800 233 9030 Outside the US and Canada please call 262 338 1191 or Fax 262 338 8489 VARIABLE FLOW SERVICE MANUAL PICK INSTANTANEOUS STEAM INJECTION VARIABLE FLOW HEATER INSTALLATION START UP AND OPERATION cura rM 3 Safety information v oido reete Ee a pU ER ie TER TERREA IN TEE US 4 Troubleshooting 2 ee ee mme 5 10 Injection eon deretur eee esee ue eo REPE Wha EUR SUN Ree wah ota 1 Obtaining the Proper Cleaning Solution 2 2 2 mee 1 Cleaning
3. At that point water exits through the relief valve allowing steam to enter and heat the water in the pump loop to the set temperature The temperature controller then closes the steam valve 20 PICK VARIABLE FLOW SERVICE MANUAL If water is not relieved from the heater in this manner the loop water will continue to cool The steam valve will continue to open eventually reaching a fully open position The closed system will then be at steam pressure As a result when a use point is opened the initial flow may consist of steam The temperature controller will bring the steam valve back under control as steam passes over it Meanwhile this steam will continue through the water piping to exit at the use point SETTING THE RELIEF VALVE SEE FIGURE 1 1 Close the water outlet valve to insure maximum static water pressure 2 Shutoff the compressed air supply to the temperature controller to insure that the steam valve is closed 3 Close the steam line block valve 4 Turn the relief valve adjustment screw counter clockwise to establish a strong flow of water through the relief valve Access to the adjustment screw may be obtained by removing the castle nut cover seal on some valves 5 Turn the adjustment screw clockwise retighten until the flow of water stops Note that the valve may drip for a short time until it reseats completely 6 Tighten the adjustment screw turn clockwise an additional turn Inst
4. number model number and size REPLACEMENT PARTS Replacement parts are available for all Pick heaters When ordering parts please include model and serial number of the heater These numbers are stamped on the outlet and inlet housings of the heater body and on the nameplate Describe the specific part required and include the part number Refer to teh heater parts list assembly drawing and the other drawings in this manual for specific information In addition when ordering replacement valves or valve parts supplied with your heater please supply the following information from the nameplate on the valve Type Size Manufacturer Serial Number 25
5. constructed from iron housings and steel pipe Directly connecting iron or steel components to copper piping will result in rapid corrosion of the iron or steel also known as galvanic corrosion 7 Bleeding air from water lines Note that water releases dissolved air when heated The water velocity is normally not high enough to flush air out of the distribution header if take off points exit the bottom or side of the water header 8 Alldistribution branches should connect tot eh top of the header or automatic air vent valve s should be installed at the high points of the header Correct the condition as necessary 9 Unstable water pressure can cause system vibration and hammer problems Heavy demands on the cold water supply can cause significant changes in the supply pressure to the heater A water pressure regulating valve may be required to stabilize the water supply pressure 10 Use point valves closing too fast can cause hydraulic shock and a system upset IMPORTANT An incorrectly installed heater will not work properly Check heater installation carefully correct piping connections as appropriate TECHNICAL ASSISTANCE Pick Heaters Inc can provide assistance and replacement parts as needed in the event of heater operating difficulties or malfunction Furnish a description of the problem including all information contained on the heater nameplate and steam control valve nameplate manufacturer name serial
6. often a Pick heater will require cleaning depend son the composition of the water being used the length of time the heater is in operation the quantity of water heated and the temperature to which the water is heated Because these factors vary from one application to another no fixed rules or schedules are possible Pick heaters may require cleaning once per year once each month or even more frequently Periodic inspection is the only sure way to determine the proper interval between cleaning IMPORTANT A significant drop in hot water temperature below the level the heater has been producing regularly indicates that the Pick heater has internal lime deposits and should be cleaned OBTAINING THE PROPER CLEANING SOLUTION The cleaning solution should be formulated such that it will not attack copper bearing alloys e g brass and bronze cast iron steel or stainless steel 31655 Some descaling agents can cause hydrogen embrittlement which may result in injection tube spring failure or cracking of the injection tube Inhibited dilute muriatic acid is widely used with satisfactory results WARNING use of improper cleaning solvents may result in reduced product life or even in catastrophic failure If the heater is used in potable water service all cleaning chemicals should be FDA approved TABLE 1 Cleaning Solution Capacity Heater Model Gallons approx 6X7 1
