Preparation
Operation
Maintenance & Repair
Read and understand the manual
Wear safety glasses
Warning - Fire risk
Warning - Hot surface
Wear safety gloves
Wear safety boots
Caution - Risk of frost damage
Caution - Read the explanatory text
Wear hardhat
Warning - Risk of suffocation
Instruction steps
Number of crew members required
This is the manual for the In-line Heater. The manual contains instructions in safety, transportation, storage, preparation for use and maintenance. The manual for the Highpressure System is a separate manual, MANU004.
Read the safety instructions in this document carefully.
Read all documentation before first use.
disclaims all liability for
and
to people and/or property caused by non-compliance with instruction requirements and the contents of this manual.
• Hot exhaust.
• Can cause fire.
• Keep flammables and people away from exhaust.
• Do NOT refuel while connected to power.
• Do not leave the In-line Heater unattended in operation.
• ONLY use outdoors and ensure good ventilation.
• Risk of CO2 poisoning when used in poorly ventilated places.
• Sub-zero temperatures can result in equipment rupture and will damage the In-line Heater.
• The In-line Heater should always be stored in a frost proof location, if this is not possible, the system must be frost protected as described in the section, Storage in cold conditions.
• Any damage caused by the use or storage of the In-Line Heater in sub-zero temperatures (i.e. below 0 °C (32 °F)) will not be covered by any warranty of the system.
• Keep away from children and animals.
• Never aim the water jet at yourself, people, animals or the machine itself.
• Do not spray on electrical wiring or installations.
• Avoid spraying on fragile surfaces and facilities.
• Never pull the In-line Heater power cables as this may result in damage to the system and lead to potentially dangerous situations.
• Only use tap water as working medium.
• Do not add cleaning agents to the cleaning medium.
• Never drink the water used in the In-line Heater even though tap water is used as medium.
• If necessary, use wheel chocks to keep the In-line Heater stationary.
• No modification must be made to the In-line Heater without the express written consent of CLIIN.
• Always wear proper personal protective equipment (PPE).
• Make sure the surface coating to be cleaned can withstand the elevated temperatures. Check coating manufacture technical data sheet (TDS) for information.
• Only trained and qualified personnel must perform lifts.
• Plan the lift and lifting route before execution, to minimise the risk of accidents.
• Only use approved equipment for lifting.
• Never stand underneath objects being lifted.
HB00001 - 220-240 V / 60 Hz
HB00002 - 110 V / 60 Hz
HB00003 - 220-240 V / 50 Hz
HB00004 - 110 V / 50 Hz
230 V power cable
High-pressure hose - 3 m
Voltage* 110 V or 220-240 V
Frequency* 50 Hz or 60 Hz
Current 2.8 A
Power connection 2 poles + earth, 6H
Working medium Freshwater (tap water)
Max working pressure 200 bar (2,900 psi)
Internal pressure loss (@ 50 l/min) 20 bar (290 psi)
Max flowrate 56 l/min (12.3 UK gal/min)
Pressure inlet/outlet connection ½” male BSPP
Fuel
Automotive diesel (according to EN 590) or Marine gasoil (grade DMX or DMA according to ISO 8217)
Fuel capacity 50 l (11 UK gal)
Fuel consumption 15 l/h (3.3 UK gal/h) Weight
kg (500 lb)
*Depending on configuration, see previous page.
Mount the handlebar to the front of the Inline Heater.
Tighten the two bolts to secure the handlebar. x2
Below installation must be performed by an authorised electrician.
230 V electric cable - 3 cores @ 1.5 mm2
Voltage rating: 100-240 V Current rating: 16 A
230 V power plug to fit the vessel electrical installation must be fitted to 230 V cable before the cable can be used. The plug must comply with applicable legislation and the specifications above.
Power inlet connection 2 poles + earth, 6H
Aft burner
Front burner
light
Alarms
Flame failure: Flashing, 1 second on / 1 second off.
Microterm failure: Flashing, 2 seconds on / 2 seconds off.
Troubleshooting can be found in the maintenance chapter.
• Only trained and qualified personnel must perform lifts.
• Always use proper PPE.
• Plan the lift and lifting route before execution, to minimise the risk of accidents.
• Only use approved equipment for lifting.
