UPY-B31040-01MO (B) Owner Manual Binder - 1

PYRO Energy Management System
Owner Manual
(1 of 1)
Yard/Customer : Astilleros Balenciaga
Hull no. : NB452-NB453
Customer reference :
Order No. : 53032- & 53033
Document name : UPY-B31040-01MO
Revision :B
Author : TB
Date First Issue : 06.07.2015
Comments : As built Hull 453
Introduction to Owner Manual 1
PROJECT SPECIFIC, Piping & Cable Diagram 2
PROJECT SPECIFIC, Internal Wiring & Pneumattic 3
PROJECT SPECIFIC, Approval 5
PRODUCT, Layout 7
PRODUCT, Wiring 8
PRODUCT, Operator Guidelines 9
10
PRODUCT, Software
11
PRODUCT, Harbour Acceptance Test (HAT)

12
Revision history manual :
Rev. Description Date Sign.
(A,B,C..) (dd.mm.yyyy)
A As built NB452 27.03.2015 TB
B As built Hull 453 06.07.2015 TB
Enclosed documents :
Section Document name

1 UPY-D11001-04SX (A) Pyro Energy Management System - Introduction to Owner Manual.pdf
2 UPY-B31040-01OR (B).PDF
2 UPY-B31040-11OR (B).PDF
2 UPY-B31040-11OT (A).pdf
3 UPY-B31040-11OW (A).pdf
5 UPY-990001-019C (-).pdf
5 UPY-G01001-01PR (A) Fuel Fired Heater_Type Approval DNV_A-14229.pdf
5 UPY-G01001-02PR (A) Fuel Fired Heater_Type Approval RINA_mac083213XG.pdf
5 UPY-G01001-04PR (-) Fuel Fired Heater_Design Assessment ABS_07-LD257077-PDA.pdf
5 UPY-G01001-05PR (-) Fuel Fired Heater_Type Approval LRS_09-00006.pdf
7 PY-4M-441.pdf
7 UPY-F51007-01PL (E).pdf
7 UPY-G12002-01PL (A).pdf
7 UPY-Y31004-01PL (A).pdf
8 UPY-G12002-01PW (B).pdf
9 UPY-G01001-01PO (L) Fuel Fired Heater_Operators Guidelines.pdf
11 UPY-G00001-01PA (H) Modbus Description.pdf
12 UPY-G01001-01PH (-) Fuel Fired Heater - HAT.pdf
Index divider: Section 1 N
Document Type: Document Name:
SYSTEM -
Introduction to owner manual UPY-D11001-04SX
Document Title: Date First Issue: Revision:
Pyro Energy Management System 28.08.2013
Author:
Arne Skotte A
Revision History
Revision: Description: Date: Sign:
A First Issue 28.08.2013 ASK
Document Summary
The Operator Manual describes issue for operation and maintenance of the system delivered by
Ulmatec Pyro.
The document includes following information:

• Project Specific, Piping, Cable and Internal Wiring Diagram
• Project Specific, Declaration & Approval
• Product, Technical Specification, Layout and Wiring Diagram
• Product, Operator Guidelines.
• Product, Spareparts.
• Ulmatec Pyro contact Information.
ULMATEC PYRO AS
Gamlem, 6280 Søvik, Norway
Tel.: +47 70 20 98 70 Pyro@ulmatec.no www.ulmatec.no Reg. No. 966 300 345
UPY-D11001-04SX (A) Pyro Energy Management System - Introduction To Owner Manual.Docx Page 1 of 4
CONTENTS
1 Abbreviations .................................................................................................................................. 3
2 Ulmatec Pyro ................................................................................................................................... 3
2.1 Office Address ......................................................................................................................... 3
2.2 Mail & Web Address ................................................................................................................ 3
2.3 Telephone & Fax ...................................................................................................................... 3
2.4 VAT Identification Number ...................................................................................................... 3
3 Order Spare Parts ............................................................................................................................ 4
3.1 Project Specific Information .................................................................................................... 4
3.2 Component Specific Information ............................................................................................ 4
3.3 Spare Part List .......................................................................................................................... 4
ULMATEC PYRO AS
1 Abbreviations
UPY Ulmatec Pyro AS
2 Ulmatec Pyro
2.1 Office Address
Ulmatec Pyro AS
Gamlem
6280 Søvik
NORWAY
2.2 Mail & Web Address
Mail: pyro@ulmatec.no
Web: www.ulmatec.no
2.3 Telephone & Fax
Telephone : +47 70 20 98 70
Fax : +47 70 20 98 90
2.4 VAT Identification Number
NO 966 300 345 VAT
ULMATEC PYRO AS
3 Order Spare Parts
3.1 Project Specific Information
When order spare parts we need following project specific information:

• Yard
• Hull No.
• Project No.
• Project Document No. (e.g. UPY-Bxxxxx)
• Plant Information (e.g. =HG_FFH…)
• Location (e.g. +CU…)
Note: Information regarding yard, hull, and project is located on the front page of the Owner Manual or
on a label located on each product.
Information regarding plant and location is located in the cable/piping diagram and on the label
located on each product.
3.2 Component Specific Information
Additional we need following component specific information:

• Component (e.g. –F1…)
• Production Number.
Note: information regarding Component and Production Number is located on the unit label.
3.3 Spare Part List
For some product you will also find enclosed a recommended spare part list.
The list includes recommendation for 2 and 5 years spare parts.
ULMATEC PYRO AS
Certificate No:
A-14229
File No:
TYPE APPROVAL CERTIFICATE 855.40
Job Id:
262.1-001812-6
This is to certify:
That the Automatic Oil Fired Water Heater
with type designation(s)

Pyro Series II, III, IV, V, VI
Issued to
Ulmatec Pyro AS
SØVIK, Norway
is found to comply with

Det Norske Veritas' Rules for Classification of Ships, High Speed & Light Craft and Det Norske
Veritas' Offshore Standards
Application :
The approval is for system design principle only.
This Certificate is valid until 2016-12-31.

Issued at Høvik on 2015-06-08
for DNV GL
DNV GL local station: Ålesund Digitally Signed By: Sneen, Ståle
Location: DNV GL Høvik, Norway
Approval Engineer: Geir Bjørn Alnes Signing Date: 2015-06-10, on behalf of
Odd Magne Nesvåg

Head of Section
This Certificate is subject to terms and conditions overleaf. Any significant change in design or construction may render this Certificate invalid.
The validity date relates to the Type Approval Certificate and not to the approval of equipment/systems installed.
Form code: TA 1411a Revision: 2014-11 www.dnvgl.com Page 1 of 3

© DNV GL 2014. DNV GL and the Horizon Graphic are trademarks of DNV GL AS.
Certificate No: A-14229
File No: 855.40
Job Id: 262.1-001812-6
Product description
Type: PYRO Automatic Oil fired and electric Water Heater
Serie II: Art. E1109, E1110, E1112

Serie III: Art. E1114, E1116, E1118
Serie IV: Art. E1120, E1122, E1124, E1127, E1129
Serie V: Art. E1130, E1131, E1133, E1134
Serie VI: Art. E1135, E1137, E1138, E1139, E1140
Burner controller type Siemens LOA24, LAL 1.25 or LAL 2.25.
Approval conditions
The following documentation of the actual application is to be submitted to the shipyard in each case:
- Reference to this Type Approval Certificate
The Type Approval covers hardware and software listed under Product description.
As long as the units are covered by the Type Approval, a product certificate according to Pt.4 Ch.9 Sec.1
A 202 will not be required. Correct configuration and set up for each delivery to be tested during
commissioning after installation.
Type Approval documentation

PYRO series II: electrical drawing UPY-G13001-01PW
PYRO series III: electrical drawing UPY-G12004-01PW
PYRO series IV: electrical drawing UPY-G11006-01PW
PYRO series V/VI: electrical drawing UPY-G11004-01PW
Data sheets:
Landis & Gyr data sheet 7153 E Oil burner control LAL Series.
Alternative wiring diagrams may be accepted provided they include the following:
- Burner controller type LOA24, LAL 1.25 or LAL 2.25.
- Alarm and shut off of fuel oil supply by means of normally closed contacts, upon
following conditions:
- Low water level
- Flame and ignition failure
- Water temperature high
- Potential free common alarm output contacts to main alarm system.
Type Approval Periodical Assessment report, DNV Ålesund 2015-01-05.

