K600 Hydroheater Manual

K600 Hydroheater®
Product Manual
Revised 7/2021 Version 1.4
Call - (800) 951-0121 Email - info@hydro-thermal.com Visit - www.hydro-thermal.com

H
ydro-Thermal Corporation manufactures all K600 Hydroheaters according to ISO
9001 standards. Printed copies of this document are controlled by the Hydro-
Thermal. Hydro-Thermal maintains a policy of continual product improvement. All
information shown is correct when published, but may change without notice. To request
an official, up-to-date manual, contact Hydro-Thermal Corporation.
Hydroheater is a trademark of Hydro-Thermal Corporation, and is registered in the United

States and abroad. The trademarks and names of other companies and products mentioned
herein are the property of their respective owners. The K600 Hydroheater was developed
by, and is manufactured and sold by Hydro-Thermal Corporation, and is protected by US
and International patents.
Copyright© 2021 Hydro-Thermal Corporation, Wisconsin, USA. All rights reserved.
Hydro-Thermal Corporation
400 Pilot Court
Waukesha, WI 53188 USA
+1.262.548.8900
+1.800.952.0121
f – +1.262.548.8908
http://hydro-thermal.com
info@hydro-thermal.com
All rights reserved.© Hydro-Thermal Corporation 2021

2 K600 Hydroheater® is trademark of Hydro-Thermal Corporation,
and is protected under US and International patents.
K600 1.4
K600 Hydroheater™ Product Manual
PRODUCT MANUAL 1.4
Table of Contents
1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Thank you for your Purchase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Purpose of the Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Principles of Direct Steam Injection (DSI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4 How the K600 Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.5 Model Number Designation, Dimensions, and Capacities. . . . . . . . . . . . . . . . . . . . . . 10
1.5.1 Explanation of Model Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.5.2 Location of Markings on Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.6 Application Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.1 Industries and Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6.2 Sizing Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7 Process and Steam Pressure Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.7.1 Maximum Process Pressure (Heater Discharge). . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7.2 Minimum Process Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.7.3 Superheated Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.7.4 Model Capacities and Heater Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 AUTOPILOT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.1.1 Starch Applications with the Autopilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 K600 Hydroheater with K6 Autopilot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Autopilot Lite: Overview and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4 K600 Hydroheater with K6 Autopilot Lite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.1 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2 Specific Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.1 General Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Hardware Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2.1 Support and Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.3 Recommended Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3.1 Steam Line Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

K600 1.4
4.3.2 Strainer Sizing Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3.3 Condensate and Blow Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.3.4 Discharge Line Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.5 Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.3.6 Utilities and Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4 Instrumentation and Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.1 General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4.2 Components and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.4.3 Typical Control Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4.4 K600 Control Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4.5 Over-Temperature Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Autopilot - Description of Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.5.1 Interconnection to the Air Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.5.2 Interconnecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5.3 Setting the Air Pressure and Operating Speed. . . . . . . . . . . . . . . . . . . . . . . 40
4.5.4 Maintenance of Oiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.5.5 Emergency Operation (Air System Failure). . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6 Autopilot Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6.1 General Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6.2 Description of Control Panel Switches and Displays . . . . . . . . . . . . . . . . . . 42
4.6.3 Alarm Lights (Quick Reference Table). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6.4 K5 Autopilot Panel Alarm Lights and Reset Button. . . . . . . . . . . . . . . . . . . . 44
4.6.5 I/O’s: Discrete and Analog Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.6.6 Control Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.6.7 Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.6.8 Interconnection Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.7 Autopilot Lite Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.1 Recommended Control Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.1.1 Automatic Combining Tube Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.1.2 Manual Combining Tube Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.2 Alarm Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.7.2.1 Overtravel / Undertravel Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.7.2.2 Position Signal Out of Range Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.7.2.3 Reverse Movement / No Movement Alarm. . . . . . . . . . . . . . . . . . . . . 53
4.7.3 Calibration Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.7.4 Filtering Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

K600 1.4
PRODUCT MANUAL 1.4
5 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1.1 Pre-Start Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.1.2 Additional Pre-Start Procedure for Autopilot or Autopilot Lite. . . . . . . . . . . 56
5.1.3 Initial Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.1.4 Additional Initial Startup Procedures for Autopilot or Autopilot Lite . . . . . . 58
5.2 Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.3 Applications with Intermittent Heat Requirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.1 Insufficient Heating Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
6.2 Rough Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.3 Excessive Temperature Variation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1 Recommended Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.2 Wear and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.3 Inventory and Spare Parts Recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.3.1 Anti-Seize Compounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.4 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.5 Complete Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.6 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.7 Rotating the Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.8 Actuator “Bench Set” Procedure (Pre-Installation of Positioner). . . . . . . . . . . . . . . . 93
7.9 Positioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
7.10 Installing and Calibrating a DVC 2000 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.10.1 Mounting Magnet Array for DVC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.10.2 Calibrating a DVC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.11 Installing and Calibrating a DVC 6200 Positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.11.1 Mounting Magnet Array for DVC 6200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.11.2 Calibrating a DVC 6200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
7.12 Calibrating a Fisher DVC 6010 Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
8 K500 TO K600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
9 LIMITED WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

K600 1.4
10 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Appendix A: Steam Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Appendix B: Saturation Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Appendix C: Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Appendix D: Table of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

K600 1.4
PRODUCT MANUAL 1.4
1 GENERAL INFORMATION
1.1 Thank you for your Purchase

Your investment in the Hydro-Thermal® K600 Hydroheater® will bring you years of service for your heating
needs. It is a highly engineered patented steam heating valve designed specifically for your process and
operating conditions.
Hydro-Thermal direct steam injection heaters offer advantages no other heater can. We are confident
you will be pleased with the performance of your heater and the increased efficiency it will bring to your
operation. In fact, we guarantee the Hydroheater will work properly for your specific application and under
the operating conditions you specified. Thank you for choosing a Hydro-Thermal heating solution.
1.2 Purpose of the Manual

Hydro-Thermal direct steam injection heaters are highly engineered products with patented complex and
precisely manufactured internal components. Regular maintenance is essential to keep the heater in peak
operating condition and continue the performance warranty. Please read the maintenance section of this
manual carefully and follow the recommended schedule.
This manual contains information regarding installation, operation, troubleshooting, maintenance,

assembly/disassembly, and spare parts for all models of the K600 Series Hydroheater. It is provided as a
guide for proper and safe operation of the unit.
CAUTION – It is essential to understand the material in this manual for proper operation of the K600.
Failure to follow these recommendations can result in equipment failure, bodily harm, or void the warranty.
NOTE – Material may be subject to change: Hydro-Thermal maintains a policy of continual product
improvement. All information shown is correct when published, but subject to change without notice.
To assist you, Hydro-Thermal offers a variety of comprehensive support programs that include
certification training, advance replacement, on-site maintenance, and total maintenance and repair/
refurbishment packages. Please call toll-free 1-800-952-0121 or +1 (262) 548-8900. You may also
visit www.hydro-thermal.com for more information.