• Inspect the lifting eye and top structure for any damage or extensive wear before attaching the lifting equipment.
• Never stand underneath objects being lifted.
the fuel tank must be drained before lifting to ensure correct balance.
To drain the system, place a container below the fuel drain and open the drain valve.
Inspect the lifting eye, top structure and bolts for damage before lifting the Inline Heater.
System weight: 225 kg (500 lb)
• Only use the dedicated lifting eye for lifting.
• Shackle must be used.
• Pictogram only for illustrational purposes.
Turn OFF both burners by turning the two knobs to the “0” position.
Let the water run through the system for another 2 minutes to cool the burner coils.
Shut off the water supply.
5. Disconnect power.
6. Disconnect high-pressure hoses.
Take care not to damage threads and fittings.
7. Let the water drain from the In-line Heater.
Activate the gun if such is installed to release the pressure.
8. Place a container under the fuel tank drain.
9. Open the valve to drain the fuel.
11. Remove the right side panel.
Open the two rubber hinges to loosen the right side panel.
12. Place a container under the fuel filter.
13. Open the drain to the fuel filter and wait for it to empty. No need for removing the plug.
Drainage is especially important when storing the system for longer periods (i.e. more than two weeks).
Drainage of the tank and filter is performed to avoid microbial contamination of the fuel system. Microbial contamination will cause fuel system clogging and damage to deaerator, pump, filter and nozzles.
14.
Close the two hinges to secure the right side panel.
Move the In-line heater to the storage position.
When the In-line Heater is in place lock the Brake. Preferably use wheel chocks to further secure the system during storage.
Take special care, when moving the system, if the vessel is in transit.
Do not store the system in freezing conditions without frost protection.
The main hose can advantageously be disassembled half way for easier handling.
Take care not to damage threads/fittings.
• For easier handling, drain water from the hoses before storage. Can easily be done with an airgun.
• Anti-seize paste can be used on the stainless steel threads to ease the disassembly.
• General cleaning before storage will prolong the life time of the equipment. Do not use high-pressure water.
• Use the cover for extra protection during storage.
Never store equipment in splash zones on vessels - e.g forecastle area.
- Avoid splash from waves and heavy weather.
• Sub-zero temperatures can result in equipment rupture and will damage the In-line Heater.
• The In-line heater should always be stored in a frost proof location, if this is not possible, the system must be frost protected.
• Any damage caused by the use or storage of the In-Line Heater in sub-zero temperatures (i.e. below 0 °C (32 °F)) will not be covered by any warranty of the system.
Dismount all hoses from the High-pressure System.
Drain the water from all hoses.
pressure valve (horizontal position).
pressure System by opening the two drain valves (vertical position).
pressure System is empty close both drains again (horizontal position).
Remove the lid from the tank.
Fill 15 l (2.2 UK gal) glycol (60/40) into the tank.
9. Turn OFF the In-line Heater and disconnect power.
10. Dismount all hoses from the In-line Heater.
11. Wait for the system to empty.
12. Mount the high-pressure hose between the High-pressure System outlet and the In-line Heater inlet.
13. Force-start the High-pressure System by pressing and holding the start button for 20 seconds. The force-start has a 10 seconds delay. The system will then only run for 10 seconds if the start button is not released before.
14. Repeat step 13 until glycol is beginning to exit the outlet of the In-line Heater. If needed add more glycol to the High-pressure System tank.
15. Stop the system by releasing the start button.
16. On the High-pressure System, close the high-pressure valve (vertical position).
17. Force-start the system again to mix the glycol with the last remaining water in the system. Let the system run till it stops by itself (10 seconds).
18. Dismount the high-pressure hose.
19. Drain the water from all hoses before storage.
20. Both the In-line Heater and High-pressure System have now been frost protected.
With correct frost protection the In-line Heater can be stored in temperatures down to -10 °C (14 °F).
Prepare System for Use - Placement During Use
Before connecting any equipment to the In-line Heater, find a suitable place near the High-pressure System and lock the wheels. If positioned on an inclined or moving surface (e.g. vessel during transit) use wheel chocks for securing the In-line Heater.
2 - 3
• Visually check the In-line Heater for any damage inflicted during storage or transport.