7. rated capacity when properly installed ad maintained and when operated under the conditions originally specified Any change in operating conditions or unauthorized modifications to the equipment will void this warranty Every Pick heater is warranted to be free from defective materials or workmanship for one year following installation or 18 months from the invoice date whichever occurs first Any defective parts will be replaced FOB West Bend WI Please note that this warranty does not extend to labor or installation costs involving replacement parts Determination of repair or replacement will be at the discretion of Pick Heaters Inc Pick Heaters shall not be liable for losses or delays resulting from damaged or defective parts This warranty does not cover damage caused by improper installation or adjustment or by willful neglect of specified operation and maintenance procedures Equipment not manufactured by Pick Heaters Inc which is supplied as a component is not covered by this warranty However Pick Heaters Inc will pass on to the purchaser any adjustment made by the supplier of any defective equipment Please read these instructions completely before installing or operating your Pick Heater VARIABLE FLOW SERVICE MANUAL This symbol is placed in this manual to call attention to safety precautions for the installation and operation of this product Observe ALL instructions accompanied by this symbol This symbol mean
8. spring Adjust actuator per 20 out of adjustment separate manual Steam control valves Water flow is higher than Reduce water flow rate is FULL OPEN originally specified Check specifications on heater order compare to actual operating conditions PICK VARIABLE FLOW SERVICE MANUAL Temperature rise may be Adjust heater operating Steam control valves greater than originally demand to original is FULL OPEN specified specifications Consult continued factory for upgrade to a different heater or steam valve if demand can t be altered Plugged steam strainer Remove steam line 22 basket basket empty debris flush basket and re 4 install Deposit accumulation on Clean injection tube 14 injection tube Contact factory for possible alternate materials Damaged injection tube Disassemble and 12 13 inspect injection tube Repair injection tube or return to Pick Heaters for complete re conditioning Steam boiler or pressure Increase steam supply 23 reducing valve PRV set pressure at boiler or lower than specified PRV Consult Pick Heaters for re sizing of steam valve Steam boiler undersized Confirm boiler output and overall steam requirements Steam supply valve NOT Confirm that all steam FULL OPEN supply valves are open Steam supply piping or Check for restrictions See components are undersized in steam supply piping Installation or restricted Upgrade supply pipe Manual
9. 6 10 1 6 25 2 6X50 4 6X75 6 6X100 11 6X150 16 31 6X200 24 53 6X350 31 58 6X500 55 97 Capacity of larger heaters depends on the size of the associated piping INTERNAL CLEANING WIHTOUT DISASSEMBLY For best results the cleaning operation should be undertaken when the internal lime deposits are wet If the internal deposits are allowed to dry before starting the cleaning procedure cleaning will be much more difficult WARNING The resulting A chemical reaction will produce foaming and gasses particularly if it is poured rapidly Provide adequate ventilation WARNING Be sure to follow the manufacturer s instructions A when handling the descaling agent As a minimum wear safety goggles ad rubber gloves A breathing filter may also be required 1 Obtain a supply of cleaning solvent from your local chemical supplier SEE TABLE 1 for the approximate quantity of solvent needed Follow 11 PICK VARIABLE FLOW SERVICE MANUAL these steps in sequence to clean your Pick heater without disassembling the unit Close the air supply valve Turn the pump motor OFF Close the stem supply water outlet and the water supply valves Drain the heater completely by opening the drain valves under the pump and the heater Remove the pipe plug or blind flange on flanged piping from the tee above the heater Remove the temperature indicator IMPORTANT The open temperature indicator port will provide
10. 6X25 4 6X50 4 28 X 3 4 5 6X75 6 6X100 6 6 150 i 12 6X200 x 12 6X350 12 6X500 18 HEATER DISASSEMBLY GENERAL INSTRUCTIONS Note These instructions assume the heater is installed in the vertical up flow orientation 1 Shut down the heater by closing the air supply to the temperature controller 2 Shut off the pump and disconnect the electric power 3 Close the manual steam supply valve 4 Cool the heater if hot by running cold water through it Close the cold water supply valve IMPORTANT Be sure the steam and water lines are shut off completely 5 Close the water outlet valve make a note of its position when open to prevent draining of the distribution system 6 Drain all water from the heater by opening the drain valves under the pump and heater DISASSEMBLY OF MODEL 6X10 THROUGH 6 500 1 Remove the heater housing bolts 2 Disconnect the union in the horizontal outlet piping on threaded units On welded assemblies remove the outlet assembly between heater and outlet valve 3 Carefully remove the outlet housing lifting it straight up until it is completely clear of the injection tube SEE FIGURE 3 outlet housing is listed in the table shown in FIGURE 1 To avoid injury provide mechanical assistance when handling housing CAUTION The weight of the IMPORTANT A minimum clearance above the heater body at least equal to dimension D in FIGURE 1 must be a
11. ANUAL Note Sealant must be FDA approved when heating potable water Thread the injection tube into the double end bushing the bushing should be clamped in a vise at the flats to prevent damage to threads Use an 8 inch pipe wrench to tighten securely Do not over tighten excessive force will damage the injection tube IMPORTANT To avoid damaging the injection tube apply the wrench on the area between the threads and the roll only Applying the wrench to the area containing the orifices may distort the tube and result in the piston sticking Install the bushing and injection tube into the housing using pipe sealant on the threads Reinstall the steam piping and union Securely tighten all joints The heater may now be returned to operation PUMP SERVICE The function of the pump 15 to provide accurate temperature control over varying flow rates The pump creates a high rate of water flow through the heating chamber and over the temperature control sensor This permits the temperature controller to track changing conditions and maintain accurate outlet temperature regardless of water flow BASIC PUMP INSTALLATION CHECKS Check the flow direction and rotation of the pump The arrow on the pump body should show flow from the temperature controller to the heater inlet normally pumping down Be sure the check valve in the pump loop is installed to permit flow in this direction Check to be sure the coupling is tigh