K600 1.4
1.3 Principles of Direct Stream Injection (DSI)
The K600 is a direct steam injection heater that heats fluids or slurries by mixing steam directly with the
product. This method provides rapid steam condensation to transfer heat to the product safely, quickly
and accurately.
Direct steam injection is capable of transferring 100% of the steam’s heat energy, and may be more efficient
and economical than indirect heating methods such as heat exchangers or tank spargers.
In a heat exchanger, the fluid and the steam conduct heat through a steel barrier layer that reduces heat
transfer by as much as 15-30%. Additionally, scale and minerals build up over time producing an insulating
effect that further decreases a heat exchanger’s effectiveness. A heat exchanger also requires more
maintenance and significantly more floor space.
Direct steam injection introduces steam directly into the product, resulting in a nearly instantaneous
change in temperature. All of the sensible and latent heat energy of the steam is absorbed into the
product, reducing actual steam usage. This efficient use of energy, along with precise temperature control,
allows for maximum performance and reduced operating costs. Actual energy savings could be up to 30%
over heat exchangers or sparging.
Direct steam injection does not require a complicated condensate return system, and since the K600 is
internally modulated, there is no requirement for an external steam control valve. For these two reasons,
and the simple system requirements detailed in 4.0 Installation, the K600 is easy to implement and
provides an enhanced cost benefit.

K600 1.4
PRODUCT MANUAL 1.4
1.4 How the K600 Works

Please reference Figure 1 below. The K600 is an internally modulated steam injector with a 90 degree
fluid flow design favorable for slurries that require high shear heating, applications with high changes in
temperature, turbulent mixing, and self cleaning for products that cause burn-on.
A liquid or slurry enters into the combining tube (CT) where steam is introduced into the fluid. Steam is
modulated by a stem/plug, through a nozzle and discharged into the liquid or slurry. The nozzle discharges
steam at very high, often sonic velocity. The turbulent nature of this high velocity discharge enables steam
to instantaneously penetrate, disperse, efficiently mix and condense with the liquid or slurry to produce
uniform heating. Temperature is measured downstream and feedback is sent to a controller. The controller
modulates steam flow by sending a signal to an actuator directly linked to the stem/plug. The actuator
opens and closes accordingly to achieve a target temperature.
The unit is designed such that steam pressure and steam velocity remain constant throughout the range of
operation, regardless of the amount of steam being added. The high velocity of the steam plug prevents
burn on while creating a turbulent interface between the product and steam. This interface causes
atomized steam to mix with the product and quickly condense, thereby transferring the heat rapidly and in
a controlled manner.
Steam Inlet
Sonic Velocity Steam Jet
Discharge
Nozzle
Slurry Inlet
Figure 1: How the K600 Hydroheater Works

K600 1.4
1.5 Model Number Designation, Dimensions, and Capabilities
1.5.1 Explanation of Model Numbers
The last two digits of the model number indicate the size of the Hydroheater.
Table 1: Explanation of Model Numbers

Model Connection in Inches [mm] Discharge in Inches [mm]
K610 2.5 inches [64 mm] 2.0 inches [51 mm]
1.5.2 Location of Markings on Body

Figure 2 shows the location on the body of the serial number and nameplate. Note that the nameplate
is in different locations for different size heaters. The nameplate contains model number, serial number,
material, year, pressure rating and temperature rating. The serial number is also stamped on the steam
inlet of the body.
The serial number (a 5 or 6 digit number) is unique to each Hydroheater unit manufactured. The code
(i.e. 123456) is listed on the unit, the purchase order, as well as on supporting documentation from
Hydro-Thermal Corporation. This serial number is crucial for ordering additional units, spare parts, and
accessories. Please refer to this serial number whenever contacting Hydro-Thermal Corporation.
Body Serial Number
Nameplate
Figure 2: Location of Markings on Body

K600 1.4
PRODUCT MANUAL 1.4
1.6 Application Criteria

1.6.1 Industries and Products
The K600 Hydroheater is a versatile direct steam heater that can be used to replace heat exchangers and/
or spargers in many situations. These heaters fit into industrial sustainability initiatives by using less water,
all of the steam’s energy and they heat precisely using up to 30% less energy than other traditional fluid
heating devices. Below is a partial list of applications for the K600 Hydroheater.
Table 2: Application Examples for the K600 Hydroheater

Industry Product of Process
Process Starch
Ethanol Industrial Mash
Slurry Starch
Size Press Starch Dilution
Size Press Starch Dilution
Size Press (Dry End) Starch Cooking
Industrial Coating Starch Cooking
Industrial Cationic (Wet-End) Starch Cooking
Pulp & Paper Process Slurry PVOH
Process Pulp Stock
Brine Dilution
Black or Other Heavy Liquor Heating
Green Liquor Heating
Whitewater Heating
Process Chemical Slurry
Chemical/ Jacketed Kettle Heating
Pharmaceutical Bio-Kill
Fermentation, Culture Growing
MSG - Mono-Sodium Glutamate
Cooking In-Line Soy Products
Cooking In-Line Sauces, BBQ, Tomato,
Ketchup, Mayonnaise, Etc
Cooking In-Line Dog Food
Food & Cooking In-Line Cheese
Beverage Cooking In-Line Baby Food
Cooking In-Line Juice
Food Related (thickening), Malt dextrin,
Fructose, Confectionery
Tapioca Processing
Dairy
Grain Processing
Multiple Water Heating

K600 1.4
1.6.2 Sizing Consideration
NOTE – For accurate sizing contact a Hydro-Thermal Representative

