Patterson-Kelley P-K Compact User's Manual
Contents
1. steam pressure steam velocity and the length of the line Steam Control Valve A self contained steam regulator or a pneumatical ly operated steam control valve is supplied Three dif ferent kinds of steam valves will operate satisfactorily on the COMPACT Connections to the valve should be made according to the installation diagrams in this manual Condensate Line NOTE Do not attempt to lift condensate above the condensate outlet without the help of a condensate pump Failure to comply with this can result in tube bundle failure and will cause erratic temperature control The condensate line requires a check valve to pre vent condensate from being drawn back into the heat exchanger Operation and Adjustment 1 Turn on water supply to unit 2 Trip relief valve to expel entrained air w Lubricate pump and read pump installation manual before starting 4 Turn on circulation pump Do not operate pump before water is in unit 5 Turn on steam 6 Turn on faucets or other devices 7 Operate unit at approximately gt rated capacity 8 Adjust the steam control valve to obtain desired outlet temperature This is the setpoint Please care fully read the manufacturer s instructions for adjusting the control valve Since the P K COM PACT is used with many steam pressures and water temperatures they are not set at the factory 9 Rerun the unit at one half low capacity as in Item 7 and recheck the setpo2. relief valve is installed on the con nection provided at the top of the heater This valve should be piped to the sewer without decreasing the pipe size or installing any valves Failure to pipe to a drain could cause a hazardous condition as well as flooding of the equipment room Heater Recirculation All COMPACT water heaters have a properly sized integral circulator all bronze The heater recircula tion pump is not intended to function as a building recirculation pump Electrical The circulation pump normally provided has a 115 volt single phase motor which may be connected to ordinary house wiring The connecting wires should be 12 gauge and a suitable fuse switch provided as protection from short circuits The wires should be protected by standard cir cuits Steam Trap A properly sized steam trap is supplied loose for field installation Pipe to the condensate connection of the unit The condensate connection is at the bottom rear of the bonnet When lift is encountered do not attempt to lift con densate above the trap Failure to permit free drainage of condensate will result in damage to the tube bundle It will also cause poor temperature control Temperature Limit System A double solenoid temperature limit system is fur nished as standard to prevent a runaway condition should the steam control valve fail in the open posi tion The double solenoid system is controlled by a single pole double throw the
3. P K COMPACT 2001 P K COMPACT Steam Fired Water Heater Operating and Maintenance Instructions P K Reference LOCATION CONTRACTOR RATING GPM F to F STEAM LINE PRESSURE P S 1 G PATTERSON KELLEY 100 Burson Street East Stroudsburg PA 18301 Phone 570 421 7500 Patterson Kelley Fax 570 476 7247 www pkwaterheaters com Harsco PLEASE READ CAREFULLY BEFORE INSTALLING General Information Upon receipt of this shipment please inspect the unit for any damage The P K COMPACT water heater was thoroughly inspected and tested prior to shipment and any damage should be reported to the transportation company immediately Please refer to the P K Serial Number of the unit when contacting the local P K Sales Representative P K COMPACT water heaters are completely pack aged ready to connect to services A standard packaged unit has the following trim Shell insulated and covered with a reinforced PVC jacket Steam control valve Steam pressure gauge e Thermometer e Circulation pump Relief valve Double solenoid temperature limit system General Operating Information The diagrams on pages four and five show the vari ous piping arrangements of the P K COMPACT water heater in operation Steam passes through the tubes of the heat ex change bundle The water is rapidly heated as it is directed over the tubes by segmental baffles Above the baffled tube bundle minimum storage volume is pro