12. Depending on the condition of the injection tube it may be necessary to grasp the spring stopper with a pliers while lightly tapping the outside of the injection tube IMPORTANT DO NOT clamp the injection tube in a vise to perform maintenance DISASSEMBLY MODEL 6X7 SEE FIGURE 4 To examine the piston and spring remove the shoulder bolt that holds the spring stopper in the injection tube A 1 8 Allen wrench is required to remove the shoulder bolt STUCK PISTON ALL MODELS A stuck piston is usually the result of foreign material wedging between the piston and the tube Thoroughly clean the outer surface of the piston and the inner surface of the injection tube Remove any sludge welding slag or other foreign material from inside the tube If necessary sue a descaling agent to remove lime deposits Refer to the discussion of cleaning fluids on page 11 Note Clean and inspect the steam elbow in the inlet housing and any other piping where debris may have accumulated Remove any burrs from the piston and tube The piston must move freely inside the tube before reassembly Scoring of the piston or injection tube will not cause a problem as long as the piston moves freely Remove any high points cause by scoring 15 VARIABLE FLOW SERVICE MANUAL FIGURE 1 Heater Model Clearance Outlet Housing Dimension D Weight 10 inches 10 12 15 T7 20 24 33 REMOVE FOR CLEANING LIQUID OUTLE
13. EAM VALVE OPENING PRESSRUE ADJUSTMENT 1 Close the steam block valve 2 Setthe temperature controller to it s coldest setting Note The following procedure may require two people People adjustments according to the instructions in the separate actuator manual 3 Energize the interlock 3 way air solenoid valve if one is installed 4 Slowly increase the output of the temperature controller until the 2 VARIABLE FLOW SERVICE MANUAL steam valve begins to open At this point read the pressure on the I to P transducer outlet gauge 5 Asingle steam valve or the small valve on a dual assembly should begin to open at 3 4 psi 6 Ifthe heater has a dual steam valve arrangement continue to increase the controller output until the second larger valve begins to open There should be a slight amount of overlap between the valves The first valve should be open about 90 approximately 9 PSI when the second valve starts to open 7 Most steam valves have an adjustment nut at the top of the yoke opening Turning this into the actuator body increases the opening pressure Unthreading the nut reduces the air pressure to begin opening the valve 8 Return the temperature controller output to zero or a negative value NOTE There will be some error when adjusting with the steam off because the steam and water should be observed during operation and further adjustment may be necessary PACKING GLAND ADJUSTMENT I
14. T CLEARANCE REQUIRED FOR x 0 REMOVAL OF STANDARD TEMPERATURE CONTROLLER VENT MEASURE PROBE ON NON STANDARD CONTROLLERS x Pus LHe f 117 7 COMPRESSED AIR REGULATE TO 20 Psi PUMP FOR 6X10 6X500 MODELS II n id RELIEF VALVE PUMP FOR DRAIN VALVES 6X10 6X75 MODELS FIGURE 2 CORRECT BRANCH FROM NO SHOCK ABSORBERS OF HEADER WATER X BRANCHES FROM BOTTOM OF THE WATER H oO gt 16 VARIABLE FLOW SERVICE MANUAL FIGURE 3 INJECTION TUBE BOLTS SPRING STOPPER 6 a HEATER ISOLATION PLUMBING STEM Y SEE PAGE 22 FIGURE 4 f SPRING STOPPER MODEL 6X7 SINGLE PIECE HEATER CASTIN APPLY WRENCH HERE E 17 VARIABLE FLOW SERVICE MANUAL FIGURE 5 y PICK STANDARD TEMPERATURE CONTROLLER PIVOT SCREWS Tur lt S 22 OC o E so pick WEST BENO WISCONSIN Ya NPT OUTLET TO STEAM CONT VALVE STOP PIN CALIBRATION gt 253 SET SCREW SIZE ALLEN MM WUE Sd SENSITIVITY ADJUSTMENT SCREW PROPORTIONAL ADJUSTMENT VALVE SEAT 18 VARIABLE FLOW SERVICE MANUAL REASSEMBLY AND INSTALLATION OF THE INJECTION TUBE ALL MODELS SEE FIGURE 3 Be sure the inside of the injec
15. Tune the controller per controller not properly tuned controller manual PID Proportional PID Parameters Integral Derivative Injection tube problem Refer to detailed 12 14 the tuning parameters Stuck piston instructions for on some electronic Plugged Orifices disassembly and and pneumatic Broken spring inspection of the heater temperature and injection tube controllers Air or gas trapped in a high Bleed air from the 23 point of the supply or the discharge piping creating an unstable condition system Remove surge tank Install automatic air vent valve s at system high points Water and steam pressures too close together Check operating pressures Reduce water pressure or increase steam pressure VARIABLE FLOW SERVICE MANUAL OBSERVATION PROBABLE CAUSE ACTION PAGE Airtrapped in a high point Bleed atr from the 23 ofthe cold water supply or water system the hot water header creating an unstable Install automatic air condition vent valve s Distribution branches not Check connection of 23 connected to the top of distribution branches water headers re pipe if necessary or Add automatic air bleeds at system high points USE POINT control valves Readjust rapid acting opening or closing too control valves rapidly Adjust or repair valves as necessary to allow smooth operation Eliminate sources of water pressure spikes or upsets Cross connection between Visually