There are many factors to consider when choosing the specific size of a heater body and the internal
components. Please note that a given body has a wide range of possible internals.
First, product flow rates, both now and in the future, should be considered to optimize performance.
However, it is important to select internals for the current conditions. If higher flows are required in the
future, they may be achievable by replacing the internals. Over sizing the components today, for possible
increased future capacity, may result in poor temperature control. Please see 6.0 Troubleshooting for more
details.
Second, heating capacity needs should be clearly defined for the full range of expected process
conditions—both process flow and temperature rise requirements.
The range of flow (steam or liquid) is called the system turndown, defined as the ratio of the maximum and
minimum flow rates.
Sizing Example 1: A system with a maximum liquid flow of 600 GPM [136 m3/h] and a minimum flow of
200 GPM [45 m3/h] will have a liquid turndown of 600/200 = 3:1.
Steam turndown is a function of both liquid turndown and a variance in discharge temperature.
Sizing Example 2: The system in Example 1 uses a K600 Hydroheater® to raise the temperature of river
water to 120° F [49°C]. In the winter, the river water is 40°F [4.4°C], so the K600 heats the water 80°F [27°C].
However, in the summer the river water is now 80°F [27°C], so the K600 only heats the water 40°F [4.4°C].
The resulting steam turndown at any given flow rate is 2:1. Further, because the system flow rate also has a
turndown ratio of 3:1, the total steam turndown for the system is 6:1.
Continuous systems with steam and liquid turndown ratios less than 2:1 typically require only simple control
schemes. As the turndown ratios increase, systems need more sophisticated instrumentation and control
schemes.
The heater internals are typically sized to operate between 20-80% valve position. In general 20% minimum
opening is necessary for accurate temperature control and for robust product reliability. Sizing to 80%
capacity allows for variations in process conditions and some additional capacity.
1.7 Process and Steam Pressure Requirements

For stable operation, a correct relationship between steam and process pressure is needed.
Please note that the pressures stated are those immediately at the heater during operation. For example,
steam pressure should be measured near the inlet flange of the heater, because extended lengths of
piping, elbows or valves would result in lower steam pressure at the heater inlet. Process pressure should
be measured near the heater discharge for the same reasons.

K600 1.4
PRODUCT MANUAL 1.4
1.7.1 Maximum Process Pressure (Heater Discharge)

In order to maintain stable flow conditions, the absolute pressure ratio of water to steam should not exceed
0.6. Table 3 shows a number of common steam pressures and each respective maximum allowable water
pressure.
Table 3: Maximum Water Pressure
Steam Max Water Steam Max Water

Pressure (psig) Pressure (psig) Pressure Pressure
20 6 [Bar (g)] [Bar (g)]
30 12 1.5 0.5
40 18 2.0 0.8
50 24 2.5 1.1
60 30 3.0 1.4
70 36 4.0 2.0
80 42 5.0 2.6
90 48 6.0 3.2
100 54 7.0 3.8
110 60 8.0 4.4
120 66 9.0 5.0
130 72 10.0 5.6
140 78
150 84
Table 3 follows a linear relationship and may be interpolated or extrapolated to approximate your specific
flow conditions. For more tailored, accurate and complete sizing, please contact your Hydro-Thermal
representative at info@hydro-thermal.com or (262) 548-8900

K600 1.4
1.7.2 Minimum Process Pressure
For a given discharge temperature, the water discharge pressure should be maintained at 5 psi [0.3 Bar]
above the saturation pressure. Table 4 shows the minimum allowable discharge pressure for a range of
temperatures. For a more complete table and curve, please see Appendix A: Steam Table and Appendix
B: Saturation Table. As a general guideline, for high temperature applications, over 250°F [121°C] or high
temperature differential, over 100°F [38°C], please contact Hydro-Thermal at (262) 548-8900 to discuss this
with one of our Applications Engineers.
Table 4: Min Water Discharge Pressure
Water Pressure Min Water Water Pressure Min Water

(Fº) Pressure (psig) (Cº) Pressure Bar (g)
210 5 100 0.34
212 5 105 0.54
220 7 110 0.76
230 11 115 1.02
240 15 120 1.32
250 20 125 1.65
260 26 130 2.03
270 32 135 2.46
280 39 140 2.94
290 48
300 57
310 68
320 80
330 93
Example:
Heating to 250˚F [121°C]
Steam Pressure: 110 psig [7.6 Barg]
Result:
Maximum Water Discharge Pressure: 60.1 psig [4.15 Barg]
Saturation Pressure at 250˚F [121°C]: 15.1 psig [1.0 Barg]
Minimum Water Discharge Pressure: 20.1 psig [1.4 Barg]

K600 1.4
PRODUCT MANUAL 1.4
1.7.3 Superheated Steam

Superheated steam should be a maximum of 50°F [28°C] above saturation temperature to assure smooth
condensation. For superheat temperatures in excess of 50°F [28°C], please contact Hydro-Thermal for
more detailed analysis.
Minimal Removal
“E”
Clearance B
K
Steam
Inlet
“G” Discharge
C
H
D
“F” Liquid Inlet A
J
Figure 3: Dimensions of K600 Hydroheater
1.7.4 Model Capacities and Heater Sizes

Table 5: K600 Dimensions
A B C D E, F G H J K
Model
in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm) in (cm)
13.19 17.31 5.00 5.00 2.50 2.00 16.00 45.00 4.00
K610
(33.50) (43.97) (12.70) (12.70) (6.35) (5.08) (40.64) (114.30) (10.16)
16.00 21.13 6.00 6.00 3.00 2.00 16.00 55.75 4.00
K611
(40.64) (53.67) (15.24) (15.24) (7.62) (5.08) (40.64) (141.61) (10.16)
16.00 21.13 6.00 6.00 3.00 2.50 16.00 55.75 6.00
K612
(40.64) (53.67) (15.24) (15.24) (7.62) (6.23) (40.64) (141.61) (15.24)
15.38 22.38 7.56 7.56 4.00 4.00 18.63 58.38 6.00
K613
(39.07) (56.85) (19.20) (19.20) (10.16) (10.16) (47.32) (148.29) (15.24)
19.50 29.50 8.88 8.88 6.00 6.00 21.13 73.13 8.00
K614
(49.53) (74.93) (22.56) (22.56) (15.24) (15.24) (53.67) (185.75) (20.32)
25.00 37.00 10.75 10.75 8.00 8.00 21.13 82.13 8.00
K615
(63.50) (93.98) (27.31) (27.31) (20.32) (20.32) (53.67) (208.61) (20.32)
38.13 52.13 12.56 10.69 10.00 10.00 21.13 102.00 9.00
K616
(96.85) (132.41) (31.90) (27.15) (25.40) (25.40) (53.67) (259.08) (22.86)
NOTE – Dimensions shown are for K600 Hydroheaters with 150# ANSI flanges and should be used for
reference only. For construction purposes, contact Hydro-Thermal directly.