Certificate No: A-14229
File No: 855.40
Job Id: 262.1-001812-6
Periodical assessment
The scope of the periodical assessment is to verify that the conditions stipulated for the type are
complied with, and that no alterations are made to the product design or choice of systems, software
versions, components and/or materials.
The main elements of the assessment are:
· Ensure that type approved documentation is available
· Inspection of factory samples, selected at random from the production line (where practicable)
· Review of production and inspection routines, including test records from product sample tests and
control routines
· Ensuring that systems, software versions, components and/or materials used comply with type
approved documents and/or referenced system, software, component and material specifications
· Review of possible changes in design of systems, software versions, components, materials and/or
performance, and make sure that such changes do not affect the type approval given
· Ensuring traceability between manufacturer’s product type marking and the type approval certificate
Periodical assessment is to be performed at least every second year and at renewal of this certificate.
END OF CERTIFICATE

PRODUCT-
Operator Guidelines UPY-G01001-01PO
Fuel Fired Heater 06.02.2013
Author: L
Arne Skotte
Revision History
A First Issue 06.02.2013 ASK
B New standard software for FFH 11.04.2013 TS
C Changed pump control setting 19.09.2013 TS
D Added configuration for LNG burner 04.10.2013 TS
E Added Alarm list 10.12.2013 TS
F Added instructions for Program download from USB-Memory 29.01.2014 TS
G Added operator guidelines for FFH without PLC 26.02.2014 ASK
H Changed setting for pumps 01.04.2014 TS
I Changed instructions for pumps 07.04.2014 TS
J Changed pump control, and safety function 28.08.2014 TS
K Safety functions to separate alarms 17.10.2014 TS
L ModBus control & Recipes 02.03.2014 TS
Document Summary
This document includes guidelines for:

- Operator Guidelines (PLC operated Fuel Fired Heater)
- Operator Guidelines (Conventional operated Fuel Fired Heater)
- Maintenance and periodical testing
- Recommended spare parts
ULMATEC PYRO AS
UPY-G01001-01PO (L) Fuel Fired Heater_Operators Guidelines.Docx Page 1 of 22
CONTENTS
1 ABBREVIATIONS ........................................................................................................................................ 3
2 OPERATOR GUIDELINES, PLC CONTROL SYSTEM ......................................................................... 3
2.1 MAIN MENU .............................................................................................................................................. 3
2.1.1 SUB-MENU DESCRIPTION ............................................................................................................. 4
2.1.2 MENU OVERVIEW............................................................................................................................ 5
2.2 OPERATING MENU .................................................................................................................................. 6
2.2.1 INFORMATION DISPLAYED ........................................................................................................... 6
2.2.2 FUEL FIRED HEATER, ON – OFF .................................................................................................. 7
2.2.3 PUMPS MAN - AUTO ....................................................................................................................... 7
2.2.4 LOW-TEMP MODE ........................................................................................................................... 7
2.2.5 HIGH-TEMP MODE ......................................................................................................................... 7
2.2.6 ALARM............................................................................................................................................... 8
2.2.7 HELP ................................................................................................................................................. 8
2.2.8 MAIN .................................................................................................................................................. 8
2.3 SETTING MENU ........................................................................................................................................ 9
2.3.1 SETTING LOW / HIGH TEMP MODE.............................................................................................. 9
2.3.2 SETTING PUMPS .............................................................................................................................. 9
2.3.3 SETTING FOR PUMP PRESSURE ALARMS AND AUTOMATIC START/STOP ............................ 9
2.3.1 EXPORT USER RECIPES TO USB MEMORY STICK .....................................................................10
2.3.2 IMPORT USER RECIPES FROM USB MEMORY STICK ...............................................................10
2.3.3 ENABLE / DISABLE MODBUS REMOTE CONTROL ....................................................................11
2.3.4 RESET TO DEFAULT SETTING ......................................................................................................11
2.3.5 HELP ................................................................................................................................................11
2.3.6 MAIN .................................................................................................................................................11
2.4 OPERATIONAL INFO MENU..................................................................................................................12
2.4.1 RUN HOURS INDICATION .............................................................................................................12
2.4.2 FUEL CONSUMPTION FOR FFH ..................................................................................................12
2.4.3 RESET RUN HOURS ........................................................................................................................12
2.4.4 HELP ................................................................................................................................................12
2.4.5 MAIN .................................................................................................................................................12
2.5 SERVICE MENU .......................................................................................................................................13
2.5.1 CONFIGURATION ...........................................................................................................................13
2.5.2 SERVICE SETTINGS ........................................................................................................................14
2.5.3 EXPORT FAT CONFIGURATION AND SERVICE SETTINGS TO USB MEMORY STICK ...........15
2.5.4 EXPORT HAT CONFIGURATION AND SERVICE SETTINGS TO USB MEMORY STICK ...........15
2.5.5 IMPORT FAT CONFIGURATION AND SERVICE SETTINGS FROM USB MEMORY STICK .....15
2.5.6 IMPORT HAT CONFIGURATION AND SERVICE SETTINGS FROM USB MEMORY STICK .....15
2.6 EXAMPLE TYPICAL MENU OPERATION. ...........................................................................................16
2.6.1 STARTING THE FUEL BURNER .....................................................................................................16
2.7 DOWNLOAD NEW SOFTWARE FROM USB MEMORY STICK .........................................................17
3 OPERATOR GUIDELINES, RELAY CONTROL SYSTEM ..................................................................18
3.1 LAYOUT CONTROL CABINET. .............................................................................................................18
3.2 SWITCHES IN THE FRONT OF THE CONTROL CABINET. ................................................................18
4 MAINTENANCE AND PERIODICAL TESTING ....................................................................................20
4.1 WEEKLY MAINTENANCE .....................................................................................................................20
4.2 MONTHLY MAINTENANCE ..................................................................................................................20
4.3 MAINTENANCE EVERY 6 MONTH.......................................................................................................20
4.4 MAINTENANCE EVERY YEAR .............................................................................................................21
5 RECOMMENDED SPARE PARTS ............................................................................................................22
5.1 FUEL BURNER .........................................................................................................................................22
ULMATEC PYRO AS
5.2 SENSOR & SAFETY VALVES.................................................................................................................22
5.3 CONTROL CABINET ...............................................................................................................................22
1 ABBREVIATIONS
HAT Harbour Acceptance Test

FAT Factory Acceptance Test
UPY Ulmatec Pyro AS
DNV Det Norske Veritas
HMI Human Machine Interface
FFH Fuel Fired Heater
2 OPERATOR GUIDELINES, PLC CONTROL SYSTEM

2.1 MAIN MENU
The MAIN MENU is used to navigate into the four sub-menu.
ULMATEC PYRO AS
2.1.1 SUB-MENU DESCRIPTION
• OPERATING MENU
Allow the operator to control the fuel burner, pumps, electric heating and view the alarm list.
• SETTING MENU
Allow the operator to adjust set-point for the burner, pumps, electric heating.
• OPERATIONAL INFO MENU
Give an overview of the delivery specific information.
• CONFIGURATION AND SERVICE
o Configuration of the Fuel Fired Heater.

