vetus WHD020 Boilers Installation Guide

: May 15, 2024
: vetus

Table of Contents

Safety
Introduction
Installation
Use
Preparation for Winter
Technical Data
References
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vetus WHD020 Boilers Installation Guide

Safety

Warning indications
Where applicable, the following warning indications are used in this manual in connection with safe

Danger

Indicates that great potential danger exists that can lead to serious injury or death.

Warning

Indicates that a potential danger that can lead to injury exists.

Caution

Indicates that the usage procedures, actions etc. concerned can result in serious damage to or destruction of the engine. Some CAUTION indications also advise that a potential danger exists that can
lead to serious injury or death.

Note

Emphasizes important procedures, circumstances etc.

Symbols

Indicates that the relevant procedure must be carried out.
Indicates that a particular action is forbidden.

Share these safety instructions with all users.

General rules and laws concerning safety and accident prevention must always be observed.

Warning

This product should only be installed and maintained by qualified personnel who have read and understood the instructions and precautions in this manual.

Failure to follow the instructions in this manual may result in serious injury or property damage. The manufacturer shall not be liable for any damages resulting from improper installation or maintenance by unqualified personnel.

Introduction

Tap water in the calorifier inner tank is heated by engine coolant which flows between the inner and outer tank.

Installation

General

First study the Installation Drawing and the Piping Diagrams, see Drawings on pages 22, 23 and 24.

Preferably fit the boiler low in the ship so that highest point of the boiler is at a lower level than the expansion tank of the ship’s engine.

This is in connection with removing air from the system, see drawings 1.

If the calorifier does have to be positioned above the level of the expansion tank for the engine an additional expansion tank must be fitted, see drawing 2.

Fit a shut-off valve between the expansion tank and the highest placed pipe between the engine and the boiler. This shut-off valve is closed during normal operation and only opened when topping up or bleeding the system.

If the calorifier is installed considerably lower than then the engine’s expansion tank, the coolant water can start to circulate when the engine has stopped. This will lead to very fast cooling of the hot tap water. To prevent this, install a non-return valve – see drawing 3.

Always install two valves (one in the inlet and one in the outlet) so that it is possible to sail with a drained inner tank or an empty water tank with both valves closed.

The resistance in the pipe can become too high if the pipes between the engine and the boiler are extremely long. The cooling fluid will then no longer circulate through the boiler. In that case fit a central heating circulation pump in the pipe, see drawing 4.

The calorifier outer tank is only suitable for use with engine coolant fluid, anti-freeze or cooling water, but absolutely not for salt water.

Pipes from Engine to Calorifier (see pages 22 and 23)

The coolant water pipes from the ship’s engine to the calorifier should be as short as possible, so that the increase in engine coolant capacity is kept to a minimum and no extra expansion space is required. These pipes must be installed so that they are absolutely self-bleeding.

The pipes should have the same cross-section as the calorifier/heater connections on the ship’s engine, so that no extra resistance is created.

Also consult the engine supplier’s instructions.

Use a good quality reinforced hose or copper pipes.

Caution

Always connect metal pipes with short lengths of hose to the engine and the calorifier. The hose will accommodate vibration and prevent the pipes splitting.

The reinforced hose should be resistant to a temperature of at least 100˚C (212˚F), and a pressure of 4 bar(4 kgf/cm2, 58 psi). You can use the same hose as for the tap water – VETUS Article Code: HWHOSE16.

Fit each hose connection with a stainless steel hose clamp.

In order to reduce heat loss with the engine off, it is recommended that the pipes and fittings are insulated.

Installing the Fittings (see page 25)

On the tap water side of the calorifier, use only corrosion-resistant fittings (stainless steel or brass).

Warning
Never use fittings made of steel or iron!

Pressure valve/non-return valve

The pressure valve and the non-return valve have been combined in a single fitting. Mount this pressure valve/non-return valve (13) on the tap water intake. The pressure valve has been set to 6 bar (6 kgf/cm2.
As the water heats up, the pressure valve will operate, water droplets and a little water loss is normal. If you do not want water running about freely, then connect the outlet connection to a pressure-free drain pipe. When assembling all accessories and fittings, use a good quality, removable screw- thread sealant. Disassembly may be necessary for maintenance, draining and preparation for winter!

Pipes for Tap Water (see page 23)

Use a good quality reinforced hose, stainless steel or copper pipes for the tap water pipes. Always connect pipes to the calorifier with short lengths of hose. These lengths of hose will accommodate vibration and prevent the pipes splitting.

The reinforced hose must be of foodstuffs quality and resistant to at least 100˚C (212˚F) and a pressure of 8 bar (8 kgf/cm2, 116 psi). Insulate the pipes and fittings to prevent unnecessary heat loss. VETUS supplies a hose which is suitable for tap water. This hose hasan internal diameter of 16 mm., is tasteless, non-toxic, resistant to temperatures up to 160˚C (320˚F), with a working pressure of 8 bar (8 kgf/cm2, 116 psi). Article Code: HWHOSE16.