K600 1.4
Table 6: Approximate Weight and
General Flow Rate Capacities
Approximate Flow Rate
Model Weight
lbs (kg) gpm (ma/h)
K610 175 (79) 28-174 (6.5-40)
K611 297 (135) 40-402 (9-91)
K612 305 (138) 40-402 (9-91)
K613 447 (203) 120-750 (27-170)
K614 704 (319) 300-1800 (68-409)
K615 934 (424) 400-2500 (91-568)
K616 1350 (612) 625-3900 (142-886)
NOTE – For accurate sizing contact a Hydro-Thermal Representative. Internals are specifically sized
for the process conditions provided at the time of sale. Guidelines vary for different fluids & process
conditions.

K600 1.4
PRODUCT MANUAL 1.4
2 AUTOPILOT
2.1 Introduction
The Hydro-Thermal K6 Autopilot® is an optional feature of the K600 Hydroheater® that will optimize
performance and reduce manual operation. It is a highly engineered device that is designed specifically to
improve your plant’s operation.
With a standard CTA, all adjustments needed for your heater to achieve the desired Differential Pressure
(DP) are done manually by turning the adjustment nut on the CTA. This will open and close the Combining
Tube (CT) and thus increase or decrease your DP. An Autopilot system performs this automatically by
monitoring the slurry pressure before and after the heater. Changes are made to the position of the
CT based on measured differential pressure (DP) and compared to the set point DP. The result of this
is a constant and more accurate DP across the heater. In addition to this, there is a safety benefit of
not requiring personnel to make manual CTA changes while in operation and therefore eliminating the
possibility of burns caused by skin contact with the heater and associated hot surfaces.
2.1.1 Starch Applications with the Autopilot

Pressure differential is a key factor in obtaining optimal starch hydrolysis. Proper adjustment of the
combining tube will result in optimal shear, so that starch is completely hydrolyzed, even under varying
process conditions.
Start-up of the K6 Autopilot should be done in manual mode. See instructions in section 5.0 Operation
for details.
Optimization trials can be performed by varying differential pressure, while controlling other plant variables
such as flow, slurry temperature, pH, and enzyme dosing. Many plants have found that a differential
pressure of 40 psi provides for thorough conversion without excessive pump requirements. Others have
found higher or lower differential pressure to be advantageous.

K600 1.4
2.2 K600 Hydroheater with K6 Autopilot
This configuration includes the components needed for operation of the K6 Autopilot system, when
automation and control logic for the K6 Autopilot is provided by Hydro-Thermal. The system components
are:
• Control Panel: A Programmable Logic Controller (PLC)-based controller which is pre-programmed
to maintain set point differential pressure, provided in a pre-wired control panel with operating
switches, alarm indicators and displays. Integration to plant DCS is required.
• Mechanical Drive: Includes drive system with Air Motor and gear reducer assembly used to supply
the operating force to open and close the combining tube. The drive is pre-mounted to the CTA
Assembly.
• Pneumatic Air Set: Provides air control for the mechanical drive to open/close the combining tube,
as well as filtration and oiling.
• Position Sensor: Sends signal back to the PLC indicating its position
• Interconnecting Cables
• Air Set to Control Panel: 2 Cables
• Position Sensor to Control Panel: 1 Cable
• Automatic CTA Assembly: To mount the mechanical drive, the automatic version of the CTA
assembly is needed. No modification to the K600 Hydroheater is required.
See the photo below with the components identified.
Pneumatic Air Set

Control Panel
CTA Assembly Air Motor
Positioner Sensor Gear Reducer
Figure 4: K6 Autopilot

K600 1.4
PRODUCT MANUAL 1.4
2.3 Autopilot Lite – Overview and Cautions

The K6 Autopilot™ is an option for the K600 series Hydroheaters, designed to automatically adjust the
position of the combining tube to maintain a constant differential pressure (DP) across the Hydroheater®.
The Autopilot Lite version uses the same mechanical components as the standard Autopilot system with
the exception of the PLC and control panel.
The Hydro-Thermal Autopilot Lite scope of delivery includes the following elements:
• Air motor for combining tube (CT) adjustment
• Pneumatic panel comprising of solenoids for CT open/close movement and air enable
• Bracket with linear position sensor
• Interconnection cables for linear position sensor and solenoids
The K6 Autopilot Lite is provided without a control panel requiring the control logic to carry out the control
functions, alarms as well as safety measures to reside in the plant DCS.
This document provides information to:
• Caution users so that the Hydroheater is not damaged
• Clarify the I/O requirements
• Recommend control logic
CAUTION – Failure to program over travel protection may result in damage of the Hydroheater internals.
It is the full responsibility of the user to verify that the combining tube will not be forced to close or open
beyond the minimum and maximum opening positions. A linear position sensor (4-20mA) is supplied in
order to provide position feedback to the DCS. However calibration of zero point and span as well as
travel limiting logic has to be programmed in the DCS by the user. Hydro-Thermal Corporation assumes no
responsibility for damage to the Hydroheater caused by over travel.

K600 1.4
2.4 K600 Hydroheater with K6 Autopilot Lite
For plants that prefer to incorporate the K6 Autopilot control logic within their DCS, Hydro-Thermal offers
the K6 Autopilot Lite. This configuration includes the components needed for mechanical operation of the
K6 Autopilot system when interfacing the controls to the plant DCS.
The system components are:

• Mechanical Drive: Includes drive system with Air Motor and gear reducer assembly used to supply
the operating force to open and close the combining tube.
• Pneumatic Air Set: Provides air control for the mechanical drive to open/close the combining tube,
as well as filtration and oiling.
• Position Sensor: Sends signal back to the PLC indicating its position
• Interconnecting Cables
• Air Set to Control Panel: 2 Cables
• Position Sensor to Control Panel: 1 Cable
• Automatic CTA Assembly
NOTE – The manual CTA cannot be integrated into the autopilot.