Selects equipment, range for sensors, position for PLC-modules
These settings are done at Factory Acceptance Test (FAT).
o Service Settings
Settings at comissioning
These settings are done at Harbour Acceptance Test (HAT).
ULMATEC PYRO AS
2.1.2 MENU OVERVIEW
MAIN MENU OPERATING MENU ALARMS
SETTING MENU
OPERATIONAL INFO MENU
SERVICE CONFIGURATION
SERVICE SETTING
ULMATEC PYRO AS
2.2 OPERATING MENU
2.2.1 INFORMATION DISPLAYED
-
Allow the user to set the Fuel Fired Heater Off and On.
- :
Allow the user to set the pumps in Manual or Auto.
- Pressure indication:
Water pressure is indicated on each side of the circulation pump.
- Operation and status indication for each electric heating section:

Grey=Off, Blue=Standby, Green=On, Red=Alarm
- Operation and status indication for each circulation pump:

- Low temp mode temperature setting and actual temperature are displayed.
Grey = Off, Green = On.
- High temp mode temperature setting and actual temperature are displayed.
Grey = Off, Green = On.
- Operation and status indication for fuel fired heater:

- Operation and status Indication sanitary circulation pump

Grey=Off, Green=On, Red=Alarm
- Operation and status indication fuel oil transfer pump

- Operation and status indication Fuel oil heating

- Two most recent alarms
ULMATEC PYRO AS
2.2.2 FUEL FIRED HEATER, ON – OFF
ON
Burner operates according to the temperature settings specified in the selected TEMP MODE.
The heating elements will operate according to the temperature settings specified in the selected TEMP
MODE.
OFF
All functions is set to OFF
2.2.3 PUMPS MAN - AUTO

MAN
Pumps can be started and stopped by pushing the pump symbol.
AUTO
Pumps starts according to pump pressure, and other pump settings.
2.2.4 LOW-TEMP MODE
The fuel fired heater will operate at the setting specified in the LOW-TEMP MODE
2.2.5 HIGH-TEMP MODE
The fuel fired heater will operate at the setting specified in the HIGH-TEMP MODE
ULMATEC PYRO AS
2.2.6 ALARM
Shows the two last alarms,

Push the button to display the alarm list and acknowledge.
2.2.6.1 ALARM LIST

Alarm Safety Stop (Emergency Stop/ Low Level/ High Temp/ Open Burner)
Alarm Ignition Failure
Alarm High Differential Pressure Pumps
Alarm Low Differential Pressure Pumps
Alarm PLC
Alarm Circulation Pump No.: 1, 2 & 3
Alarm Heat Section No.: 1, 2, 3 & 4
Alarm Sanitary Circulation Pump
Alarm Fuel Oil Transfer Pump
Alarm Sensor Water Temperature
Alarm Sensor Exhaust Temperature
Alarm Sensor Pump Pressure In
Alarm Sensor Pump Pressure Out
Alarm Burner Motor
Alarm Emergency Stop
Alarm Low Water Level
Alarm Safety Temperature Switch
Alarm Oilon LNG Burner
Warning Standby pump started
Safety Stop alarm is triggered when, emergency stop, low water level, burner open or high
temperature is activated. Some fuel fired heaters has only a combined alarm for the safety
function. The safety stop alarms will set the FFH to OFF, and the pumps to MAN with all pumps
in stop position.
After a reset of this alarm, the FFH must be manually set back to ON, and the pumps to AUTO.
2.2.7 HELP
Shows help instruction for the actual menu.
2.2.8 MAIN
Change to MAIN MENU
ULMATEC PYRO AS
2.3 SETTING MENU
2.3.1 SETTING LOW / HIGH TEMP MODE
STOP HEATING (Nozzle 1 and Nozzle 2)

START BURNER STEP 1 (Nozzle 1)
START BURNER STEP 2 (Nozzle 2)
CONNECT EL-HEATING SECTION 1
Electric heating sections has a default hysteresis at +/- 1 °C (Can be adjusted by service)
Stop heating temperature is valid for both nozzle.
2.3.2 SETTING PUMPS

Pump priority: Select Manual or Auto priority (Selected is indicated by green background)
In manual mode priority can be changed for each pump.
In Auto, the pump priority is decided according to run hours.
Operate pump symbol for the pumps to be included in the automatic priority change
(Green pump is included)
Set “Check every” to how often the pump priority shall be updated.
Changes to the settings must be loaded to the PLC. Unloaded status are indicatd by yellow background.
The black button loads the changes.
Pump jog:
The pump jog functionality is used to prevent that the sealing of the pump shall harden. The pump will
start and run for a short time. Both the run time and the time between each jog can be set from the service
menu.
2.3.3 SETTING FOR PUMP PRESSURE ALARMS AND AUTOMATIC

START/STOP
Pressure setting: If differential pressure is above Max diff pressure setting an alarm is activated, and
all circulation pumps will stop. If differential pressure is below Min diff pressure setting, the next
pump will automatically start. If all pumps are running, and differential pressure is below the limit an
alarm is given.
If the last pump is started a warning for stand by pump started is given on the screen.
Timer extra pump: The extra pumps will run for the given time and then stop.
If the pressure still is to low, the extra pumps will start again
ULMATEC PYRO AS
2.3.1 EXPORT USER RECIPES TO USB MEMORY STICK
- Put a memory stick into the back of the panel. (Picture 1)
- Select recipe you want to save, or make a new by typing in recipe name.
- All settings will be saved in a report and a recipe in the USB memory stick.
2.3.2 IMPORT USER RECIPES FROM USB MEMORY STICK
- Put the memory stick with the new recipe into the back of the panel (see picture 1)
- The recipe you want to replace, must be removed from the internal memory in the panel.
- Then the recipe can be imported from the memory stick by pressing the import button.
- After importing recipe, you must load the recipe from the internal memory in the panel to your system.
- Select the recipe you want to load, and press load.
NOTE: only deleted recipes will be updated with the ones on the memory stick.
ULMATEC PYRO AS
2.3.3 ENABLE / DISABLE MODBUS REMOTE CONTROL
Press button to enable/disable MODBUS remote control
When enabled, the button is yellow, and these values can be controlled from MODBUS
- Setpoints
- Heater ON/OFF
- Temperature mode HIGH/LOW
When remote control is enabled, the text “Remote control enabled. To disable, go to settings” is shown on
the local control panel.
2.3.4 RESET TO DEFAULT SETTING

All settings will be reset to default. Password is required.
2.3.5 HELP
Shows help for the actual menu.
2.3.6 MAIN
Change to MAIN MENU
ULMATEC PYRO AS
2.4 OPERATIONAL INFO MENU
2.4.1 RUN HOURS INDICATION

Shows total run hours, and run hours since last time the running hours was reset by the operator.
2.4.2 FUEL CONSUMPTION FOR FFH

Shows fuel consumption since last time the fuel consumption was reset by the operator.
2.4.3 RESET RUN HOURS

Operator can reset the run hours.
The reset buttons for total run hours are only visible for service. Operator shall not reset total run hours.
2.4.4 HELP
2.4.5 MAIN
Change to MAIN MENU
ULMATEC PYRO AS
2.5 SERVICE MENU
Service menu is password protected and intended for service operator
2.5.1 CONFIGURATION
2.5.1.1 SELECT EQUIPMENT