16. a vent for gasses that may be formed during the cleaning operation On flanged systems a short stand pipe must be installed in the temperature indicator port It should extend6 above the top of the outlet horizontal outlet pipe Close the drain valves under the pump and heater Carefully pour cleaning solvent into the opening at A Slowly fill the heater to the level of this opening SEE FIGURE 1 On flanged units only fill horizontal outlet 1 3 to full DO NOT fill above temperature indicator port Turn on the pump motor Allow the cleaning solvent to circulate in the heater for approx 60 minutes running the pump motor throughout this period The time required to clean the Pick heater will depend on how much lime deposit is on and in the injection tube assembly good indication of when the unit is clean is the cessation of foaming Turn off the pump motor Drain the cleaning solution into suitable containers by opening the system drains Be sure to follow manufacturer s cleaning instructions for handling storing or disposing of the material Many cleaning agents can be used more than once before losing effectiveness Consult a local chemical supplier 11 Reinstall the temperature indicator and pipe plug blind flange Flush the heater completely by opening the water supply valve while leaving the drain valves open Turn on the pump motor When the water exiting form the drain valves is clean and clear cl
17. all and tighten the castle nut if so equipped It is now set approximately 15 psi above the water pressure 7 The valve is now reset The water outlet valve steam block valve and air supply to the temperature controller may now be opened STEAM CONTROL VALVE IMPORTANT Do not install valve positioners A valve positioner cases the steam valve to move too fast to a new position resulting in hammer vibration and poor temperature control If installed place in a bypass dampen or remove the positioner STEAM VALVE LEAKAGE Overheating of product when the steam valve is closed 1s an indication of EXCESS LEAKAGE The maximum leakage rate should not exceed 01 of full open valve capacity ANSI CLASS IV Steam leakage can be observed by disconnecting the union or flange between the steam valve and heater then slowly opening the block valve steam block valve is closed and the heater is drained prior to disconnecting the union or flange CAUTION make sure that the If excess leakage 1s observed Check valve travel stop if applicable Disconnect the air line from the steam valve actuator If leakage decreases either the steam valve opening pressure is less than 3 PSI or there is a temperature controller o I to P transducer problem if installed which is holding the steam valve slightly If the leakage still exists the steam valve requires repair Please refer to the valve service manual for instructions ST
18. andard or faulty tuned to allow 7 10 temperature controller seconds for full valve travel Injection tube problem Refer to detailed 11 13 instructions for disassembly and inspection of the heater and injection tube Replace piston spring or injection tube if required Crack or hole in steam flow Repair or replace inlet house CONSULT FACTORY Steam control valve moves Remove valve too fast due to use of valve positioner s positioner s Steam valve opening Adjust valve according 20 pressure out of adjustment to steam valve instruction manual Valve packing gland too Adjust packing gland 21 tight according to valve manual Unstable steam pressure reducing valve upstream of the system Examine reducing valve repair or replace if necessary OBSERVATION PROBABLE CAUSE ACTION PICK VARIABLE FLOW SERVICE MANUAL PAGE Supply failure from the water source Examine water supply system correct all problems Broken or plugged pipe fittings including check valves gate valves strainer etc Inspect water supply lines replace plugged or faulty components Clean water strainer OBSERVATION valve PROBABLE CAUSE basket if applicable OBSERVATION PROBABLE CAUSE ACTION PAGE Particularly after Temperature controller set Reset controller to the extended heater too high during initial setup desired temperature shutdown or during a previous See installation operati
19. bservations are listed in the OBSERVATION column PROBABLE CAUSE is the likely cause of the problem and ACTION indicates the suggested operation to resolve the problem The PAGE column directs the technician to additional service or repaid instructions for the suggested action if applicable If you are not able to solve a problem with your heater as described in these pages or if your problem is not cocered in this manual please contact your local Pick representative or call Pick Heaters at 800 233 9030 Outside the US and Canada call 262 338 1191 or Fax 262 338 8489 PROB ate ot heat liquid to the desired tempera OBSERVATION PROBABLE CAUSE ACTION PAGE Steam control valve is Insufficient supply air Check air supply set FULL CLOSED pressure filter regulator at 20 psi Temperature controller Check temperature 21 problem controller components and supply See separate manual for optional temperature controller RTD failure or polarity on Check wiring for loose I to P Transducer may connections refer to be reversed optional separate manuals for electronic controller only wiring diagrams Steam control valve is Improper controller Increase controller 21 PARTIALLY OPEN calibration setting and re calibrate Inadequate air pressure Check air pressure supplied set filter regulator at 20 psi I to P tranducer calibration Calibrate I to P per optional separate manual Steam valve actuator