• Check that the exhaust is free from any obstacles.
• Check and clean inlet/outlet connection threads and seals for dirt.
• Anti-seize paste can be used on the stainless steel thread to ease the disassembly.
3
• Inspect the entire length of the highpressure hose for damage before use.
• Check and clean threads and seals for dirt.
• Check the entire length of the power cable and plug for damage.
4
Go through the preparation steps in the High -pressure System manual before continuing. Only clean fresh water (tap water) must be used as working medium.
5
4 - 5
Mount the 3 m high-pressure hose between the High-pressure System outlet and the Inline Heater inlet.
Anti-seize paste can be used on the stainless steel thread to ease the disassembly.
Connect the main hose, to the outlet of the In-line Heater.
Make sure both burners are in OFF
The first 12.5 meters (41 feet) of the main hose is strengthened by a plastic hose protec-
Make sure to place the strengthened part of the main hose where sharp edges are found
This can prevent damage to the main hose.
Remove the left side panel.
Adjust the temperature of the water on the two knobs on the right hand side of the control boxes. Adjust equally.
The temperature cannot be adjusted higher than 80 °C (176 °F).
Make sure the surface coating to be cleaned can withstand the elevated temperatures. Check coating manufacture technical data sheet (TDS) for information.
Most coatings do not withstand temperatures above 60 °C (140 °F).
Open the two rubber hinges to loosen the left side panel.
Check for water in the bottom of the fuel filter view glass.
• If water is found continue with next preparation step.
• If no water is found continue to preparation step 14.
Place a container under the fuel filter drain.
Open the drain to the fuel filter and wait for all the water to exit. No need for removing the plug.
16 - 18
Remove the tank lid.
Place the funnel in the tank neck and fill the tank with clean fuel (50 l (11 UK gal)).
Only use automotive diesel (according to EN 590) or marine gasoil (grade DMX or DMA according to ISO 8217).
Use fuel from service/day tanks that is continuously treated for water and impurities.
Do not tap the fuel from tank drainage points.
The use of other fuel grades or contaminated fuels may result in filter clogging and consequently damage to pump and nozzles.
Make sure the strainer is correctly placed in the funnel.
Remount the tank lid.
18 16 17
20
19
Connect power.
Current rating: 2.8 A
Voltage rating: see specifications
Frequency: see specifications
Power to the In-line Heater can be checked by turning either of the burners ON (1) and listening for the sound of the fan wheel. Turn OFF (0) the burner again after the check. As water is not yet flowing, the burner will not start (ignite).
19 - 20
• Go through the preparation steps before continuing with operation.
• Keep flammables and people away from the exhaust.
• Do NOT refuel while connected to power.
• ONLY use outdoors and ensure good ventilation.
• Make sure the output end of the high-pressure hose is under control before starting the Highpressure System to avoid injury and damage to personnel and equipment.
• Remove any equipment that cannot withstand cleaning by high-pressure and high temperature water.
• Make sure the surface coating to be cleaned can withstand the elevated temperature.
• Never aim the water jet at yourself, people, animals or the machine itself.
• Do not spray on electrical wiring or installations.
• Avoid spraying on fragile surfaces and facilities.
• Do not leave the In-line Heater and High-pressure System unattended in operation. Turn OFF the main switches before leaving.
1 1 - 3
Turn ON both burners by turning the two knobs to the position.
Do not activate the water flow yet.
2
Let the blowers run until they stop automatically (30 seconds).
The In-line Heater is ready for use and normal operation can begin. 3
• Make sure the surface coating to be cleaned can withstand the elevated temperatures. Check coating manufacture technical data sheet (TDS) for information.
• Most coatings do not withstand temperatures above 60 °C (140 °F).
• When the start-up procedure is completed, normal operation can begin.
• The In-line Heater will automatically start and stop when water is flowing/not flowing.
• When water flow is commenced:
• The blowers will start immediately.
• The burners will start with a 5 second delay.
• The burners will start/stop according to the set temperature.
• When water flow is stopped:
• The burners will stop immediately.
• The blowers will continue additional 30 seconds before stopping.
White smoke is expected from the exhausts when the burners stop.
If the burners do not stop when the water flow is stopped, disconnect the power immediately.