See the photo below with the components identified.
Pneumatic Air Set
CTA Assembly Air Motor

Positioner Sensor Gear Reducer
Figure 5: Autopilot Lite

K600 1.4
PRODUCT MANUAL 1.4
3 SAFETY PRECAUTIONS
3.1 General Safety

It is the owners’ and installers’ responsibility that the installation conforms to all applicable local, state,
regional and federal codes and standards. Accommodation should be made for compliance with further
regulations relating to specific industries.
Complete systems incorporating a K600 should be designed to meet or exceed the temperature, pressure
and flow ratings as specified under the DESIGN CONDITIONS on the EQUIPMENT SPECIFICATIONS sheet
provided with the original quotation. Installation of single or double action Back Flow Preventer and/or
Vacuum Breakers when connected to a potable water supply may be necessary.
The K600 is not designed to provide tight shutoff of steam flow. If the heater or its associated piping is to
be disassembled in any way, the steam supply should be isolated from the K600 by closing a steam shutoff
valve located on the steam line upstream of the K600.
If the process requirements exceed this limit, contact Hydro-Thermal technical service at 1-800-952-0121 or
+1 (262) 548-8900.
The following symbols will be used throughout this manual. The basic definitions are listed below:
WARNING – This warning symbol means danger. You are in a situation that could cause bodily injury.
Before you work on any equipment, be aware of the hazards involved with electrical circuitry and be
familiar with standard practices for preventing accidents.
CAUTION – This caution symbol means reader be careful. You are capable of doing something that
might result in equipment damage or bodily injury.
3.2 Specific Safety

WARNING – If the K600 or its associated piping is to be disassembled, the steam supply should be
isolated from the unit by closing a steam shutoff valve located on the steam line upstream of the unit.
Follow Lockout/Tagout procedures.
WARNING – The K600 is capable of heating water to very high temperatures. Access to extreme water
temperatures and flash steam is a possibility. To avoid serious injury, use extreme care and wear protective
gloves, garments and safety glasses at all times.
WARNING – Do not use the K600 with steam that exceeds the temperature and pressure rating of the
unit.
WARNING – Use of copied or modified parts could result in deviation of the pressure vessel resulting in
code violation and personal injury. Do not substitute any component parts of the assembly. Use only factory
produced Hydro-Thermal genuine parts. Order through your Hydro-Thermal Representative or email: info@
hydro-thermal.com. Factory leads time apply.

K600 1.4
CAUTION – To ensure stable operation of the K600, steam will be injected at full pressure. For correct
operation of the K600, refer to section 1.7 Process and Steam Pressure Requirements.
CAUTION – Read and understand all instructions before operating the K600. The K600 must only
be operated by persons trained in its installation, operation, and maintenance. Hydro-Thermal offers
maintenance and operations training for your plant personnel. Inquire to info@hydro-thermal.com
CAUTION – Always keep hands and fingers clear of moving parts and pinch points as the Actuator
operates. Always wear protective clothing, gloves, and eyewear when working with steam.
CAUTION – Only use K600 for the intended purpose of heating appropriate liquids and slurries.
CAUTION – If you require assistance, or if your K600 cannot be installed in accordance with these
recommendations, please contact Hydro-Thermal Technical Service, toll-free at 1-800-952-0121 or
+1 (262) 548-8900 or info@hydro-thermal.com.
CAUTION – In high temperature applications (above 212°F [100°C]), the back pressure required to
prevent flashing should be at least 5 psi [0.3 bar] higher than the saturation pressure given in Appendix A:
Steam Table. Both the steam and the water supply pressures must be constant for the heating systems to
operate with a uniform discharge temperature.

K600 1.4
PRODUCT MANUAL 1.4
4 INSTALLATION
4.1 General Installation

Installation of the K600 requires American Society of Mechanical Engineers (ASME) or equivalent
applicable codes for piping systems. The K600 can be mounted in any position. However for best
operation, it is recommended that the heater be mounted with the steam line horizontal, or entering from
above, leading directly into the heater as depicted in Figure 6. This preferred orientation will minimize
backfilling (“dead-legs”) in the steam line simplifying purging of condensate at start-up. If the K600 must
be mounted vertically, the discharge should be orientated downward.
CAUTION – If the K600 is mounted with the actuator below the heater, leakage from the assembly may
cause the steel actuator to corrode and fail unexpectedly.
To provide sturdiness, pipes should have a minimum wall thickness according to ASTM standard
A53 grade B schedule 40, or equivalent, for at least 10 pipe diameters to the inlet and 40 pipe
diameters at the discharge.
CAUTION – If your K600 cannot be installed in accordance with these recommendations,

please contact Hydro-Thermal Technical service for assistance.

K600 1.4
4.2 Hardware Requirements
4.2.1 Support and Mounting
Piping surrounding the K600 should be adequately mounted, yet allow for thermal expansion. A possible
rigid mounting configuration is shown in Figure 6 below.
CAUTION – The K600, like any fluid heating device, must be properly secured with rigid support for
process instability conditions.
WARNING – The customer is responsible for adequately supporting the K600/ piping system in
accordance with ASME B31.1 (Power Piping Code) and ASME B31.3 (Process Piping Code) while
minimizing external loading to K600 flange connections.
Pipe Supports
Support
from
Bottom
Figure 6: Support Diagram

K600 1.4
PRODUCT MANUAL 1.4
4.3 Recommended Installation

See Figure 7 and Figure 8
Installation Notes:
1. Recommended straight lengths of pipe without directional or size change:
Inlet- 3 pipe diameters minimum