20. ection tube piston can cause system vibration The piston must respond to the steam flow variations which are the result of changes in the temperature rise r flow See injection tube inspection Page 13 4 The water pressure must be less than the steam pressure If the water pressure is close to or greater than the steam pressure the heater can not be made to work properly Water temperature variations and vibration often result if the heater is operated under these conditions In most cases the water pressure should be at least 20 psi less than the steam pressure 5 If the water pressure is higher and or the steam pressure is lower than originally specified the steam valve may not be large enough for proper operation of the Pick heater The flow through the steam valve is a function of the supply pressure and pressure drop across the valve The steam supply pressure and the water pressure at the heater determine the pressure drop across the valve If this pressure drop is less than originally specified the maximum flow through the valve 24 VARIABLE FLOW SERVICE MANUAL will be reduced A larger steam valve and possible a larger steam line may be required If these conditions are suspected and are preventing proper operation of your heater please consult the factory 6 Install dielectric unions at all connections between the Pick heater and copper piping For the most part standard Pick water heaters are
21. ed controllers are reworked and placed in factory rebuilt stock CONTROLLER LINKAGE ADJUSTMENT Set knob to cold Remove knob and nameplate to expose inner mechanism Check movement of thermal valve arm to make sure arm is centered over valve seat and has a slight sideplay If necessary correct movement by adjusting pivot screws Reinstall nameplate and knob When heater is operating satisfactorily it may be necessary to recalibrate the temperature controller ADJUSTMENT AND MAINTENANCE OF OPTIONAL TEMPERATURE CONTROLLERS If the Pick heater is equipped with an optional temperature controller follow the adjustment and calibration procedures as detailed in the separate temperature controller manual furnished with the heater Service or repair of theses units must be performed by qualified individuals 23 VARIABLE FLOW SERVICE MANUAL Improper servicing can lead to a malfunction of the heater and can even result in dangerous operating conditions Consult Pick Heaters or the local representative if internal servicing is required HEATER SYSTEM ISOLATION It is relatively easy to determine whether vibration is due to a problem within the heater and or supply lines or is caused by a condition in the hot water distribution system SEE FIG 3 HEATER ISOLATION PLUMBING INSTALLATION 1 Shut down the heater Remove the temperature controller and bushing Install a short nipple and tee the same size as the bushin
22. ent screw and allow air to blow out through the opening to make sure it is clear Wipe off the needle and resinstall Turn the adjustment screw in all the way then open one half turn The adjustment screw may need to be further adjusted a maximum of one quarter turn in either direction for best control Make adjustment in one eighth turn increments Give the heater time to respond between adjustment Check the supply and control ports The supply from the regulator enters the controller from the right when looking at the nameplate in the upright position The left port should be connected to the tubing going to the steam valve Note The supply is marked with S the control port is marked R on the bottom of the controller Check the control knob and calibration The control knob might be loose and may not actually be turning the shaft If the stop pin has been sheared the controller may be one or more turns out of calibration To check remove the control knob by loosening the set screw Turn the shaft to obtain correct temperature Install the knob to indicate the actual water temperature Tighten the set Screw REPAIRS OF THE STEANDARD PICK TEMPERATURE CONTROLLERS All needed repairs on standard temperature controllers should be performed at the factory To minimize heater downtime Pick Heaters will send a fully warranted factory rebuilt temperature controller in exchange for a used controller Us
23. g 3 Install the temperature controller with bushing in one run of the tee Install discharge piping to the branch of the tee with a manual valve in it 4 Close the heater outlet valve 5 Start up the heater discharging the water through the temporary piping If the heater runs smoothly in this configuration the problem is elsewhere in the hot water distribution system If the heater continues to malfunction in this configuration check the diagnostic table for solution IF problem cannot be corrected consult local representative or Pick Heaters OTHER SYSTEM TROUBLESHOOTING ISSUES 1 If steam pressure is below specification or fluctuates temperature variations and system vibration can result A Pick heater cannot perform properly under these conditions Diminishing steam pressure is often the result of undersizing or restrictions in the steam supply system If as the steam valve opens the pressure falls off at the Pick steam inlet assembly a restriction in the steam supply line or limited steam supply exists The steam line strainer basket may be plugged restricting steam flow to the heater A DANGER Close steam block valve before servicing the strainer basket or other steam line component 2 Steam lines and valving must be sized for maximum steam flow with negligible pressure loss Manual globe valves if used in the steam supply piping should be oversized to minimize pressure drop 3 stuck inj