Tic the check box for system specific equipment
2.5.1.2 SENSORS
Set scale for analog sensors
Select order specific sensors
2.5.1.3 RESET TO DEFAULT CONFIGURATION

Resets all configuration to factory settings
2.5.1.4 PROJECT INFORMATION

o Yard
o Hull no.
o Ulmatec Pyro Order no.
o Plant
2.5.1.5 MODBUS STATION NUMBER

Select the station number for the Modbus. See cable diagram UPY-Bnnnnn-31OR.
2.5.1.6 ENABLE MODBUS REMOTE CONTROL

If selected the operator can give the command to a remote system connected to the Modbus. See
settings.
2.5.1.7 SEPARATED SAFETY ALARMS

If selected, emergency stop, low water level, open burner and safety thermostat are separated in three
different alarms. If not selected the alarms are combined in one safety alarm.
2.5.1.8 HELP
2.5.1.9 SERVICE MENU
Change to SERVICE MENU

ULMATEC PYRO AS
2.5.2 SERVICE SETTINGS
2.5.2.1 ALARM DELAY FOR ALL ALARMS

Factory setting is 5 second
2.5.2.2 RESET TOTAL RUN HOURS

Reset buttons for total running hours
2.5.2.3 PUMP JOG SETTINGS

Set how often you want pump jog, and for how long you will jog the pump
2.5.2.4 SETTING FOR PUMP PRESSURE ALARMS AND AUTOMATIC

START/STOP
Pressure setting: If differential pressure is above Max diff pressure setting an alarm is activated, and
all circulation pumps will stop. If differential pressure is below Min diff pressure setting, the next
pump will automatically start. If all pumps are running, and differential pressure is below the limit
an alarm is given.
If the last pump is started a warning for stand by pump started is given on the screen.
Timer extra pump: The extra pumps will run for the given time and then stop.
If the pressure still is to low, the extra pumps will start again
2.5.2.5 RANGE FOR DIFFERENTIAL PRESSURE

Maximum and minimum range for differential pressure over the pump set must be according to the
pump-curve for the actual pump
2.5.2.6 HYSTERESIS EL-HEATING

+/- Value for hysteresis on each electric heating section
2.5.2.7 RESET TO DEFAULT SETTING

Resets all configuration to factory settings
2.5.2.8 HELP
2.5.2.9 SERVICE MENU
Change to SERVICE MENU
ULMATEC PYRO AS
2.5.3 EXPORT FAT CONFIGURATION AND SERVICE SETTINGS TO USB
MEMORY STICK
All configurations and service settings will be saved to a USB memory stick connected at the back of the
panel. (picture 1, page 10). Press yes to replace the recipes
2.5.4 EXPORT HAT CONFIGURATION AND SERVICE SETTINGS TO USB

MEMORY STICK
All configurations and service settings will be saved to a USB memory stick connected at the back of the
panel. (picture 1, page 10). Press yes to replace the recipes
2.5.5 IMPORT FAT CONFIGURATION AND SERVICE SETTINGS FROM

USB MEMORY STICK
- Put the memory stick with the new recipes into the back of the panel. (picture 1, page 10)
- Press delete old recipes
- Press yes to delete
- Press Import, and all deleted recipes will be loaded from the memory stick to the internal memory in the
panel
- Next popup appears
- Press load FAT service setting and configuration recipe
2.5.6 IMPORT HAT CONFIGURATION AND SERVICE SETTINGS FROM

USB MEMORY STICK
- Put the memory stick with the new recipes into the back of the panel. (picture 1, page 10)
- Press delete old recipes
- Press yes to delete
- Press Import, and all deleted recipes will be loaded from the memory stick to the internal memory in the
panel
- Next popup appears
- Press load HAT service setting and configuration recipe
ULMATEC PYRO AS
2.6 EXAMPLE TYPICAL MENU OPERATION.
2.6.1 STARTING THE FUEL BURNER
: On the OPERATIING MENU
Activate LOW-TEMP MODE or HIGH TEMP MODE and oil burner ON.
Set pumps to AUTO
: The burner begins its starting cycle (approx.60.sec.).
: The burner fan starts the burning chamber preparing period (30.sec.). The air flap will open.
: The ignition transformer is activated. The fuel oil solenoid valve opens, and the flame occurs.
: The photo-cell activates and surveys the flame.
: On two step burners, nozzle 2 will open after 15sec. The air flap will open to nozzle 2 set-point.
: The water heater will now operate automatically on the thermostat, normally adjusted to 65°C for
LOW-TEMP MODE and 90°C for HIGH TEMP MODE.
The temperature for nozzle 2 should be adjusted approx. 5°C lower than nozzle 1.
ULMATEC PYRO AS
2.7 DOWNLOAD NEW SOFTWARE FROM USB MEMORY STICK
Program updates can be downloaded to the PLC and the Control Panel from an USB Memory Stick.
Load files sent from Ulmatec Pyro to an USB Memory Stick.
These files must be on the memory stick. The file fcu.fx may have a different name (*.fx)
Put the memory stick into the USB-port at the back of the control panel, and disconnect the power.
Reconnect the power, and the menus below will appear.
Press yes to copy project form USB memory.

Press no to Backup existing project.
Press yes to download the program to the PLC.
Select the program in the list, and press OK
Press no to upload PLC program.
The new software is now installed
ULMATEC PYRO AS
3 OPERATOR GUIDELINES, RELAY CONTROL SYSTEM
3.1 LAYOUT CONTROL CABINET.
3.2 SWITCHES IN THE FRONT OF THE CONTROL CABINET.
- COMMON ALARM
Alarm for High Temp, Low water level, Ignition/Flame Failure and Motor circuit breaker circulation
pump
- RESET FUEL BURNER:

Switch to reset the fuel fired heater after a failure situation.
- BURNER OFF/AUTO:
To stop the fuel burner this switch shall be set to position OFF.
To start the fuel burner the switch shall be set to position AUTO.
ULMATEC PYRO AS
- CIRCULATION PUMP
The system is normally delivered with two circulation pump.
Each pump has a separate switch for start/stop of the pump.
In most cases only one of the pumps has to run to cover the energy requirement.
- ADJUSTING WATER OPERATING TEMPERATURE

The operation temperature is adjusted on the temperature sensor located on the fuel fired heater.
The operation temperature is common for both electric heating element and fuel burner.
- ADJUSTING CIRCULATION PUMP PRESSURE

The circulation pump pressure is adjusted on the sensor located on the circulation pump unit.
The pressure is adjusted during the commission period.
- OPTIONAL, ELECTRIC HEATING

The fuel fired heater can as an option is delivered with one or two section with electric heating element.
Each electric heating section has then a switch to set the heating on/off.
- OPTIONAL, SANITARY HOT WATER PUMP

The fuel fired heater can as an option is delivered with one sanitary heating coil and sanitary hot water
circulation pump. The circulation pump has then a switch to start/stop the pump.
- OPTIONAL, FUEL OIL TRANSFEER PUMP

The fuel fired heater can as an option is delivered with fuel oil transfer pump. The fuel oil transfer pump
is then equipped with a switch to start/stop the pump.
- OPTIONAL, FUEL OIL HEATER

