hydro THERMAL K500 - User Manual

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Version 3.5

Revised 8/2016

K500

Hydroheater

Main Page

Table of Contents3
K500 Automatic Hydroheater - General Information5
Your Smart ENERGY Investment5
Purpose of the Manual5
Principles of Direct Steam Injection (DSI)5
How the K500 Works6
Model Number Designation, Dimensions and Capacities7
Explanation of Model Numbers7
Location of Markings on Body7
Application Criteria9
Industries and Products9
Sizing Considerations10
Process and Steam Pressure Requirements11
Maximum Process Pressure (Heater Discharge)11
Minimum Process Pressure12
Superheated Steam12
Model Capacities and Heater Sizes13
Safety Precautions14
General Safety14
Specific Safety15
Installation16
General Installation16
Hardware Requirements17
Support and Mounting17
Recommended Installation17
Steam Line Requirements20
Strainer Sizing Table21
Condensate and Blow down21
Discharge Line Requirements22
Insulation23
Utilities and Environmental Requirements23
Instrumentation and Control24
General Overview24
Components and Functions24
Typical Control Logic26
K500 Control Characteristics26
Over Temperature Protection27
Operation28
Pre-Start28
Initial Startup29
Shutdown Sequence30
Shut down Sequence (Long Term with Dirty Fluids)30
Applications with Intermittent Heat Requirement31
Troubleshooting31
Insufficient Heating Capacity31
Rough Operation32
Excessive Temperature Variation33
Maintenance33
General Practices33
Recommended Maintenance34
Signs of Wear34
Anti-Seize Compounds37
Inventory and Spare Parts Recommendations38
Disassembly and Assembly41
Head-Actuator Removal41
Complete Disassembly42
Assembly47
Torque Requirement58
Installing a Manual Combining Tube Adjustment (CTA)58
Zeroing Procedure59
How to Reverse Mount a New Style CTA60
Rotating the Actuator61
Illustrated Parts List63
Exploded View - K50063
Exploded View - CTA Assembly66
Bench Setting of K500 Hydroheater Actuator & Positioner69
Actuator "Bench Set" Procedure (Pre-Installation of Positioner)69
Positioners72
Calibrating a Fisher DVC 6010 Positioner72
Installing and Calibrating a DVC 2000 Positioner75
Mounting Magnet Array for DVC 200075
Calibrating a DVC 200075
Installing and Calibrating a DVC 6200 Positioner78
Mounting Magnet Array for DVC 620078
Calibrating a DVC 620078
Limited Warranty81
Appendix82
Appendix A: Steam Table82
Appendix B: Saturation Table84
Appendix C: Table of Figures85
Appendix D: Table of Tables86
Contact Information87

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hydro THERMAL K500 Specifications

General

Brand	hydro THERMAL
Model	K500
Category	Heater
Language	English

hydro THERMAL K500 - User Manual

Table of Contents

hydro THERMAL K500 Specifications