Discharge- 10 pipe diameters minimum
2. Temperature sensor should be located 20-40 pipe diameters from the heater discharge
(process parameters may influence exact locations).
3. For units 8” and above (K615 and larger) a steam warm-up valve (as shown on Figure 8) may be
recommended. Contact Hydro-Thermal Customer Service for further information.
4. Control system should verify process flow before permitting Auto On/Off Steam Valve to open,
either through Flow Switch shown or another method.
5. Abrupt flow variations can cause temperature swings. The control system designer should allow for
transient conditions and tune the temperature loop accordingly. If water flow is shut off quickly the
heater should be closed and Auto On/Off steam valve should be disabled.
6. See sizing sheet for maximum discharge pressure. Pressure gauges should be installed for verification.
7. Steam check valve should be located 3-5 pipe diameters upstream from the heater.
8. Hydroheater can be oriented in any position, however, the preferred orientation is with steam entering
horizontally or if not, then from above. Steam lines entering from below the unit could result in
condensate slugging and possible damage. For larger units (typically 4” and above) the Hydroheater is
best supported horizontally.
9. Steam line between the Auto On/Off steam valve and the heater should slope downward towards the
heater.
10. Check valve at process inlet may not be required for all fluids or system configurations.
11. Isolation valves should be provided on each side of the Hydroheater for maintenance purposes.
12. Steam strainer to have maximum screen size noted in 4.3.2 Strainer Sizing Table.
13. All piping, including downstream components, should be rated for the full supply steam pressure or
have an adequate safety relief.
14. For further details call Hydro-Thermal Customer Service at 800-952-0121 or

email info@hydro-thermal.com.

K600 1.4
Steam Line
Isolation Valve
Steam Header Steam Strainer

Pressure Gauge
Auto On/Off
Drip Leg Steam Valve
Manual Valve
Pro Pressure Check Valve
ces
sD Gauge
isch
arg
e
Pro Steam
ces
s In Trap
let
To Drain
Positioner
(Optional)
Isolation Pneumatic
Valve Actuator
Flow Temp Check
Switch Sensor Valve Pressure
Gauge Hydroheater
Figure 7: Piping Configuration

K600 1.4
PRODUCT MANUAL 1.4
Steam
Header
Steam Auto On/Off

Strainer Steam Valve
Warm - Up Process
Valve Hydroheater
Inlet
Drip Leg & Trap

Process
Discharge
Figure 8: Process Diagram

K600 1.4
4.3.1 Steam Line Requirements
Typically, the steam branch line is constructed of carbon
steel, but can be substituted with stainless steel based on the
application. The flange rating of the steam should be based on
the pressure of the system and ASME, or other international
code governing bodies, as well as local codes.
Steam
The steam branch line should be sized for allowable pressure Main
drop and velocities. This is generally the same size, or a pipe size
larger, than the heater steam inlet flange. The steam line should Branch Line
be sized to provide the pressure and capacity required at the
heater during operation. The steam line should be engineered
to minimize the number of bends and flow interruptions leading
to the steam heater.
Steam branch connections should connect to the top Figure 9: Line Connections
of the steam main, rather than the side or bottom to
avoid condensate and debris which will adversely affect
equipment performance.
The shutoff valves or warm-up valve should be opened slowly

to allow any existing condensate to flow through the drain traps
before high velocity steam is introduced. This is especially
important at a cold start-up.
The steam line must also include a check valve immediately

upstream of the heater to prevent backflow. The shutoff valve
should be automated to close when flow is not sensed.
CAUTION – It is necessary to install a properly rated shutoff

valve on the steam inlet piping to the K600. The heater does
not meet class IV shutoff guidelines.
A pressure gauge should be installed downstream of the check

valve. It is necessary to read this pressure in order to properly
adjust the heating system.
4.3.2 Strainer Sizing Table

In keeping with good piping practice, install a steam strainer in the supply line to prevent any rust or scale
from entering the Hydroheater and downstream piping.
Table 7: Strainer Sizing Table

Model Max Screen Size
K610, K611, K612 3/64” Perf
K613, K614, K615, K616 1/8” Perf

K600 1.4
PRODUCT MANUAL 1.4
4.3.3 Condensate and Blow Down

The Hydroheater requires dry steam to operate, therefore adequate condensate removal through steam
traps and drip legs is essential to eliminate rough operation.
A steam trap and drip leg with blow down valve should be installed on the steam inlet piping, upstream
of the check valve. Steam piping should be blown down after any extended shutdown to ensure all
condensate has been purged from the steam line. Install a trap in the steam supply line close to the
Hydroheater to remove any condensate before it can cause noise and vibration in the Hydroheater.
Refer to Figure 10.
Steam
Main
To Steam Main To
Hydroheater Hydroheater
Min. Dia - See Text Min. Dia - See Text

Min. 18” Min. 18”
Drip Drip
Pocket Pocket
Preferred Installation Alternative Installation
Figure 10: Drip Leg Installation
CAUTION – Steam and water exiting a trap or blow down valve is very hot and may cause severe burns.
Adequate personal protection should be used by all personnel.
To help avoid water hammer, steam lines should be installed with a gradual fall in the direction of flow, and
with drain points installed at low points and at regular intervals. Check valves should be installed after all
steam traps. If they are not, condensate could run back into the steam line or plant during shutdown.
Drip leg diameter should be equal to the steam line diameter for 2-inch to 6-inch [50-150 mm] diameter
steam lines. For 8-inch [203 mm] diameter steam lines or larger, the drip leg diameter should be one pipe
size smaller than the steam line diameter.
Drip leg length should be 18 inches [457 mm] or greater for pocket length, with a blow-off valve at the end
of the drip pocket. Allow 3 inches [75 mm] or more off the bottom of the connection for the drain line to the
steam traps. (See Figure 10).
NOTE – Proper steam trapping will ensure dry steam and smooth operation.