The fuel fired heater can as an option is delivered with fuel heating element. The fuel oil heating element
can then be switched on/off with a switch located on the front of the control cabinet.
ULMATEC PYRO AS
4 MAINTENANCE AND PERIODICAL TESTING
4.1 WEEKLY MAINTENANCE
Checkpoints:
Description Personal requirement
Functionality test, Circulation pump Owner
Functionality test, Hot water circulation pump Owner
Functionality test, Fuel transfer pump Owner
Functionality test, Electric heating Owner
Functionality test, Fuel heating Owner
Functionality test, Fuel burner. Owner
Functionality test, Verify reading from exhaust gas temperature sensor Owner
Functionality test, Verify reading from fuel flow meter. Owner
Inspection, The water level shall be checked. If necessary, refill water. Owner
4.2 MONTHLY MAINTENANCE

Checkpoints:
Control the installation for fuel leakage. Owner
Control the installation for water leakage Owner
Control the installation for exhaust leakage. Owner
Verify the emergency stop functionality Owner
4.3 MAINTENANCE EVERY 6 MONTH

Checkpoints:
Clean the fuel filter in the burner. Owner
Replace the external fuel filter in the front of the fuel fired heater (filter cartridge). Owner
If the filter is dirty, the filter in the fuel pump shall be cleaned.
Inspect and if necessary replace the ignition electrode Owner
Clean the fuel fired heater. Owner
Dismount the burner and the burner plate / cleaning doors.
Clean the exhaust pipe Owner
Inspect the hatch seal Owner
Check air inlet and blower wheel. Clean if necessary. Owner
Circulation pump electric motors with grease nipples should be lubricated with a high Owner
temperature lithium based grease,
ULMATEC PYRO AS
4.4 MAINTENANCE EVERY YEAR
Checkpoints:
Replace the fuel nozzle Ulmatec service engineer
Safety function, Flame control when starting Ulmatec service engineer
Safety function, Flame control when running Ulmatec service engineer
Safety function, Safety temperature switch Ulmatec service engineer
Safety function, Water Low level switch Ulmatec service engineer
Safety function, Safety pressure valve Ulmatec service engineer
Failure modes, power supply Ulmatec service engineer
Failure modes, Interfaces Ulmatec service engineer
Failure modes, Protection circuits Ulmatec service engineer
Inspection, Expansion tank (air pressure) Ulmatec service engineer
Inspection, Circulation pump Ulmatec service engineer
Inspection, Hot water circulation pump Ulmatec service engineer
Inspection, Fuel transfer pump Ulmatec service engineer
Inspection, Electric heating Ulmatec service engineer
Inspection, Fuel heating Ulmatec service engineer
Inspection, Fuel burner. Ulmatec service engineer
Inspection, Check through the inspection glass when the burner is running. Ulmatec service engineer
If it is coke residue in combustion chamber the unit need to be cleaned.
Inspection, Check ceramic plates on the burner plate Ulmatec service engineer
Control system, SW updates Ulmatec service engineer
Control system, Verify system setting Ulmatec service engineer
Control system, Electrical Installation Ulmatec service engineer
ULMATEC PYRO AS
5 RECOMMENDED SPARE PARTS
5.1 FUEL BURNER
Checkpoints:
Description Number of units
Photocell 1 pc
Ignition transformer. 1 pc
Nozzle 1 pc of each type
Ignition cable 1 pc
Ignition electrode 1 pc
Burner motor 1 pc
Baffle plate 1 pc
Oil pump 1 pc
Oil tube (oil pump) 1 pc
Servo motor (2 x nozzle) 1 pc
Air fan 1 pc
Coil for solenoid valve 2 pc
5.2 SENSOR & SAFETY VALVES

Checkpoints:
Fuel Fired Heater, Water low level safety switch (pressure switch) 1 pc
Fuel Fired Heater, Safety temperature switch. 1 pc
Fuel Fired Heater, Operating water temperature 1 pc
Fuel Fired Heater, Safety valve (3 bar) 1 pc
Circulation pump, Pressure switch 1 pc
5.3 CONTROL CABINET

Checkpoints:
Fuel Burner Controller 1 pc
Operator panel with SW installed. 1 pc
PLC main unit with SW installed 1 pc
PLC analogue input 1 pc
AC/DC Power supply 1 pc
ULMATEC PYRO AS
Index divider: Section 11
PRODUCT-
Modbus Description UPY-G00001-01PA
Fuel Fired Heater 23.01.2014
Author:
Arne Skotte H
Revision History
D Changed high temp low level to Safety Stop Alarm 29.09.2014 TS
Includes High temp, Low Level, Open Burner, and Emergency
Stop
E Changed Modbus description 07.10.2014 TS
F Added three alarms, and common alarm 24.10.2014 TS
G Changed configuration of order 23.02.2015 TS
H Added read/write information 02.03.2015 TS
Configurable station number
Added address for remote control enabled, address 11701 ??
Added GUIEnableRemoteControl, GUIFFHControl, and
GUITempMode
Modbus Description
- Modbus Protocol: RTU

- Slave station no.: Configurable, see cable diagram UPY-Bnnnnn-11OR.
- 32 –bit word mapping: Little-endian (Intel)
Example:
The 32-bit word will in this case be treated as MSB\LSB consisting of 2 x 16 bit word with 2 holding register
addresses for each parameter. Observe the addresses are of DINT or FLOAT type.
- Addressing: Desimal
- Start address: 0-based
- Max block size (words): 16
- Baudrate: 19200
- Databit: 8
- Stopbit: 1
- Parity: 1
Configuration of order
Optional
- Configuration of actual order is found in project drawing UPY-Bxxxxx-11OT
ULMATEC PYRO AS
UPY-G00001-01PA (H) Modbus Description_Front Page.Docx Page 1 of 1
UPY-G00000-01PA Fuel Fired Heater, Modbus Description
Description Variable name Type ModBusAdress Read ModBusAdress Write Value Comment
Alarm Safety Stop (HT/LL/Open Burner/E.stop) AlarmHighTempLowLevel Bit 11501 - NO -
Alarm ignition failure AlarmIgnitionFailure Bit 11502 - NO -
Alarm high diff pressure pump unit AlarmHighDiffPressure Bit 11503 - NO -
Alarm low diff pressure pump unit AlarmLowDiffPressure Bit 11504 - NO -
Alarm PLC AlarmPLC Bit 11505 - NC -
Alarm circulation pump no. 1 AlarmCircPump1 Bit 11506 - NO -
Alarm electric heating element section no. 1 AlarmElHeatSection1 Bit 11509 - NO -
Alarm sanitary pump AlarmSanitaryPump Bit 11513 - NO -
Alarm fuel oil transfer pump AlarmTransferPump Bit 11514 - NO -
Warning standby pump started WarningStandByPumpStarted Bit 11515 - NO -
Alarm emergency stop AlarmEmergencyStop Bit 11516 - NO -
Sensor alarm water temperature FFH AlarmSensorWaterTemp Bit 11517 - NO -
Sensor alarm exhaust temperature AlarmSensorExhaustTemp Bit 11518 - NO -
Sensor alarm pressure into pump unit AlarmSensorPressureIn Bit 11519 - NO -
Sensor alarm pressure out from pump unit AlarmSensorPressureOut Bit 11520 - NO -
Alarm burner motor AlarmBurnerMotor Bit 11521 - NO -
Alarm low water level AlarmLowWaterLevel Bit 11522 - NO -
Alarm safety tempertaure switch AlarmSafetyTempSwitch Bit 11523 - NO -
Alarm LNG heater AlarmLNGHeater Bit 11524 - NC -
Alarm Common AlarmCommon Bit 11525 - NO -
Run signal circulation pump no. 1 CircPumpOn1 Bit 11601 - 0-1 0 when running
Run signal electric heating section no. 1 ElheatingOn1 Bit 11604 - 0-1 0 when running
Run signal sanitary water pump SanitaryPumpOn Bit 11608 - 0-1 0 when running
Run signal fuel oil transfer pump TransferPumpOn Bit 11609 - 0-1 0 when running
Run signal fuel hater (standby) FuelHeaterOn Bit 11610 - 0-1 0 when running
Run signal burner motor BurnerMotorOn Bit 11611 - 0-1 0 when running
Setpoint alarm high diff pressure pump unit SPAlarmMaxDiffPressure INT 47531 47531 0-10bar Scaling: 0,01
Setpoint alarm low diff pressure pump unit SPAlarmMinDiffPressure INT 47532 47532 0-10bar Scaling: 0,01
Setpoint runtime extra pumps SPPumpTimer INT 47533 47533 0-10h -
Time between check if extra pump is necessary GUIStatusTimeCheckPriority INT 47534 47534 0-120s -
Setpoint high el. Heating section no. 1 SPElHeaterHighTemp1 INT 47535 47535 0-100 -
Setpoint low el. Heating section no. 1 SPElHeaterlowTemp1 INT 47539 47539 0-100 -
Setpoint high start nozzle no. 1 SPStartNozzle1HighTemp INT 47543 47543 0-100 -
Setpoint low start nozzle no. 1 SPStartNozzle1LowTemp INT 47544 47544 0-100 -
Setpoint high start nozzle no. 2 SPStartNozzle2HighTemp INT 47545 47545 0-100 -
Setpoint low start nozzle no. 2 SPStartNozzle2LowTemp INT 47546 47546 0-100 -
Setpoint high stop burner SPStopBurnerHightemp INT 47547 47547 0-100 -
Setpoint low stop burner SPStopBurnerLowtemp INT 47548 47548 0-100 -
Setpoint hysteresis el-heating SPHysteresisElHeating INT 47549 47549 0-100 -
Operating water temperature OperatingWaterTemp INT 47731 - -50-150 -