Use

Warning

This product should only be operated by persons who have read and understood the instructions and precautions in this manual. Failure to follow the instructions in this manual may result in serious injury or property damage. The manufacturer shall not be liable for any damages resulting from improper operation.

Proceed as follows before using the calorifier for the first time.

Clean the inside of both inner and outer tank by rinsing with clean tap water.
Open the stop cock in the water pipe between pump and tank.
Open the hot water tap to release air from the tank and it fills with water.
Fill outer tank from the engine cooling system. Bleed air from the outer tank if this is mounted vertically. ‘E’ is the outer tank air bleed valve.
Check all connections, pipes and fittings for leaks.

Caution

Stop the engine immediately if a leak occurs. Repair the leak before restarting the engine.

Stop the engine and check the coolant level. Top up if necessary.
The calorifier is now ready for use.

Heating

The engine has to run for a certain time before the tap water heats up. The time required depends on the size of the calorifier and the size of the engine.

Warning

The hot tap water can be very hot, temperatures up to 80˚C (176˚F) are possible!
For safe use, always mix with cold water.

Electric Heating

The electrical heating element can be used to heat up the water to the correct temperature or to keep it hot if the engine is not running. Heating up tap water in the calorifier tank by using the electric heating element will take considerably longer than heating with engine heat.

Information

The amount of heat created by an internal combustion engine, and thus available for heating the calorifier, is about the same as the engine power output. So an engine which delivers 50 kW at the shaft will also provide about 50 kW of heat! An electric heating element is only 0.5 or 1 kW.

Warning

Never switch on the electric heating element if the calorifier tank is not completely filled with tap water.

Preparation for Winter

When the ship’s engine cooling system contains a coolant fluid or an anti- freeze and water mixture with sufficient protection at low temperatures, then the outer tank will not need to be drained.

When the engine’s cooling system contains ordinary water, this will not provide any protection at low temperatures, so the outer tank will have to be drained, see “11 Draining the Boiler” on p. 28.

To do this, remove hose connections ‘A’ and ‘B’ and allow the outer tank to drain empty. Open the air bleed valve ‘E’ if necessary. Protect the outer tank against corrosion by filling with anti-freeze.

The entire drinking water system, including the boiler’s tap water tank, must be completely drained. See “11 Draining the Boiler” on p. 29. Never fill the drinking water system with anti-freeze as an alternative. This is very toxic.

To drain the boiler, remove the hoses from connections C and D.
Open the tap water taps so that the tap water pipes drain completely.
Remove the screw from the pressure valve/non-return valve and open the purge valve. The boiler’s tap water tank can now drain completely.
Once the tap water tank has been drained, close the purge valve and re-fit the screw.

Warning

If the inner tank has been drained, or if the water tank is empty and the outer tank is still full, never run the engine with the shut off valves open. The inner tank should first be filled before the engine is used after the winter period.

Heating Element

There is an electrical heating element, power 1500 Watt / 230 V, fitted in the calorifier. The heating element is controlled by a thermostat.

Connect the heating element as shown in the wiring diagram. Connect the earth terminals, both from the boiler and the heating element, to the earthing point on the boat!

A different heating element can be fitted as an alternative. The following electrical heating element (with adjustable thermostat) is available:

Art. code: Power / Voltage
WHEL220: 1000 W / 230 V
WHEL22500: 500 W / 230 V
WHEL110: 1000: W / 120 V

All heating elements are fitted with external screw thread G 1 1/4.

Use a right-angled open-ended spanner or an open ring spanner, size 55 when assembling and disassembling the heating element.

Clean the screw thread if necessary and fit the heating element using hemp and liquid packaging to seal the screw thread connection.

Technical Data

Type	WHD 020	WHD 031	WHD 045	WHD 055	WHD 075

Tap Water Tank

Capacity, litre	20	31	45	55	75
Imp. gallon	4.4	6.8	9.9	12.1	16.5
US gallon	5.3	8.2	11.9	14.5	19.8
Heated surface	0,37 m2	0,52 m2	0,71 m2	0,85 m2	1,08 m2
4 ft.2	5.6 ft.2	7.6 ft.2	9.1 ft.2	11.6 ft.2
Max. Pressure	6 bar (6 kg/cm2, 87 psi)
Material	AISI 316L, thickness 1.2 mm (1/16”)
Heat Loss	About 12˚C (54˚F) per 24 hours

Outer Tank (Engine coolant)

Capacity, litre	2	3	5	7	9
Imp. gallon	0.44	0.66	1.09	1.54	1.97
US gallon	0.52	0.79	1.32	1.84	2.37
Connections	G 1/2, male thread
Max.Pressure	3 bar (3 kgf/cm2, 43 psi)
Material	AISI 316L, thickness 1.2 mm (1/16”)
Insulation	Polyurethane, 35 mm (1 3/8”) thick with AISI 304 cover