K600 1.4
4.3.4 Discharge Line Requirements
The piping diameter at the heater discharge should remain unchanged for at least ten pipe diameters
from the heater flange to ensure good flow conditions.
Bends, elbows, and tees must not occur for at least ten pipe diameters downstream of the K600.
Thereafter, piping bends should be minimized, large radius bends should be used, and gradual, concentric
pipe size transitions should be used because these disturbances typically propagate steam flashing and
process instability. When processing slurries that increase viscosity with heating, a 50% pipe size gradual
increase should occur every ten pipe diameters, for three consecutive segments.
Discharge piping should be designed using Schedule 40 minimum for at least 40 pipe diameters to
accommodate potential erosion.
An isolation valve, for maintenance needs, should be located a minimum of 40 pipe diameters downstream
of the K600 to minimize the flow disturbances.
A temperature sensor should be located 20 to 40 pipe diameters downstream of the K600 to provide
fast temperature response, yet protect the element from steam damage.
A liquid pressure gauge should be installed 20 to 40 pipe diameters downstream of the K600 to properly
adjust and troubleshoot the system.
If the K600 discharges to atmospheric pressure (e.g. into a tank or open vessel), the piping should be
arranged to assure the system piping is flooded at all times.
A flow control valve can be located in the discharge piping; however, it is important that the discharge
pressure does not exceed the limits given in 1.7 Process and Steam Pressure Requirements.
Consideration should be given to control temperature above 212°F [100°C] with a back pressure valve
and proper safety precautions.
4.3.5 Insulation
It is essential to insulate system piping to minimize energy loss and workplace safety. Every surface over
120°F [49°C] should be insulated including the steam leg and K600, and if applicable the product inlet leg
and discharge leg.
CAUTION – The steam branch line will exceed 212°F [100°C], therefore safety precautions must be
followed by properly insulating.
Insulation that has been damaged will also contribute to loss of efficiency, and should be promptly repaired
or replaced. Wet insulation damage can be avoided by investigating and eliminating leaks from valves,
flange connections, or adjacent equipment.

K600 1.4
PRODUCT MANUAL 1.4
4.3.6 Utilities and Environmental Requirements

Use either 1/4-inch [6.35 mm] pipe or 3/8-inch [9.53 mm] tubing between the air supply, the positioner,
and actuator. Keep the length of tubing as short as possible to avoid transmission lag in the control signal.
NOTE – Air supply must be clean, dry, and of instrument air quality. Use filters and separators as
necessary to remove condensation. At start-up, air lines should be purged of condensation prior
to final connection.
When the actuator is completely installed and connected to the instrument, check for correct action,
air-to-open, to match the controlling instrument.
Typical Requirements:
Maximum Air Supply Pressure 75 psig [5.17 Barg]
Minimum Air Supply Pressure 40 psig [2.76 Barg]
Air pressure requirements and air volume requirements vary dependent upon actuator sizing and usage.
Typical air consumption varies between 0.8 scfm (small units) to 7 scfm (large units). For further air
requirements, refer to the associated actuator and positioner instruction manual.
The standard actuator temperature is rated at -40 to 180°F [-40 to 82°C].
4.4 Instrumentation and Controls

CAUTION - Proper control mechanisms should be considered and incorporated.
The instrumentation and controls necessary to properly operate the K600 are application-specific;
however, various components are utilized in most applications. The following sections describe typical
instrumentation and controls.
4.4.1 General Overview

K600 units are typically controlled by a single loop temperature control system, based on heater discharge
temperature. A temperature sensor at the heater discharge is used as the input to a loop controller. The
loop controller output manages the K600 position, metering flow into the process to maintain the set point
temperature.
Discrete inputs to enable or disable operation can be based on various operating criterion; for example,
flow rate within a given range, temperature not exceeding an alarm, remote or local control chosen and
others.
Various systems components are utilized for measurement and control. These devices are best supplied
as a system by Hydro-Thermal Corporation because the function, interaction, and benefits have been
optimized over years of experience in thousands of applications.

K600 1.4
For example, the standard control system includes a flow sensor, temperature sensors (for the heater inlet
and discharge), a 4-20mA control, and automatic on/off steam valve control, and recirculation pump.
Steam flow is internally modulated in the Hydroheater using a diaphragm type, air-to-open, spring return
actuator. It receives a control air signal (3-15 psig or 6-30 psig) [0.21 – 1.03 Barg or 0.41 – 2.07 Barg] typically
to modulate its position. It is recommended that a positioner be used with the actuator. Positioner options
include pneumatic, electro-pneumatic (4-20 mA) with various communications protocols and levels of
diagnostics. Selection of the positioner depends on the response time, actuator size, and other factors.
Refer to the Operations Manual of the positioner from the manufacturer or vendor for further details of
product features and capabilities, as well as operations and maintenance information.
4.4.2 Components and Functions

CAUTION – The temperature sensor should be installed without a thermowell (unless necessary) on the
discharge line at a distance of 10-20 pipe diameters from the K600 discharge flange. The location and type
of temperature sensor should be selected to minimize the time required to sense and accurately transmit
the process temperature. If using a thermowell, it is recommended that a spring-loaded sensor be utilized,
in conjunction with thermal conductive heat transfer paste to improve temperature reading response.
The K600 control has virtually no lag time (i.e. discharge temperature is solely dependent on heater plug
position). As a result, it is quite possible to overheat and flash the process fluid if the controller response
significantly lags behind the actual process temperature.
Steam Inlet Isolation Valve

A manual or automatic valve which provides for steam isolation. As noted previously, the K600 is not rated
as a tight shutoff valve. An automatic version consists of the valve body and air actuator.
Flow Sensor
This sensor detects the flow/no flow condition of the process fluid to enable/disable steam supply for
heating. Dependent on the flow sensor type, flow threshold and response time has to be adjusted during
commissioning for the flow conditions of the respective installation.
Temperature Sensor
This device measures water temperature and transmits the signal to the digital loop controller. This is
typically a Thermocouple or RTD. The heater discharge sensor provides the process variable (PV) for the
heating PID loop control.
Digital Loop Controller

This controller receives the process temperature signal, compares it to the programmed temperature
set-point, and uses a PID algorithm to respond with a control output signal (4-20mA) to the Hydroheater,
modulating stem position (thus steam flow) to maintain the desired process temperature. The controller
is generally 2-mode (Proportional/Integral). A 3-mode (Proportional/Integral/Derivative) controller may be
used, but generally the derivative function is set to zero because the heater responds so quickly. A single-
mode (Proportional only) is only recommended for very stable systems with small flow rate or temperature
variations or when temperature control is not important.