• During operation, keep both burners ON and temperatures equally set to reach the wanted temperature.
• The burner smoke must be nearly transparent during normal operation.
• See the maintenance chapter for failure modes and troubleshooting.
Activate the gun, if such is installed, and let the water flow for another minute to cool the burner coils.
1 - 3 1
Turn OFF both burners by turning the two knobs to the position.
2
3
Refer to the “preparation - storage” chapter for the further process of preparing the In-line Heater for storage.
Always store the In-line Heater in a frost-free place. If not possible refer to the “preparation - storage in cold conditions” chapter.
• Only trained personnel and authorised electricians are allowed to operate within the control boxes.
• No modification must be made to the In-line Heater without the express written consent from CLIIN.
• Under no circumstances tamper with the probe in the exhaust and connected thermostat.
• Any warranty of the system will be waived if the mentioned restrictions are not meet.
Burner do not ignite when water is flowing
Possible cause: Solution:
Power missing. Check the power connection. Check power plugs for dirt and clean if necessary. Connect the In-line Heater to power.
Burner switched OFF. Turn ON the burners by turning the knob to the “1” position.
Low fuel. Fill the fuel tank with clean fuel. Only use automotive diesel (according to EN 590) or marine gasoil (grade DMX or DMA according to ISO 8217).
Low thermostat adjustment. Check the temperature adjustment of the burners. Follow the preparation steps 9 through 11 to ensure correct temperature adjustment.
Clogged fuel nozzle. Replace the nozzle/electrode assembly as described in the service section.
Flow switch stuck or broken. Check the burners individually. See the service section of this chapter for instructions. Contact CLIIN.
Faulty thermostat. Check the thermostats individually. See the service section of this chapter for instructions. Contact CLIIN.
Defect in the electrical controls. Contact CLIIN.
Wrong frequency configuration.
Check power supply frequency corresponds the In-line Heater. Contact CLIIN.
Possible cause: Solution:
Water or dirt in the fuel.
• Only use automotive diesel (according to EN 590) or marine gasoil (grade DMX or DMA according to ISO 8217).
• Only use fuel from service/day tanks that is continuously being treated for water and impurities.
• Do not tap the fuel from tank drainage points.
• When refuelling the In-line Heater use the funnel with strainer.
• Replace the nozzle/electrode assembly and the fuel filter as described in the service section.
Wrong oil pressure. Contact CLIIN.
Wrong frequency configuration. Check power supply frequency corresponds the In-line Heater. Contact CLIIN.
Burner stop during use (flame failure) - Alarm light flashing, 1 second on / 1 second off.
Possible cause: Solution:
Low fuel. Fill the fuel tank with clean fuel. See preparation step 17 for guidelines.
Electrodes misaligned or dirty. Clean and realign electrodes. See the service section of this chapter for instructions.
Worn electrodes. If the tips of the electrodes are worn (round and not pointy) they need changing.
Fuel nozzle clogged. Replace the nozzle/electrode assembly as described in the service section.
Fuel filter clogged.
• Only use automotive diesel (according to EN 590) or marine gasoil (grade DMX or DMA according to ISO 8217).
• Only use fuel from service/day tanks that is continuously being treated for water and impurities.
• Do not tap the fuel from tank drainage points.
• When refuelling the In-line Heater use the funnel with strainer.
• Clean the nozzle and replace the fuel filter.
Possible cause: Solution:
Calcified coils.
Twists or sharp bends on the hoses.
1. Detach any output hoses to the In-line Heater. Water must run freely from the output.
2. Start the High-pressure System and let water run through the In-line Heater.
3. Read the pressure on the gauge on the High-pressure System.
• If pressure is above 30 bar.
• Investigate pressure loss in the High-pressure System.
• Exchange the coil. Contact CLIIN.
• Descale the coil. Descaling can be done with 1:10 acetic acid and water. Thorough flushing afterwards is crucial. After descaling there is a high risk of high-pressure nozzle clogging due to loose scale. Descaling is thus not a recommended solution.
• IF pressure is below 30 bar, the In-line Heater is not the problem.
Straighten the hoses and make sure no objects is placed on top of the hoses.
Possible cause:
Solution:
Power missing. Check the power connection. Check power plugs for dirt and clean if necessary. Connect the In-line Heater to power.