4. VATER HEATER har varer TEMPERATURE SENSOR TEMPERATURE CONTROL VALVI STEAM ACCUMULATED STE CONDENSATE PRT TRAP CONDENSATE LIFT CAUSES FLOODING FIGURE 2 Illustrates how condensate formed in the steam feed line can accumulate under no or low water flow rates This condensate will be carried with the steam when the valve opens damaging the valve and tubes It also shows how the tubes will flood when trying to lift conden sate at less than de traps or check valves that can avoid this condition when there is no steam pressure in the tubes ign flow rates There are no types of WATER HEATER Z hor WATER TEMPERATURE SENSOR CONDENSATE CONDENSATE DRAIN BY GRAVITY WITHOUT LIFT DR BACK PRESSURE FIGURE 1 Illustrates the proper method to be used to drain condensate from a semi instantaneous water heater Note the drip trap before the temperature control valve to prevent condensate from accumulating under no er low water flow thereby avoiding erratic temperature control valve damage or impingement of condensate on the tubes All condensate must drain from the tubes by gravity with out lift or back pressure ATER WEATER rer vane oecearune senso Toeceatue corre FIGURE 3 Illustrates the same problems shown in FIG URE 2 but with the addition of a condensate receiver employing a back pressure vent valve in the receiver vent line This has become a popular method of avoiding a flash
5. g tube bundle use 10 Pressure gauge steam new gaskets supplied by manufacturer DRAINING CONDENSATE FROM DOMESTIC WATER HEATERS The heating of domestic water with steam has been going for over 100 years The principle is to extract the latent heat from the steam in the tubes resulting in the steam condensing In the last 30 years the Semi Instantaneous water heater has grown in acceptability due to its compact size and its accurate temperature control For proper operation the Semi Instantaneous design requires the rapid removal of condensate Proper drainage of the condensate from the tubes of the water heater is needed to avoid 1 Possible tube rupture 2 Damage to steam traps 3 Damage to the temperature control valve 4 Erratic water temperature control Keep in mind that the sole function of the tempera ture control valve is to control the outlet temperature of the water To do this the temperature control valve will proportion the steam flow according to the water flow rate This means that at lower flow rates the steam in the tubes can be at a sub atmospheric pres sure Since the water heater will operate at less than its design capacity 90 of the time the steam pressure in the tubes will be lower than the design pressure and cannot possibly be used to lift condensate above the trap level To assist in visualizing the proper method of draining condensate from the water heater note the following diagrams
6. int om PIPING ARRANGEMENTS Steam System Single Unit Installation POH seo vave fH Srorer Note Relief valve LAY check vave i abet Vale must be piped to a drain to prevent HRH conta vate q Theat hazardous condition Note Installer must LH orice unen HAH steam Trap provide SSR DN Thermal sa Err Gage EH Creve Pressure cage intal Balancing Cook eo esse ra Compound Indeater ect AL Fe Valve must be piped to a drain to prevent hazardous condi Note Relief valve must be piped to a drain to prevent hazardous condition Note Installer must provide strainer on steam supply line 7 Valve must be piped to a drain to prevent hazardous condition Steam System Parallel Installation es Steam System Accumulator Type Tank Application High Recovery Water Heater HH sion vane HoH sraner Check Vave Reie Vave conr vave rer t ornes unon z Swan Tap Bae Creator Pressure cage Lp saarerg z enon er Meera q Pow necator Note Relief valve must be piped to a drain to prevent oN hazardous condition n Note Installer must provide NG strainer on steam supply line Steam System Stratified Storage Application Limited Recovery I Water Heater Note Installer must provide strainer on steam supply an Valve must be piped t
7. o a drain to prevent hazardous condition Note Relief valve must be piped to a drain to prevent hazardous condition Valve must be piped to a drain to prevent hazardous condition SERVICE TIPS Failure Remedy 1 Water temperature too high Check setting of temperature sensor e Check for dirt or foreign material in bleed ports on self contained steam piloted valves e Check for proper spring tension on air operated valves Check for dirt under seat of valves e Check for proper seating of valve Bad sensing element See enclosed valve literature 2 Banging or pinging in heater e Check for proper condensate drainage Do not atempt to lift condensate above tube bundle Check for back pressure in condensate line Condensate should flow by gravity to vented receiver Check traps for proper oeration when used See trap literature 3 Erratic temperature control Check for proper rotation of circulation pump Check for flow of circulator pump be sure pump is pumping Check valves in pipe line must be open Check for condensate lift e Check for proper steam pressure Be sure it is not more than heater is designed to operate at Check traps for proper operation when used 4 Loss of recovery or poor recovery Check for proper air pressure on air operated valves See valve bulletin Shut down unit remove steam chamber and tube bundle Inspect tube bundle for scale or fouling which could restric
