Heatpac® EHS-71 System

System Instructions

Product No. 9016616-01 to -07

Printed Jun 2015

Book No. 9020063-02 V1

Marine & Diesel Equipment

Alfa Laval reserve the right to make changes at any time without
prior notice.
Any comments regarding possible errors and omissions or
suggestions for improvement of this publication would be
gratefully appreciated.
Copies of this publication can be ordered from your local
Alfa Laval company.
Published by: Alfa Laval Tumba AB
Marine & Diesel Equipment
S - 147 80 Tumba
Sweden
© Copyright Alfa Laval Tumba AB Jun 2015.
The original instructions are in English
Contents
1 Warning signs in text 7
1.1 Warning signs 7

2 Scope 9

3 System Description 11
3.1 Basic Concept 11
3.1.1 Principle Diagram 11

4 Heatpac Working Principle 17

5 Operating instructions 19
5.1 Before Start 19
5.2 Start-up 19
5.3 Operation 20
5.4 Stop 20

6 Alarms and Fault Finding 21

6.1 Alarm Indication 21

7 Diagrams 23
7.1 Electrical System Layout 23
7.2 Cable List 24
7.3 Interconnection Diagram 25
7.4 Installation Diagram 26

8 Installation 27
8.1 General Installation 27
8.2 Electrical Installation 28

3
 !

Study instruction manuals and observe the

warnings before installation, operation,
service and maintenance.

Not following the instructions can result

in serious accidents.

In order to make the information clear only

foreseeable conditions have been considered.
No warnings are given, therefore, for situations
arising from the unintended usage of the
machine and its tools.

5
!
 1 Warning signs in text

1.1 Warning signs

Pay attention to the safety instructions in this
manual. Below are definitions of the three
grades of warning signs used in the text where
there is a risk for injury to personnel.

NGE R
! DA
DANGER indicates an imminently hazardous situation
which, if not avoided, will result in death or serious
injury.

NG
WARNI
!
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.

ON
CAUTI
!
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury.

NOTE

NOTE indicates a potentially hazardous situation

which, if not avoided, may result in property damage.

7
1 Warning signs in text
 2 Scope

The Heatpac® EHS-71 system is designed

for the heating of mineral oils in a centrifugal
separator cleaning system and/or in a fuel
conditioning system (FCM).
This system description is valid for the Heatpac®
EHS-71 Heating System.

9
2 Scope
 3 System Description

3.1 Basic Concept

The Heatpac® EHS-71 basic concept comprises
an electric heater of EHM type combined with
an electronic control unit, power unit, and a
number of ancillary components.

3.1.1 Principle Diagram

G1120811

11
3 System Description

3.1.1.1 Basic Equipment

G1119711

1. Oil heater 5. Pressure gauge 9. Washer

2. Temperature sensor 6. Needle valve 10. Self-sealing nipple
3. Safety valve 7. Copper washer 11. Power unit
4. Temperature sensor 8. Nipple 12. Control cabinet

12
 3 System Description

Basic Equipment EHS-71, 7/8 kW

Pos Qty Part No. Name Remark
580974 80 Oil heater, 7 kW, 230 V 230 V
580974 81 Oil heater, 7 kW, 400 V 400 V
580974 82 Oil heater, 8 kW, 440 V 440 V
580974 83 Oil heater, 8 kW, 480 V 480 V
1 1 580974 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
580940 80 Power Unit 7-24 kW 400V,440V,480V,690V
11 1 9017568 80 Power Unit 7-22 kW, 230 V 230V
12 1 9016858 80 Control cabinet kit

Basic Equipment EHS-71, 14/16 kW

Pos Qty Part No. Name Remark
580975 80 Oil heater, 7 kW, 230 V 230 V
580975 81 Oil heater, 7 kW, 400 V 400 V
580975 82 Oil heater, 8 kW, 440 V 440 V
580975 83 Oil heater, 8 kW, 480 V 480 V
1 1 580975 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
580940 80 Power Unit 7-24 kW 400V,440V,480V,690V
11 1 9017568 80 Power Unit 7-22 kW, 230 V 230V
12 1 9016858 80 Control cabinet kit

13
3 System Description

Basic Equipment EHS-71, 22/24 kW

Pos Qty Part No. Name Remark
580976 80 Oil heater, 7 kW, 230 V 230 V
580976 81 Oil heater, 7 kW, 400 V 400 V
580976 82 Oil heater, 8 kW, 440 V 440 V
580976 83 Oil heater, 8 kW, 480 V 480 V
1 1 580976 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
580940 80 Power Unit 7-24 kW 400V,440V,480V,690V
11 1 9017568 80 Power Unit 7-22 kW, 230 V 230V
12 1 9016858 80 Control cabinet kit