Exhaust temperature ExhaustTemp INT 47732 - 0-400 -
Pump pressure in PumpPressureIn INT 47733 - 0-10 Scaling: 0,01
Pump pressure out PumpPressureOut INT 47734 - 0-10 Scaling: 0,01
Fuel consume FuelConsume INT 47735 - 0-> -
Total run hours circulation pump no. 1 TotTimeCircPump1 DINT 47811 - 0-> -
Total run hours sanitary pump TotTimeSanitaryPump DINT 47817 - 0-> -
Total run hours fuel oil transfer pump TotTimeTransferPump DINT 47819 - 0-> -
Total run hours FFH TotTimeFFH DINT 47821 - 0-> -
Run hours after reset circulation pump no. 1 TimeCircPump1 DINT 47823 - 0-> -
Run hours after reset sanitary pump TimeSanitaryPump DINT 47829 - 0-> -
Run hours after reset fuel oil transfer pump TimeTransferPump DINT 47831 - 0-> -
Run hours after reset FFH TimeFFH DINT 47833 - 0-> -
Remote Control Enabled GUIEnableRemoteControl Bit 11701 - 0-1 Remote ON/OFF
Temp mode selected GUITempMode Bit 1801 1801 0-1 0=Low - 1=High
Fuel Fired Heater On/ OFF GUIFFHControl Bit 1802 1802 0-1 Heater ON/OFF
Index divider: Section 12
PRODUCT –
Harbour Acceptance Test (HAT) UPY-G01001-01PH
HAT, Heat Generator – Fuel Fired Heater 12.03.2014
Author: -
Arne Skotte
Ulmatec Pyro AS, Project Information:
Project No:
…………………………………………………………………………….
Yard:
…………………………………………………………………………….
Hull Number:
…………………………………………………………………………….
Customer Reference:
…………………………………………………………………………….
Ulmatec Pyro AS, Test Information:
Location:
…………………………………………………………………………….
Test Date:
…………………………………………………………………………….
Ulmatec Pyro AS
Service Engineer: …………………………………………………………………………….
ULMATEC PYRO AS
UPY-G01001-01PH (-) Fuel Fired Heater - HAT.Docx Page 1 of 13
CONTENTS
2 ABBREVIATIONS ...................................................................................................................................... 3
3 SAFETY ....................................................................................................................................................... 3
4 GENERAL INFORMATION, SYSTEM HAT ......................................................................................... 4
4.1 PURPOSE SYSTEM HAT ............................................................................................................................. 4
4.2 TEST REQUIREMENT................................................................................................................................... 4
4.3 HAT COMMISSION TEST............................................................................................................................ 4
4.4 TEST CONFIGURATION ............................................................................................................................... 4
4.5 SPECIAL TOOLS ......................................................................................................................................... 4
5 PRE-COMMISSION ................................................................................................................................... 5
5.1 ARRANGEMENT DRAWING......................................................................................................................... 5
5.2 SYSTEM INSTALLATION ............................................................................................................................. 5
5.3 MOUNTING FUEL FIRED HEATER ............................................................................................................... 5
5.4 TECHNICAL INSTALLATION FUEL FIRED HEATER. ..................................................................................... 5
5.5 CIRCULATION PUMP (LOCAL UNIT) ........................................................................................................... 6
5.6 EXPANSION TANK...................................................................................................................................... 6
5.7 CONTROL SYSTEM, FUEL FIRED HEATER .................................................................................................. 7
5.7.1 Visual Inspection:............................................................................................................................ 7
5.7.2 Software Updates: ........................................................................................................................... 7
5.7.3 Supply Burner Motor and Circulation Pump .................................................................................. 7
5.7.4 Electric Heating Coil ...................................................................................................................... 7
5.7.5 Circulating pump............................................................................................................................. 7
5.7.6 Sanitary hot water circulation pump ............................................................................................... 7
5.7.7 Fuel transfer pump .......................................................................................................................... 8
5.7.8 Fuel Heating.................................................................................................................................... 8
5.7.9 Burner motor ................................................................................................................................... 8
5.7.10 System Operation, HMI pump control ........................................................................................ 8
5.7.11 System Operation, HMI heating element control ....................................................................... 8
5.7.12 System Operation, System Setting............................................................................................... 8
5.7.13 Operation, Fuel Burner .............................................................................................................. 8
5.7.14 System Operation – Start Oil Burner......................................................................................... 9
5.7.15 System Operation – Setting Menu............................................................................................... 9
5.7.16 System Operation – Pump Menu .............................................................................................. 10
5.8 ORDER SOFTWARE BACKUP ..................................................................................................................... 10
5.9 COMMENTS AND SIGNATURE: .................................................................................................................. 10
6 HARBOUR ACCEPTANCE TEST (HAT) ............................................................................................. 11
6.1 SAFETY FUNCTION – TEMPERATURE SWITCH .......................................................................................... 11
6.2 SAFETY FUNCTION – FLAME CONTROL WHEN STARTING ....................................................................... 11
6.3 FAILURE MODES – CONTROL SYSTEM .................................................................................................... 11
6.4 SAFETY FUNCTION – FLAME CONTROL WHEN RUNNING ....................................................................... 12
6.5 SAFETY FUNCTION – WATER LOW LEVEL SAFETY SWITCH ..................................................................... 12
6.6 COMMENTS AND SIGNATURE: .................................................................................................................. 12
7 PUNCH LIST ............................................................................................................................................. 13
ULMATEC PYRO AS
2 Abbreviations
HAT Harbour Acceptance Test
FAT Factory Acceptance Test
UPY Ulmatec Pyro AS
DNV Det Norske Veritas
HMI Human Machine Interface
S/N Serial Number
3 Safety
Ensure that all personnel involved in the commission of the equipment have the required knowledge regarding:
- System architecture.
- Product included in the scope of supply.
- Commission procedure.
- Local safety rules.
Important safety rules:

- Secure the commission area.
- Safe briefing shall be arranged with all personnel involved in the commission.
- Use suitable protective clothing and equipment.
- Potential risk  the system can be pressurized with hot water.
- Potential risk  the system can be powered up.
ULMATEC PYRO AS
4 General information, System HAT
4.1 Purpose System HAT

This document is a guideline for the system HAT implementation for the Fuel Fired Heater.
The HAT is divided into a Pre-commission (assisted by Ulmatec service engineer) and a Quayside test.
4.2 Test requirement

Before the HAT test following have to be performed:
 FAT test for each product delivered by Ulmatec PYRO AS.
 The System is installed according to the installation guidelines from Ulmatec Pyro AS.
 The system shall be filled up with water.
 Fuel shall be available.
 Power shall be available to all units.
4.3 HAT Commission Test

Before the quayside test is started the Ulmatec service engineer shall finish all pre-commission.
The HAT (quayside) test shall be verified by the Ulmatec service engineer and the customer for each test:
 If a test is not valid it shall be marked “NA” (Not Applicable).
 Any other comments shall be marked in the “Comment Field”.
 If a comment requires any correction it shall be noted on the “punch list”.
After completing the HAT test:

 All representatives shall sign the commission part of the HAT for verification.
 The signed document shall be stored in the folder:
(M;)\PYRO Released Documentation\UPY-B………\UPY-B………-01OH (A) Signed HAT.pdf
4.4 Test Configuration

The unit included in the test is shown on the order arrangement drawing.
Interface to external system is listed on the order cable routing diagram.
Installed software version is listed on the order related FAT.
If the software is updated during commission this will be noted in this document.
4.5 Special Tools

No special tools are required for commission of the system.
ULMATEC PYRO AS
5 Pre-Commission
5.1 Arrangement Drawing

Checkpoints:
Description Verified  √,
Not Applicable  NA
Check all units for visual damage.
Observe that all units are mounted according to the system arrangement drawing.
Check that the piping is connected according to the arrangement drawing.
Check that the piping size is according to the arrangement drawing.
5.2 System Installation

Checkpoints:
Check with the yard representative that all pipes are cleaned.
Manually open all valves and control that the system is filled up with water.
Measure the antifreeze point of the liquid: Degrees Celsius.
----------------
5.3 Mounting Fuel Fired Heater

Checkpoints:
Check for visual damage.
Service space, possible to disassemble sanitary heat water coil.
Service space, possible to disassemble electric heating element.
Service space, possible to disassemble steam coil.
Unit mounted according to specification.
5.4 Technical Installation Fuel Fired Heater.

Checkpoints:
Oil filter mounted (enclosed by Ulmatec Pyro AS)
Oil supply connected.
Oil day tank is not located more than 3m lower than the fuel fired heater or fuel
transfer pump if included in the scope of supply.
Observe that the fuel valves (in & out) are open and no oil leakage is detected.
Safety valve no. 1 and 2 is mounted with drain (pre-set to 3 Bar).
(enclosed by Ulmatec Pyro AS)
Safety valve sanitary hot water is mounted with drain (pre-set to 9 Bar).
ULMATEC PYRO AS
5.5 Circulation pump (Local unit)
Checkpoints:
Specify location:
----------------------------------------------------------------------------
IMPORTANT  Check that all valves are open and the pump is not running dry.
Mounted so that service is possible.
Unit fasten to the foundation according to specification.
Bled the pump before operating.
Observe that there is no leakage from the unit or the piping.
Verify that the pump runs in the correct direction.
Verify the pressure before the pump is correct : Bar
------------------
Verify the pressure after the pump is correct : Bar
------------------
5.6 Expansion Tank

Checkpoints:
Unit mounted according to specification.
Measure system pressure at the location of the expansion tank : Bar
Note: Open system to atmosphere. ---------------
Add air pressure to the expansion tank (system pressure + 0,2Bar): Bar
---------------
5.7 Lubrication of internal and external fuel pump.

Checkpoints:
Before start-up the internal fuel pump on the oil burner shall be lubricated.
(Add lubrication oil in the suction pipe)
Before start-up the external fuel transfer pump shall be lubricated.
(Add lubrication oil in the suction pipe)
ULMATEC PYRO AS
5.8 Control System, Fuel Fired Heater
5.8.1 Visual Inspection:
Checkpoints:
Cabinet earth screw earthed connected to ship chassis.
Cable mounted according to specification.
Cable screen earthed according to the cable diagram.
Cabinet mounted according to environmental specification
(temperature, humidity and IP protection)
Power supply according to specification and from specified source.
5.8.2 Software Updates:

Following software updated during commission:
Description SW Updated during commission
Beijer IX Developer (HMI)
Beijer GX-IEC Developer (PLC)
Pyro order related (HMI)
Pyro order related (PLC)
5.8.3 Supply Burner Motor and Circulation Pump

Checkpoints:
Adjust the setting for the frequency inverter according to the order related
documentation.
Verify that the motor frequency is constant when the input frequency is alternated.
5.8.4 Electric Heating Coil

Checkpoints:
Operate the Electric Heating coil and observe the functionality is correct.
5.8.5 Circulating pump

Checkpoints:
Operate the pump and observe that the rotation direction is correct.
5.8.6 Sanitary hot water circulation pump

Checkpoints:
ULMATEC PYRO AS
5.8.7 Fuel transfer pump
Checkpoints:
5.8.8 Fuel Heating

Checkpoints:
Operate the heating element and observe the functionality.
5.8.9 Burner motor

Checkpoints:
5.8.10 System Operation, HMI pump control

Checkpoints:
Verify local start stop of the circulation pumps
Verify local start stop of the sanitary hot water circulation pumps
Verify local start stop of the fuel oil transfer pumps
5.8.11 System Operation, HMI heating element control

Checkpoints:
Verify local control of the electric heating element.
Verify local control of the fuel heating element.
5.8.12 System Operation, System Setting

Checkpoints:
Adjusting setting for “Low Temp Mode” and “High Temp Mode”
Adjust setting start requirement for the circulation pump.
Adjust setting stop requirement for the circulation pump
Only if we delivered flow control unit.
5.8.13 Operation, Fuel Burner

Checkpoints:
Start the Oil Burner from the HMI, “Low Temp Mode”
Change the temperature to “High Temp Mode” and observe that the fuel fired heater
operate automatically on the thermostat setting for “High Temp Mode”.
ULMATEC PYRO AS
5.8.14 System Operation – Start Oil Burner
Checkpoints:
Start the Fuel Burner from the HMI,
“Fuel burning” Auto -and “High Temp Mode”  On.
Burner start cycle for approx. 60 second.
Burner fan starts for burning chamber ventilation (approx. 25 sec.)
Ignition transformer is activated, fuel oil solenoid open and flame occurs.
Can be observed from the inspecting opening.
The photo cell activates and surveys the flame.
On two-step burner nozzle 2 will open after 15 sec. if thermostat nozzle 2 is closed.
Air flap will open to nozzle 2 set point.
The fuel fired heater will operate automatically on the thermostat
setting for “High Temp Mode”.
Change the temperature to “Low Temp Mode” and observe that the fuel fired heater
operate automatically on the thermostat setting for “Low Temp Mode”.
Use an external pressure gauge to measure the nozzle pressure: Bar
_________
5.8.15 System Operation – Setting Menu

Checkpoints:
For mode “Low Temp Mode” and “High Temp Mode” adjust following:
- Stop Heating: ____ Degrees
- Start Burner Step No. 1: ____ Degrees
- Start Burner Step No. 2: ____ Degrees
- Connect Electric heating Section No.: ____ Degrees
Water Level pressure switch adjusted to 0.2 – 0.3 Bar.
High Temp safety switch adjusted to 95 degrees.
ULMATEC PYRO AS
5.8.16 System Operation – Pump Menu
Checkpoints:
For each circulation pump adjust following:
- Start requirement, differential pressure in Bar.
See order documentation (lowest pressure pump curve): ________Bar
- Stop requirement, differential pressure in Bar.