24. g a length of CLEAN rod HEATER REASSEMBLY MODELS 6X10 THROUGH 6X500 Inspect the inlet housing elbow and associated piping for lime deposits and debris Remove any foreign material Examine the threads for damage Apply a moderate amount of paste type pipe sealant with Teflon to the injection tube threads Note Sealant must be FDA approved when heating potable water IMPORTANT Place the wrench over the rivets in the same position used when loosening the tube Tighten snug but do not over tighten Applying force by using an extra long wrench or by placing a length of pipe over the handle of the wrench is likely to damage the injection tube Examine the gasket surface for cleanliness and install a new gasket Install the outlet housing IMPORTANT Carefully install the outlet housing straight over the injection tube Avoid contact between the housing and injection tube Reinstall all heater flange bolts and install nuts finger tight Reassemble and tighten the outlet union If the union is flanged clean the gasket surface and install a new gasket Securely tighten all heater flange nuts working in a cross alternate patter The Pick heater may now be returned to operation HEATER REASSEMBLY MODEL 6X7 SEE FIGURE 4 If injection tube was removed from the double end bushing apply a moderate amount of paste type pipe sealant with Teflon to the injection tube threads 19 VARIABLE FLOW SERVICE M
25. ith a soap solution If bubbles form a leak exists Repair all leaks Possible lead points to check include e air piping and connections e The steam valve diaghram may have a hold in it e The actuator stem O ring may be cut or worn TEMPERATURE CONTROLLER ADJUSTMENT AND SERVICE SEE FIGURE 5 Proper operation and adjustment of the temperature controller is vital to the proper functioning of your Pick heater A faulty or incorrectly calibrated controller can cause 22 VARIABLE FLOW SERVICE MANUAL temperature control problems however several other components also affect temperature control should be checked before replacing the temperature controller CALIBRATION Adjust the controller until the outlet thermometer is at the desired temperature Loosen the control knob set screw Turn the knob to the indicated temperature Tighten the set screw 3 32 inch Allen wrench 18 required ADJUSTMENT OF STANDARD PICK TEMPERATURE CONTROLLERS Confirm the air pressure regulator setting of 20 psi If the pressure gauge has a dual scale English Metric be sure to take readings from the psi scale English IMPORTANT Manual steam valve and air valves must be closed when servicing the temperature controller FIGURE 5 Check the sensitivity adjustment screw located on the bottom of the controller near the air supply inlet It may be covered with a sealant which can be removed Remove the adjustm
26. mportant Consult Steam Valve Manual for proper adjustment Packing gland adjustment is required when either of two conditions exist 1 Leakage around the valve steam indicates a need to tighten the packing gland nuts slightly or replacing packing Tighten evenly 2 Fluctuations in product temperature may be caused by excessive drag between the packing gland and steam valve stem The steam valve moves in a jerky motion Slight loosening of the packing gland nuts may correct the condition WARNING Loosen packing A gland nuts slightly DO NOT REMOVE NUTS COMPLETELY If steam leaks around the packing gland retighten the nuts until the leakage stops OPERATION BELOW MINIMUM STEAM VALVE TURNDOWN Operating the heater at a steam flow that requires the control valve to be less than 20 open can cause vibration bounce flutter or hammer If your application requires operation under these conditions a dual steam valve assembly or a smaller steam valve should be installed Contact Pick Heaters or your Pick representative for more information NOTE This situation can be checked by throttling the steam block valve enough to open the steam control valve at least 50 If the vibration ceases the steam control valve was operating too close to the seat AIR LEAKAGE Air leaks between the steam valve actuator and the temperature controller can result in temperature controller problems Leaks can be detected by coating the area w
27. n It is not necessary to remove the piston for cleaning if the piston is not stuck If the piston moves freely in the tube and no damage is noted proceed with cleaning Submerge the injection tube assembly in a container of cleaning solution descaling agent Refer to OBTAINING THE PROPER CLEANING SOLUTION Section page 11 for recommended cleaning solutions After 30 minutes flush the injection tube with water Inspect the injection tube to determine whether all the scale has been removed BE SURE THE PISTON MOVES FREELY INSIDE THE TUBE If necessary re submerge the tube in the cleaning solution When all scale is removed and the piston moves freely flush completely with water Reinstall the injection tube assembly then reassemble the heater per the following instructions IMPORTANT Do not leave the injection tube assembly in the cleaning solution longer than required Extended contact may damage the spring or tube INJECTION TUBE DISASSEMBLY CAUTION The spring stopper is under a moderate spring load Hand pressure can restrain the spring force However care should be exercised when removing the 14 PICK VARIABLE FLOW SERVICE MANUAL stopper during injection tube disassembly DISASSEMBLY MODELS 6X10 THROUGH 6X500 SEE FIGURE 3 Remove the nuts and bolts retaining the spring stopper from the unthreaded end of the tube Remove the spring stopper and spring and inspect each part for wear or damage
28. ng session manual for calibration procedure Air pressure supplied to the Reset air pressure to 20 temperature controller too psi high Relief valve not functioning Inspect adjust or repair 19 20 properly as necessary Lead in the steam control Inspect and repair as 20 necessary PROBLEM Temperature indicator doesn t agree with controller setting ACTION PAGE Water temperature is stable and satisfactory Temperature controller not properly calibrated Re calibrate temperature controller See separate manual for optional controllers PROBLEM Discolored Water 21 dissimilar metals between heater and system piping OBSERVATION PROBABLE CAUSE ACTION PAGE Problem in the supply water Inspect water lines system correct any deficiencies Galvanic corrosion due to Install dielectric unions 23 at all connections between the heater and copper piping Problem in the steam supply system Examine the steam supply system correct any deficiencies 10 PICK VARIABLE FLOW SERVICE MANUAL INJECTION TUBE SERVICE INJECTION TUBE ORIFICES PLUGGED The most common cause of this problem is hard water When hard water is heated above 120 F the lime in the water precipitates out of the water and coats the injection tube and other surfaces These deposits can be removed by circulating an appropriate cleaning agent through the heater and pump loop WHEN TO CLEAN THE PICK HEATER How
