(Horizontal Model) Semi-Instantaneous Water Heater Steam to Water Design Manual # 9636-0555 Rev. B Operation & Maintenance Manual 340 West 8th Street Peru, IN 46970 PH: 765‐472‐3351 FX: 765‐472‐3968 www.thrushco.com COPYRIGHT THRUSH CO., INC.
Thrush Co. Manual #9636-0555 Table of Contents Section No. Description Page No. 1 General Product Information 1 2 Safety Information/Warnings 2-3 3 Component and Operational Information 4-10 4 Installation, Initial Startup and Operation 11-19 5 Maintenance Information 20-22 6 Electrical Drawings 23-25 7 Parts Ordering/Contact Information 26 THIS DOCUMENT CONTAINS INFORMATION THAT THRUSH DEEMS CONFIDENTIAL AND PROPRIETARY.
Thrush Co. Manual #9636-0555 Section 1 General Product Information 1.1 Overview The Thrush Hot-Pak® has been carefully assembled and factory tested to provide years of trouble-free service. This manual provides information to allow the installer/operator to install, operate, service and maintain the Hot-Pak. In this manual the installer/operator will find that multiple Hot-Pak models are covered. Visually these different models will look very similar.
Thrush Co. Manual #9636-0555 Section 2 Safety Information/Warning 2.1 Safety Information Practical safety features have been incorporated into the design and manufacture of the Thrush Hot-Pak. If questions are not answered by this manual, or if specific installation, operation, and/or maintenance procedures are not clearly understood, contact your Thrush representative before proceeding.
Thrush Co. Manual #9636-0555 2.1 Safety Information continued Before making any piping connections, assure that all piping is clean and free of any foreign material such as debris or scale. Foreign material in the piping can cause damage to the unit and/or affect the performance and operation. Manual shutoff valves should be installed upstream/downstream from all connections to act as an isolation device. These valves should be in the closed position and remain so until the installation is complete.
Thrush Co. Manual #9636-0555 Section 3 Component and Operational Information 3.1 Component Identification The following paragraphs contain functional descriptions for each of the major components of a standard Thrush Hot-Pak. This manual provides information for multiple Hot-Pak models. All the components listed have the same functional purpose throughout each model. Although a standard Hot-Pak will be used for illustrations, optional equipment will also be shown for reference.
Thrush Co. Manual #9636-0555 3.1.1 Safety Relief Valve The safety relief valve is a valve that automatically relieves pressure on the inside of the shell (also known as the water side). If the temperature or pressure inside the shell exceeds a specified setting, the valve will open. Field installation is required for the safety relief valve and also requires an adequate drain be piped to the discharge side of the valve.
Thrush Co. Manual #9636-0555 3.1.3 Temperature Aquastat The temperature aquastat limits the temperature of water inside the shell. The aquastat must be set 15 degrees higher than the maximum operating temperature. If the water temperature exceeds this limit, the aquastat sends a signal to the solenoid valve to dump the overheated water. (Figure 3-4) Figure 3-4 Temperature Aquastat 3.1.4 Solenoid Valve The solenoid valve is an electrically actuated valve that dumps overheated water.
Thrush Co. Manual #9636-0555 3.1.5 Circulator Pump The circulator pump circulates heated water from the top of the shell into the water inlet. This action helps to maintain a constant temperature of water inside the shell. The circulator pump must be on at all times to ensure proper operation and prevent damage of the unit. (Figure 3-6) Figure 3-6 Circulator Pump 3.1.6 Vacuum Breaker The vacuum breaker prevents a vacuum from forming in the steam side of the unit.
Thrush Co. Manual #9636-0555 3.1.7 Pressure Gauge Assembly The pressure gauge is a visual representation of pressure level in the steam side of the unit. A gauge cock and pigtail siphon is included. (Figure 3-8) Figure 3-8 Pressure Gauge Assembly 3.1.8 Control Panel (Standard) The standard Hot-Pak control panel is an electrical connection panel only. The circuit breaker (located on the center of the panel) only shuts down the circulator pump.
Thrush Co. Manual #9636-0555 3.2 Optional Equipment Although the standard Hot-Pak was designed to meet customer requirements, the need for optional equipment may apply. Thrush can provide many various options to ensure that our Hot-Pak meets your needs. Listed below, but not limited to, are some of the common requests for optional equipment. For more detailed lists and descriptions, please contact your representative. 3.2.
Thrush Co. Manual #9636-0555 3.2.2 Temperature Control Valves A temperature control valve is required for the Hot-Pak to operate. These valves regulate the amount of steam that enters the unit. Various temperature control valves can be used with the Hot-Pak such as pneumatic, self-contained or electrically operated. Thrush offers a variety of temperature control valves to meet system requirements.
Thrush Co. Manual #9636-0555 Section 4 Installation, Initial Start-Up and Operation 4.1 Pre-Installation Assembly The following procedures are to aid the operator in installing, operating and maintaining the Thrush Hot-Pak. All procedures are to be performed by experienced, trained, and certified personnel only. There is a potential for severe personal injury or death if proper rigging procedures are not followed. Rigging should be done with proper equipment and qualified personnel 1.
Thrush Co. Manual #9636-0555 4.1 Pre-Installation Assembly (Continued) Figure 4-1 Adjustable Support Stand Assembly #1 6” & 8” part no. 7000-1390, 10” & 12” part no.
Thrush Co. Manual #9636-0555 4.1 Pre-Installation Assembly (Continued) The adjustable support stand was designed to aid the installation process of the Hot-Pak into system piping. The adjustable support stand is not a replacement for system piping supports. System piping must be supported before and after Hot-Pak in conjunction with the adjustable support stand. 7. With the Hot-Pak assembled, attach the safety relief valve to the open connection of the shell (Figure 4-3).