Basic Equipment EHS-71, 36/40 kW

Pos Qty Part No. Name Remark
580977 81 Oil heater, 7 kW, 400 V 400 V
580977 82 Oil heater, 8 kW, 440 V 440 V
580977 83 Oil heater, 8 kW, 480 V 480 V
1 1 580977 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580942 80 Power Unit 36-40 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit

14
 3 System Description

Basic Equipment EHS-71, 50/56 kW

Pos Qty Part No. Name Remark
580978 81 Oil heater, 7 kW, 400 V 400 V
580978 82 Oil heater, 8 kW, 440 V 440 V
580978 83 Oil heater, 8 kW, 480 V 480 V
1 1 580978 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580942 81 Power Unit 50-72 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit

Basic Equipment EHS-71, 65/72 kW

Pos Qty Part No. Name Remark
580979 81 Oil heater, 7 kW, 400 V 400 V
580979 82 Oil heater, 8 kW, 440 V 440 V
580979 83 Oil heater, 8 kW, 480 V 480 V
1 1 580979 84 Oil heater, 7 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580942 81 Power Unit 50-72 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit

15
3 System Description

Basic Equipment EHS-71, 100/130 kW

Pos Qty Part No. Name Remark
580979 91 Oil heater, 130 kW, 400 V 400 V
580979 92 Oil heater, 130 kW, 440 V 440 V
580979 93 Oil heater, 130 kW, 480 V 480 V
580979 94 Oil heater, 130 kW, 690 V 690 V
580978 91 Oil heater, 100 kW, 400 V 400 V
580978 92 Oil heater, 100 kW, 440 V 440 V
580978 93 Oil heater, 100 kW, 480 V 480 V
1 1 580978 94 Oil heater, 100 kW, 690 V 690 V
2 1 597256 01 Temperature sensor High temp alarm
1761805 01 Safety valve, 6 bar 6 bar
3 1 1761805 02 Safety valve, 15 bar 15 bar
4 1 597256 01 Temperature sensor
543054 01 Pressure gauge 0-6 bar
5 1 543054 09 Pressure gauge 0-16 bar
6 1 1763903 01 Needle valve
7 4 1761834 01 Cu washer for G½ conn.
8 1 1763729 01 Nipple
9 1 1761834 07 Washer for G3/8 conn.
10 1 1763752 01 Self-sealing nipple
11 1 580944 80 Power Unit 100-130 kW 400V,440V,480V,690V
12 1 9016858 80 Control cabinet kit

16
 4 Heatpac Working Principle

Oil to be heated is fed continuously to the

EHM heater. A temperature sensor in the
outlet senses the oil temperture and signals
the control unit. The control unit compares the
values received with the set parameter values.
The control unit then signals the power unit to
increase or decrease the electrical supply to the
heater as required.
The system temperature is monitored and
displayed in the control unit. If the preset alarm
levels are exceeded, an alarm indication is
given.
The Heatpac® EHS-71 system has a standard
safety function, comprising a high temperature
sensor (Pt100) located in the heater and
connected to an electronic temperature limiter
located in the power unit. A signal from this
equipment directly shuts off the heater, thus
protecting it from overheating. This equipment
works independently of the control unit.
The heating system is also interlocked with the
feed pump, so that the heater is stopped when
the pump is stopped.
A safety valve protects the heater from
excessive pressure.

17
4 Heatpac Working Principle
 5 Operating instructions

5.1 Before Start

1. Check the external condition of the heating
system for leaks or damage. Make sure
that the necessary valves are open.
2. Set the main switch to position 1 and the
function switch to position OFF.

ON
CAUTI
!
Check that the High Temperature Switch, Pump
Interlock, and Safety Valve are functioning properly.
See the appropriate booklets.

5.2 Start-up
1. Compare the parameter values in the
control unit with the plant set values shown
on the inside of the control unit.

NOTE

Where there is booster heating (e.g. during

manoeuvering when marine diesel or lighter
fuel is used) the temperature set point must be
reduced to a temperature suitable for the fuel
used.

2. Start the oil pump if not already running.

3. Start the heater via the control unit.
The temperature increases up to the set
point, and can be read on the control unit
display.

NOTE

Where there is booster heating, the temperature

setpoint must gradually be raised to normal
operating temperature at the same time as the
change-over from light to heavy fuel.

19
5 Operating instructions

NG
WARNI
!
To avoid risk for overheating and fire, make sure that
there is full oil flow at all times during operation.