Burner switched OFF. Turn ON the burners by turning the knob to the “1” position.
Defect/burned fuse. Check the fuses in the control boxes. Replace the fuse if necessary.
Defect motor. Contact CLIIN.
Incorrect voltage. A new system is needed. Contact CLIIN. 5
Possible cause:
Solution:
6
Low thermostat adjustment. Check the temperature adjustment of the burners. Follow the preparation steps 9 through 11 to ensure correct temperature adjustment.
Calcified coils. Investigate, follow test described in troubleshooting no. 4.
Sooted burner chamber. Check, by looking into the exhaust, if the coils are heavily sooted. Contact CLIIN for cleaning or exchanging the coils.
Microterm failure - Alarm light flashing, 2 seconds on / 2 seconds off.
Possible cause: Solution:
Flow switch stuck or broken. The water is reaching a too high temperatures and the system is automatically shutting down. Check the flow switches individually. See the service section in this chapter for instructions. Contact CLIIN. 7
The blower engine is noisy
Possible cause: Solution:
Power issues. Check the power connection is within specifications. Check power plugs for dirt and clean if necessary.
8
• Fuel filter replacement
• Nozzle and electrode replacement
• Electrical wiring inspection
• Lifting arrangement inspection
• Flow switch test
• Thermostat test
Needed kits and special tools can be ordered at CLIIN before commencing the service. Consult the maintenance chart or contact CLIIN for correct order.
4 Remove the top frame.
4 - 5 x6
Loosen and remove the six bolts securing the top frame.
5
Place a container under the fuel tank drain and Open the valve to drain the fuel. Empty the tank.
Place a container under the fuel filter.
Open the drain to the fuel filter and wait for it to empty. No need for removing the plug.
Loosen the small bolt placed at the top center of the filter and remove the bolt, washer and O-ring from the top.
Remove the filter bottom, view glass and two seals from the bottom of the filter.
Remove the filter cartridge.
Replace the seal and O-ring at the top of the filter.
Be careful not to damage the sealing surfaces.
Mount the new filter cartridge.
12 - 14
Replace the O-ring on the bolt.
12
Replace the seal on the top of the view glass.
Mount the view glass and the bottom of the filter to the rest of the assembly.
The replacement of the nozzles and electrodes are performed similarly on the front and aft burner. Have cloths ready to wipe up any fuel from the fuel system.
Very carefully lift op the solenoid valve assembly to the banjo bolt goes free of the nozzle holder. Swing the assembly free of the electrode and nozzle assembly.
Dismount the three bolts. 19 19 - 20
x3
Remove and discard the nozzle and electrode assembly.
Side view Front view
On the new nozzle and electrode assembly check the relative placement of the nozzle and electrodes before continuing.
Fasten the three bolts. 23
Mount the new nozzle and electrode assembly.
Fasten the banjo bolt.
Very carefully lift op the solenoid valve assembly and mount the banjo bolt onto the nozzle holder.
Make sure the aluminium washers are placed on both sides of the banjo fitting.
Repeat service step 16 through 26 on the aft burner.
Inspect all visible wiring for damage to the insulation.
The wiring is not shown on the illustration.
Inspect the top frame for any damage and potential weaknesses (e.g. extensive corrosion).
Inspect the bolts for securing the top frame and the plates to which the top frame is attached.
Close the two rubber hinges to secure the right side panel.
Do not mount the left side panel. 34
Prepare the system for test by going through the preparation steps.
Mount the gun and lance at the end of the main hose. 35 x2
Turn ON both burners by turning the knobs to the “1” position. 37
Start the High-pressure System by pushing the “START” button on the control panel.
Deactivate the gun. Both burners must stop immediately.
Activate the gun. After 5 seconds both burners must
30 seconds after gun deactivation both blower wheels must stop rotating.
- 43
Activate the gun and leave it open. None of the burners must start.
-
thermostats to 60 °C. The respective burner must now start. x2 44
Reverse the thermostat back to OFF and the burner must stop. Perform the test on both burners. 45
This concludes the yearly / 1000 hour service.
During the first start-up after service, be aware of the following:
• Leaks on the fuel system.
• The smoke from the exhaust must be
• Abnormal noises.