8. rmostat which should be set at least 15 F above the control point of the temperature control valve sensor In the event of con trol sensor failure the thermostat will activate the three way solenoid valve relieving the pressure on the steam valve diaphragm and allow the valve to close Pipe Dump Valve to Drain A 4 solenoid dump valve located on top near the hot water outlet will allow any excess hot water in the tank to be dumped into a drain preventing overheated water from entering the hot water piping of the build ing The dump valve should be piped to a drain Failure to pipe to a drain could cause a hazardous condition as well as flooding of the equipment room Steam Line A properly sized steam line with strainer should be connected to the COMPACT The strainer should be installed to protect the control valve from any for eign materials carried through the steam line A drip trap should be installed in the dirt leg just before the steam control valve to protect the valve from steam hammer When the steam line is over 10 ft long it should be trapped ahead of the strainer to prevent condensate from collecting Condensate would be carried through the valve at such a velocity that damage could occur When the steam line is of any great length it may be necessary to provide a pipe size which is greater than the pipe size of the strainer In selecting the prop er steam line size consideration should be given to the
9. steam flume to the atmosphere and any complaints by a client that ener being lost It can also provide addi tional net positive suction head pressure to the conden sate pump to aid in pumping hot condensate This design however may cause serious drainage problems for the water heater condensate
10. t heat transfer Clean with Dow Chemical Versene 100 or equal e Replace tube bundles using new gaskets eCheck and be sure heater design rating is not being exceeded See specifications on front cover of this manual e Check for fouling of steam pilot and self contained valves due to carry over of treatment compound Removal of Tube Bundle Recommended Spare Parts To remove tube bundle use the following prodedure Circulator pump bearing and seal assembly Valve off steam supply 2 Thermometer 2 Valve off cold water supply to heater a J 3 Valve off hot water to building 3 Temperature sensor on air operated valve use Accritem 4 Valve off recircuations line On steam piloted valve use thermal system for Sarco i PANVE Ores ee valve and thermostat assembly on Spence valves 5 Turn off all power to heater de 6 Break flange or union on steam valve and condensate 4 Relief valve line in Solenoid 3 way valve for pneumatic 2 way for self 7 Loosen nuts on top of tube bundle flange This will per contained mit dropping of tube bundle for inspection without breaking steam chamber seal 8 To check the tube bundle for leaks simply remove the 7 Replacement tube bundle steam chamber only Tubesheet is threaded to permit 8 Steam trap cage unit if used examination of possible ruptured tubes without draining heater 9 Tube bundle gaskets Solenoid Thermostat 9 When reassembling heater or replacin
11. vided to give the controls sufficient time to pro duce the close temperature control The circulation pump maintains proper water veloc ity across the tubes producing a high rate of heat transfer Constant circulation produces extremely high performance and close temperature control while pre venting scale formation in all but the harshest hard water conditions The shell section functions primarily as a mini mum storage to permit the temperature control valve to open or close according to hot water demands with out discharging unheated or overheated water The Anticipator temperature control is located in the small storage section just above the heat exchanger Placement The heater should be placed to permit gravity flow of condensate to the condensate return system The head room above the heater should be at least 8 to permit the removal of the relief valve The heater should be secured to the building floor or mounting pad Plumbing Water Connections Connect properly sized water service lines to the heater without check valves and provide a suitable gate valve The hot water outlet may be run dead end however a recirculated hot water line will provide hot water more rapidly to the fix tures When two or more heaters are piped in parallel be sure the cold water inlet and hot water outlets are equally balanced to prevent one heater from carrying the bulk of the load Relief Valve A properly sized
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