ON
CAUTI
!
If the safety valve opens, or the high temperature
switch trips repeatedly, the heater should be opened
up for inspection and cleaning.

5.3 Operation
The Heatpac® electric heating system requires
no special attention during normal operation.
For further information on alarm functions, see
6 Alarms and Fault Finding on page 21.

5.4 Stop
1. Stop the heater via the control unit.

NOTE

Where there is booster heating, the temperature

setpoint must gradually be lowered to a
temperature suitable for the fuel used.

2. If the oil feed pump is to be stopped, wait 1

minute after the heater has been switched
off before stopping the pump.

ON
CAUTI
!
Be sure to switch off the heater system before
stopping the oil feed pump.

20
 6 Alarms and Fault Finding

6.1 Alarm Indication

A fault in the Heatpac® EHS-71 heating system
is normally indicated by an activated alarm in
the control unit. Below is a list of possible alarm
causes and remedies.

Causes Corrective action

High temperature
Alarm limit for high temp. too low. Adjust parameter for high temperature limit.
Flow irregularities or abnormal input conditions. Check oil flow and inlet temperature. Adjust
process condition.
Faulty triac module(s) in the power unit. Check the Triacs. Replace if necessary.
Broken wiring or defective heater resistance. Check wiring and heater resistance of each block
or heater element. See EHM heater component
booklet.

Low temperature
Alarm limit for low temp. too high. Adjust parameter for low temperature limit.
Flow irregularities or abnormal input conditions. Check oil flow and inlet temperature. Adjust
process condition.
Broken fuses or burned contactors. Find the cause of the broken fuse and remedy.
Renew broken fuses.
Check wiring and contactor coils.
Faulty controller in the control unit. Check the control unit and the electric heater kit.
Clogged heater element. Dismantle the heater and check for clogged
element. Clean the heater elements in suitable
solvents.
Broken wiring or defective heater resistance. Check wiring and heater resistance of each block
or heater element. See EHM heater component
booklet.
Safety function released
Temperature switch tripped Check temperature setpoint in the control unit.
Reset temperature switch and restart heater.
Oil pump stopped Check piping and restart the oil pump and heater.
Broken temperature switch Check the temperature switch for broken circuit,
Replace if broken. Readjust. See Temperature
switch component booklet.
Broken wiring or faulty controller in the control Check wiring in the power unit and temperature
unit. switch circuits.
If wiring OK:
Replace the control module in the control unit.

21
6 Alarms and Fault Finding
 7 Diagrams

7.1 Electrical System Layout

G1119311

Alfa Laval ref. 9020040 rev. 0

23
7 Diagrams

7.2 Cable List

G1119411

Alfa Laval ref. 9020041 rev. 0

24
 7 Diagrams

7.3 Interconnection Diagram

G1119511

Alfa Laval ref. 1766846 rev. 0

25
7 Diagrams

7.4 Installation Diagram

G1119611

Alfa Laval ref. 9016653 rev. 0

26
 8 Installation

8.1 General Installation

The Heatpac® system should be installed in the
separation system according to specifications.
Detailed information about installation of the
individual components can be found in the
component description booklets. Attention must
be paid to particular recommendations and
use of specified materials. For non-specified
materials, qualities common for this type of
installation should be used.

NOTE

If the specifications are not followed, Alfa Laval

cannot be held responsible for any malfunction of the
installation.

Specifications

• Install the heater with sufficient room for

dismantling of heater elements and for
easy access to ancillary components.
• The control unit should be positioned where
ventilation is good and where it is protected
from heat and humidity. The ambient
temperature must not exceed 55 °C.
• The contactor box must be within
convenient reach of the control unit.
Electrical wiring should be kept to a
minimum.
• The temperature sensor must not be
removed from the heater and repositioned.
• If the service tank or piping is located lower
than the temperature sensor, a pipe bend
must be arranged so as not to drain the
heater outlet pipe.
• The high temperature switch must not be
removed from the heater and repositioned.

27
8 Installation

8.2 Electrical Installation

The following must be considered when
installing the electrical system:

• Cables must be marked at both ends

according to the illustration.
• Screened cables must be used for input
signals from the temperature sensor, flow
switch, and high temperature switch.
• Power cables and fuses must be
dimensioned for the installation capacity.

G025211A

• The screened cables must be kept well

away from the power cables. The minimum
specified distance is 300 mm.
• Screens must be earthed as close as
possible to the earth bar.
• Cables to the external alarm panel and for
series computer communication must be
installed according to the manufacturer’s
recommendations.

G003141A

28