See order documentation (highest pressure pump curve): ________Bar
5.9 Order Software backup

Checkpoints:
Create a backup of all software that has been changed during commission.
Create a backup of all SW configuration files.
The SW backup shall be returned to technical department.
5.10 Comments and signature:

Comments:
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
Signature:
Location and date: …………………………………………………………………….……………………….
Service Engineer : …………………………………………………………………….……………………….
ULMATEC PYRO AS
6 HARBOUR ACCEPTANCE TEST (HAT)
6.1 Safety Function – temperature switch

Checkpoints:
Set point for the safety temperature switch shall be adjusted to a value below the set
point of the working thermostat switch.
The safety temperature switch will stop the fuel fired heater and the electric heating
element.
The set point of safety temperature switch shall be adjusted to 95 degrees.
Restart is not possible before the water temperature is 15 degrees below the set points
for the safety temperature switch and the sensor is manual reset.
6.2 Safety Function – Flame Control when starting

Checkpoints:
Before starting up, withdraw the photocell from socket (false flame failure). Photocell
shall be kept in dark. Activate electric heating.
Start the oil burner.
Flame ignites.
Power supply shall be cut after a delay of 5 sec.
The "FLAME FAILURE", lights up.
External and internal alarm is issued.
Note: The electric heating element shall still be on.
Refit the photocell in socket and fuel fired heater is restarted by pushing
“Reset Burner Control”.
6.3 Failure modes – Control system

Checkpoints:
Activate the emergency stop and observe fuel oil burner shutdown and external alarm
is activated.
Switch off the protection circuit to the electric heating element and observe that the
internal and external alarm is activated.
Switch off the protection circuit to the burner motor and observe fuel oil burner
shutdown (burner will try to restart) and external alarm is activated.
Switch off the protection circuit to each circulation pump and observe that the internal
and external alarm is activated.
Switch off the protection circuit to the sanitary hot water circulation pump and observe
that the internal and external alarm is activated.
Switch off the protection circuit to each fuel transfer pump and observe that the
internal and external alarm is activated.
Switch off the protection circuit to each fuel heating and observe that the internal and
external alarm is activated.
Increase the limit for low differential pressure over the pump to check that the stand by
pump will start. (The stand by pump will then run for a given time (default 5 hours)).
Check that alarm for low differential pressure is given if all pumps are running and the
differential pressure is still too low.
ULMATEC PYRO AS
6.4 Safety Function – Flame Control when running
Checkpoints:
The heater plant is running at normal working temperature.
Withdraw the photocell from socket (false flame failure).
Photocell shall be kept in dark.
The power supply to the burner shall be cut after a time delay of 5 sec.
The burner tries one restart after a time delay of approx. 2 min
The "FLAME FAILURE", lights up.
External and internal alarm is issued.
Note: The electric heating element shall still be on.
Refit the photocell in socket and fuel fired heater is restarted by pushing
“Reset Burner Control”.
6.5 Safety Function – Water low level safety switch

Checkpoints:
The heater plant is running at normal working temperature.
The set-point of the pressure switch is set 0.2-0.3bar. Water shall be drained off until
the water low level safety switch is tripping the burner.
Alternatively the water level pressure switch could be checked with a pressure pump
on the test- flange connection.
External alarm is issued.
Remove the water low level alarm level to normal value, and the heater restarts.
6.6 Comments and signature:

Comments:
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………….
Signature:
Location and date : ……………………………………………………………….……………………….
Service Engineer : ……………………………………………………………….……………………….
Yard & Customer : ……………………………………………………………….………………………

(Optional)
Classification Society : …………………………………..………………………….……………………….
Ship Owner : ………………………………..…………………………….……………………….

(Optional)
ULMATEC PYRO AS
7 PUNCH LIST
All action that required correction shall be noted in the punch list
Punch Punch Description:
Number
10
ULMATEC PYRO AS

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PYRO Energy Management System

PROJECT SPECIFIC, Piping & Cable Diagram 2

PROJECT SPECIFIC, Internal Wiring & Pneumattic 3

PROJECT SPECIFIC, Approval 5

PRODUCT, Operator Guidelines 9

PRODUCT, Harbour Acceptance Test (HAT)

Section Document name

The document includes following information:

2.1 Office Address

2.2 Mail & Web Address

2.3 Telephone & Fax

2.4 VAT Identification Number

NO 966 300 345 VAT

3.1 Project Specific Information

When order spare parts we need following project specific information:

3.2 Component Specific Information

Additional we need following component specific information:

3.3 Spare Part List

with type designation(s)

is found to comply with

This Certificate is valid until 2016-12-31.

Odd Magne Nesvåg

Form code: TA 1411a Revision: 2014-11 www.dnvgl.com Page 1 of 3

Serie II: Art. E1109, E1110, E1112

Burner controller type Siemens LOA24, LAL 1.25 or LAL 2.25.

Type Approval documentation

Type Approval Periodical Assessment report, DNV Ålesund 2015-01-05.

Form code: TA 1411a Revision: 2014-11 www.dnvgl.com Page 2 of 3

Form code: TA 1411a Revision: 2014-11 www.dnvgl.com Page 3 of 3

This document includes guidelines for:

HAT Harbour Acceptance Test

2 OPERATOR GUIDELINES, PLC CONTROL SYSTEM

The MAIN MENU is used to navigate into the four sub-menu.

• OPERATIONAL INFO MENU

Give an overview of the delivery specific information.

• CONFIGURATION AND SERVICE

o Configuration of the Fuel Fired Heater.

OPERATIONAL INFO MENU

2.2.1 INFORMATION DISPLAYED

- Operation and status indication for each electric heating section:

- Operation and status indication for each circulation pump:

- Operation and status indication for fuel fired heater:

- Operation and status Indication sanitary circulation pump

- Operation and status indication fuel oil transfer pump

- Operation and status indication Fuel oil heating

- Two most recent alarms

2.2.3 PUMPS MAN - AUTO

2.2.4 LOW-TEMP MODE

2.2.5 HIGH-TEMP MODE

Shows the two last alarms,

2.2.6.1 ALARM LIST

Shows help instruction for the actual menu.

Change to MAIN MENU

2.3.1 SETTING LOW / HIGH TEMP MODE

STOP HEATING (Nozzle 1 and Nozzle 2)

2.3.2 SETTING PUMPS

2.3.3 SETTING FOR PUMP PRESSURE ALARMS AND AUTOMATIC

- Put a memory stick into the back of the panel. (Picture 1)

2.3.2 IMPORT USER RECIPES FROM USB MEMORY STICK

- Select the recipe you want to load, and press load.

2.3.4 RESET TO DEFAULT SETTING

Shows help for the actual menu.

Change to MAIN MENU