Thrush Co. Manual #9636-0555 4.2 Installation (Continued) REDUCER SPOOL (IF REQUIRED) Y‐STRAINER TEMP SENSOR PROBE SAFETY RELIEF VALVE (PIPED TO ADEQUATE DRAIN) STEAM INLET CONTROL PILOT HOT WATER OUTLET STEAM CONTROL VALVE) GATE VALVE Y‐STRAINER COLD WATER INLET DIRT LEG STEAM TRAP (PIPED TO ADEQUATE DRAIN) Figure 4-3 Piping Installation 1. Connect the cold water source to the water side connection port. Be sure the upstream manual shutoff valve is in the closed position.
Thrush Co. Manual #9636-0555 4.2 Installation (Continued) A safety solenoid should be installed on the temperature control valve pilot or pneumatic control and connected to the control panel. Terminal connections for a safety solenoid are provided on the terminal strip of the control panel. For a direct acting temperature control valve, a normally closed solenoid valve is usually used. For a pneumatic type control valve, a three-way solenoid is usually used.
Thrush Co. Manual #9636-0555 4.3 Initial Startup Procedure (Continued) 1. Assure that all manual shutoff valves on the water and heat sources are closed. Verify that electricity is off as well. 2. Slowly open the manual shutoff valve or valves on the cold water side of the HotPak and check for any leaks. Repair any leaks before proceeding. Allow the tank to fill completely with water. Opening the safety relief valve to vent the air out of the shell will speed up this process. 3.
Thrush Co. Manual #9636-0555 4.3 Initial Startup Procedure (Continued) 8. As the water temperature rises, check the accuracy of the temperature control valve and make any adjustments using valve manufacturer’s instructions. 9. Once the temperature control valve has been properly adjusted, the simulated demand can be shut down. 10. Lower the temperature setting of the aquastat to a temperature lower than the desired water temperature.
Thrush Co. Manual #9636-0555 4.5 Operation The Thrush HOT-PAK is an indirect fired semi-instantaneous water heater. It utilizes a shell and tube heat exchanger and industry standard controls to provide a constant source of hot water for an open system. Figures 4-5, 4-6 and 4-7 show the Hot-Pak in various stages of the operation sequence. A standard Hot-Pak is shown, actual configuration may vary. To protect the tube bundle from damage, the unit must be filled with water before allowing steam to enter.
Thrush Co. Manual #9636-0555 4.5 Operation (Continued) Figure 4-6 Operating Sequence (Steam Flow) The circulated water inside the shell is forced to flow across the hot tubes, transferring heat to the water (Figure 4-7). This will continue until the desired temperature is reached. Once the desired temperature is reached, the control valve will close. To maintain the temperature inside the shell and pre-heat incoming water, the circulator pump continues to cycle.
Thrush Co. Manual #9636-0555 Section 5 Shutdown and Maintenance Procedures 5.1 Shutdown Procedure The following sequence outlines the proper procedure for shutting down a Thrush Hot-Pak. When shutting down, always shut off the hot fluid first. 1. Close off valves in the steam supply line. 2. Turn the control panel on/off switch to the off position and shut-off all electrical power. 3. Relieve all pressure from the steam or heating medium supply. 4. Close off all remaining valves in the following order: a.
Thrush Co. Manual #9636-0555 5.2 Maintenance (Continued) Thrush Co. offers an optional Double Wall configuration for leak detection. This option utilizes tubes with an additional tube inside each of them. If the outer tube becomes punctured for any reason, the inner tube maintains the separation of steam and process water. The space between the inner and outer tubes will then start to fill with water and leak out of the Leak Detection Grooves at the bottom of the unit (Figure 5-1).
Thrush Co. Manual #9636-0555 5.2 Maintenance (Continued) Gasket Creep is inherent to most gasket joints, and retorquing is required. The greater the operating temperature, and pressure, the greater the problem can become. It is imperative that the head bolts be torqued after installation, after initial startup, and inspected seasonally to be sure the bolts are torqued correctly. The bolts should be torqued incrementally to 30%, 60% and then to 100% of the appropriate value shown in Figure 5-2.
Thrush Co. Manual #9636-0555 Section 6 Electrical Drawings 6.1 Electrical Drawings The following electrical drawings are for reference only. Each unit is shipped with a set of electrical drawings specific to that model.
Thrush Co. Manual #9636-0555 6.1 Electrical Drawings (Continued) CONTROL LOGIC NOTE: SOLID LINE REPRESENTS FACTORY WIRING DASHED LINE REPRESENTS FIELD REQUIRED WIRING INCOMING 120V / 1PH / 60Hz POWER SUPPLY L1 N G N G OFF SWITCH TURNS OFF ON CIRCULATOR ONLY ! DS 120V / 1PH / 60Hz TO CIRCULATOR 1 GREEN PUMP ON PL2 FU1 2.8A 2 5 WHITE PL1 RED L1 FU2 2.
Thrush Co. Manual #9636-0555 6.
Thrush Co. Manual #9636-0555 Section 7 Contact Information 7.1 Contact Information Any additional information not supplied in this manual can be given by your representative. If your representative cannot be reached, please contact our customer service department: Thrush Co., Inc. PO Box 228 340 West 8th Street Peru, IN 46970 Attention: Customer Service Group Phone: Fax: E-mail: (765) 472-3351 (800) 755-8110 (765) 472-3968 customerservice@thrushco.