29. ose the drain valves Open the water outlet valve Open the use point nearest from that location until the water 18 clean and clear Close the use point valve and turn off the pump 12 The Pick heater is now ready to be returned to service Please refer to normal heater startup procedures in the Installation Manual NOTE The piston in the injection tube must be free to respond to variations in steam flow If restricted hammer or vibration will result Disassembly is a straightforward and relatively simple procedure subject to a few common sense precautions Before proceeding with disassembly please read this entire section carefully to avoid damage to your heater HEATER DISASEMBLY IMPORTANT The following parts are required for proper re assembly Make sure parts are on hand before taking the unit out of service for maintenance or cleaning SEE FIGURE 1 The body of a Pick heater except Model 6X7 consists of two housings that are flanged together Before proceeding be sure a replacement gasket is available for reassembly If the injection tube is disassembled new stainless steel bolts and flexlock nuts will be required to properly install the spring stopper See TABLE 2 for quantity for each heater model 12 PICK VARIABLE FLOW SERVICE MANUAL TABLE 2 Size and QTY of Injection Tube Fasteners Heater Bolt Size Quantity Model 6X7 74 28 1 Shoulder Bolt 6X10 4 28 x 5 8 3
30. rances and is a key component of your Pick heater It can be removed from the double end bushing an 8 inch pipe wrench Larger wrenches are not recommended IMPORTANT The proper location for placement of the wrench is between the threads and the roll in the tube SEE FIGURE 4 INJECTION TUBE INSPECTION ALL MODELS Inspect the injection tube If mineral deposits are evident clean the tube as described in Injection Tube Cleaning The piston must move freely in the tube Use a clean rod placed in the threaded end of the tube Manually move the piston through is full travel Work the piston up and down several times It must move to the spring stopper and return smoothly If the piston does not move smoothly proceed with disassembly ad further inspection of the injection tube components Note The injection tube assembly can be returned to the factory for prompt and comprehensive servicing Cleaning inspection and repair or replacement of parts will be performed as necessary to return the part to original specifications Many customers keep a spare injection tube on hand to minimize downtime during maintenance INEJCTION TUBE CLEANING ALL MODELS A CAUTION When handling and using a cleaning solution be sure to follow the manufacturer s instructions to prevent personal injury or damage to equipment As a minimum wear goggles and rubber gloves The cleaning should be performed in a location with good ventilatio
31. s ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Be familiar with the varying degrees of hazard represented by the signal words CAUTION and WARNING CAUTION indicates a need to be aware of situations or conditions which demand greater attention to safety practices when operating or servicing the unit WARNING indicates a situation demanding full attention to safety precautions due to possible hazards Segments of information preceded with the word should be noted as damage may occur to the unit or system if detailed instructions are not followed Note Most Pick Variable Flow Heaters are used to heat water However these units also find extensive service in processing water miscible products Installation maintenance and troubleshooting procedures are not affected b the nature of the liquid being heated To avoid complications this manual uses water to refer to any liquid or slurry being heated VARIABLE FLOW SERVICE MANUAL TROUBLESHOOTING Pick heaters rarely require troubleshooting or repair thanks to the simplicity of design and operation Many apparent difficulties with heater operation are actually the result of a problem or adverse condition in the steam supply system or product supply and distribution lines The following pages are to direct the technician through a logical approach for system troubleshooting General problem are shown in the header of each table Key physical o
32. size see Steam 22 Supply section for steam line sizing calculations Water pressure is too high Install pressure 23 Supply pressure higher than reducing valve design Consult factory Water pressure reducing Reduce setting valve is set too high PROBLEM Heater will not heat liquid to the desired temperature OBSERVATION PROBABLE CAUSE ACTION PAGE Pump not circulating water Inspect and repair See parts list pump as necessary VARIABLE FLOW SERVICE MANUAL Malfunction in the pump look check valve Inspect and repair check valve as necessary Capacity of heater is Consult Pick Heaters exceeded for heater upgrade information Faulty temperature Repair or replace 21 controller controller Steam inlet pressure Boiler or supply not Check steam supply 22 varies adequately sized to provide sizing and boiler for enough steam to pressure fluctuations accommodate all demands in the steam system Steam quality may be poor Install a drip leg witha See excess condensate steam trap upstream of Installation entrained in system the strainer to maintain Manual high quality steam at the heater Steam valve has a Steam valve packing gland Adjust steam valve 21 too tight stem packing gland f Air leak in the control line Use Soap solution to 21 detect any leaks Repair leaks or replace line Steam valve oscillates Optional temperature
33. t on both the pump and the motor shaft 1f so equipped Models 6X100 through 6X500 CIRCULATING PUMP SERVICE CAUTION Be sure the pump motor is turned off and the electrical supply is locked out before servicing the pump Close water inlet and outlet and steam block valves Drain water from the heater Refer to the pump service sheet for detailed pump repairs Completely assembled bearing housings are available from the factory if applicable Model 6X100 through 6X500 RELIEF VALVE FUNCTION The relief valve has two functions 1 to dampen pressure spikes and 2 to permit steam to enter the heater during A periods when water is not being used WARNING The relief valve must be set to relieve at a pressure between the water and steam pressures If the relief valve is removed plugged or set above the steam pressure overheated water or steam may be discharged into the downstream piping THIS COULD CAUSE DAMAGE TO THE EQUIPMENT OR COULD RESULT IN SERIOUS INJURY ONE POUND OF STEAM HAS A VOLUME OF ALMOST 27 CUBIC FEET WHEN DISCHARGED INTO THE ATMOSPHERE When water is not being used and all outlets are closed the heater and associated piping become a closed filled chamber As the pump loop cools the temperature controller calls for steam to maintain the set temperature Initially steam can not enter the heater As the steam valve opens the pressure in the heater increases until it reaches the relief valve setting
34. tion tube is clear of all deposits and foreign material Note that in some heaters the piston and spring stopper have the same outside diameter but are NOT interchangeable The piston has a 055 hole in the center of the flat end while the spring stopper has a 1 4 or larger hole Reinstall the piston in the tube so the pillow or open side of the piston is facing the spring stopper end of the tube allowing the spring to fit inside the piston Reinstall the spring and spring stopper IMPORTANT Model 6X7 only Install the spring stopper with the open end over the spring The spring stopper will rest under the shoulder bolt SEE FIGURE 4 The spring stopper injection tube has scribe marks on the end of the tube that indicate the proper positioning for alignment of the spring stopper bolt holes except model 6X7 Reinstall the bolts that hold the spring stopper in place but DO NOT re use the old nuts IMPORTANT Install NEW stainless steel flexlock nuts to insure proper locking Replacements can be obtained from Pick Heaters SEE TABLE 2 Page 12 The model 6X7 injection tube uses a shoulder bolt to hold the spring stopper in place Use a new stainless steel flexlock nut when re assembling SEE TABLE 2 After the injection tube is reassembled make sure the piston operates freely Check to be sure there is no binding or restriction in the tube by manually working the piston through its full travel several times usin
35. trace all lines the hot water line and to locate possible cross another water line connections Eliminate the cross connection with installation of check valves or other valving Water and steam pressures Check operating 23 too close together pressures Reduce water pressure or increase steam pressure Unstable water pressure Observe operation of valve in system all valves with steam to the heater turned off Adjust or replace faulty valves as necessary Shock absorber or pulsation Remove all shock dampener device in the absorber devices surge system tank Supply water pressure may With steam off be unstable inspect water supply system or pressure and correct as necessary Install water pressure control valve if required Continued next page PICK VARIABLE FLOW SERVICE MANUAL Steam quality may be poor Examine the steam See excess condensate system correcting any installation entrained in steam deficiencies manual Install a drip leg with steam trap upstream of the strainer to maintain high quality steam at the heater Steam control valve Check steam valve 21 positioned less than 20 travel when operating open operating below Valve must be open minimum turndown more than 20 open Consult Pick Heaters about a smaller or dual steam valve arrangement Steam control valve moves The temperature too fast only with non controller should be st
36. vailable to remove the outlet housing Life the outlet housing straight up using care to prevent accidental contact between the housing and the injection tube during lifting damage to the injection tube may result REMOVING THE INJECTION TUBE The injection tube is machined to close tolerances and is threaded into the inlet housing It can be removed with a pipe wrench or chain wrench Place the wrench over the rivets near the threaded end of the tube If additional force is required a second wrench can be applied over the bolts holding the spring stopper at the opposite end of the tube SEE FIGURE 3 IMPORTANT To avoid damaging the injection tube apply the wrench on the rivet area only Do not apply the wrench to the area containing orifices i e between the rivets and spring stopper retaining bolts DISASSEMBLY AND INSPECTION OF THE MODEL 6X7 HEATER The body of the 6X7 heater consists of a single housing See Figure 4 13 VARIABLE FLOW SERVICE MANUAL 1 Disconnect the steam line union located between the steam valve and the heater 2 Loosen the double end bushing one quarter turn and remove the steam line nipple to facilitate removal of the double end brushing 3 Unscrew the double end bushing from the heater housing and remove the injection tube assembly if required Most service procedures can be performed with the tube in the bushing IMPORTANT The injection tube is machined to close tole
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