K600 1.4
PRODUCT MANUAL 1.4
Positioner
An electro-pneumatic device converts a 4-20mA control signal from the loop controller into the pneumatic
signal (3-15 psig or 6-30 psig) [0.21 – 1.03 Barg or 0.41 – 2.07 Barg]. This pneumatic signal controls the
position of the heater actuator and subsequently the steam flow. A positioner is essential to precisely
control temperature, for rapid response time applications and when valve position feedback is needed.
Pressure Gauges
Should be installed on all three connection lines to the K600. The gauges should be installed between any
valves, reducers, etc. and the heater to assure the gauge pressure is equal to the pressure at the K600.
It is important to install gauge cocks on each pressure tap to isolate the gauge from the process when
measurements are not required. If the process fluid is slurry or contains suspended solids, a diaphragm
sealed gauge should be used to reduce the probability of plugging. Fluid filled gauges are recommended
and should have a siphon installed when in a steam line.
4.4.3 Typical Control Logic

CAUTION – The control system should verify process flow before permitting the steam valve to open.
This can be accomplished by a flow switch or some other method.
CAUTION – Inlet pressure must not exceed the figures in 1.7 Process and Steam Pressure Requirements
The K600 heater can be enabled when specific operating criterion is met. These criterion are application-
specific, but can include the following:
• The operator enables heater operation, either in manual or automatic mode
• Process flow through the heater is verified
• Temperature does not exceed a high temperature set-point
• There is a call for heat
Once the operating criteria have been met, the heater will begin controlling to maintain temperature.
If the operating criterion is not met, the heater should be disabled.
Several examples follow:

• If loss of flow is detected, the system should rapidly close the steam shutoff valve and close the
K600 heater.
• If a high temperature alarm is detected, the system should rapidly close the steam shutoff valve and
close the K600 heater.
The operator chooses to shut the unit off. In this case, the shutdown sequence described later in the
section should be followed.

K600 1.4
4.4.4 K600 Control Characteristics
The K600 is a precise and repeatable temperature control device. Successful operation of the K600 is
dependent upon the design, installation, and tuning of its instrumentation loop.
The K600 has been designed for specific process conditions and needs to be operated within these
circumstances in order to assure smooth operation. If the conditions vary from those listed in the
specification sheet, contact Hydro-Thermal Customer Service for assistance. See Figure 11 below for a
typical K600 system temperature profile.
Hydroheater Response
300 150
250
Temperature
200 100
% Open
150
100 50
50
0 0
0
0
0
0
110
20
50
60
90
80
30
40
70
10
0
10
12
15
16
13
14
Time
Tactual
Figure 11: Typical K600 Response Time T Measured
% Open
4.4.5 Over-Temperature Protection

To minimize the chance of overshoot or flashing in the discharge piping upon startup, an interlock should
be provided to close both the K600 actuator and the upstream automatic steam block valve if there is no
liquid flow through the heater. Depending upon system control complexity, this may take several forms:
Rapidly close the K600 when a loss of flow signal or high temperature alarm is reached. Generally, a K600
utilizing a positioner can close within 2-10 seconds.
The K600 could be closed independently of the control loop by utilizing a solenoid valve in the actuator
air line. For this application a 3-way, normally open, bleed to atmosphere valve would be used. The “permit
to run” (Enable) logic could be based on a flow switch (verifying flow through the Hydroheater), a high
temperature alarm (verifying that temperature does not exceed the high alarm set point) or a combination.

K600 1.4
PRODUCT MANUAL 1.4
The K600 steam valve could be closed using the same logic as described above. (See Figure 12 below).
“Permit to Run”
(Enable)
Auto Steam Valve

(On/Off)
Figure 12: Logic for Closing the Steam Valve
NOTE – It is very important that the K600 control system be designed to ramp the heater to set point from
a fully closed position upon startup.

K600 1.4
4.5 Autopilot - Description of Components
The following section is a brief description of the components for the Autopilot System pneumatics and
their functions. If additional information is required please call the Hydro-Thermal Service Department at
(262) 548-8900 or visit our website at www.hydro-thermal.com.
Main Air Valve: Open or close to energize air set assembly
Main Air Enable Solenoid (Dump Valve): When energized the solenoid allows air to flow through the
assembly to the open/close solenoids.
Condensate Removal: Removes water/condensate from the air line. This item should be checked on a
regular basis. Frequency of emptying this depends on the quality of the air provided.
Air Oiler: Supplies oil to the air stream to prevent solenoid valves and the air motor from seizing due to
corrosion. This item needs to have oil at all time, amount of oil consumed depends on the duty cycle of the
Main Autopilot System. Hydro-Thermal recommends this is checked on a weekly basis.
Exhaust Ports: Allows air to be exhausted from the air motor
Open/Close Solenoids: When energized, these solenoids allow air to the drive motor which then rotates in
the direction indicated
Open/Close Regulator & Gauge: Allows the ability to adjust the air pressure for the respective direction
Main Air Enable Open Regulator and Gauge

Solenoid (Dump Valve)
Close Solenoid
Air Oiler
Main Air Valve
Condensate
Removal Exhaust Ports
Open Solenoid
Close Regulator and Gauge
Figure 13: Pneumatic Air Set

K600 1.4
PRODUCT MANUAL 1.4
4.5.1 Interconnection to the Air Motor

The following photos show proper connections of the air supply to the drive motor. Please refer to Figure
14, Figure 15, and Figure 16 for additional information. If you have any questions, please do not hesitate
contacting the Hydro-Thermal Service Department at (262) 548-8900.
Air Motor Connections
Air Set Connections
Figure 14: Air Motor Connections

K600 1.4
Close
Open
Figure 15: Side View of the Pneumatic Airset
Open
Close
Figure 16: From the Top View of the Air Motor

K600 1.4
PRODUCT MANUAL 1.4
4.5.2 Interconnecting Cables

The following photos show the interconnecting cables for the Autopilot system, which are available
from Hydro-Thermal. In the event one of these is damaged, please contact the Hydro-Thermal Service
Department for a replacement.
Figure 17: Close Up of Valve Forward/Reverse Connector
Figure 18: Close Up of Position Sensor Connector
Figure 19: Close Up of Air Enable Connector

K600 1.4
4.5.3 Setting the Air Pressure and Operating Speed
The operational speed of the Autopilot can be regulated based on plant regulations. This is done by
regulating the speed of the air motor. This setting is normally done at initial installation and start-up.
The following steps describe how this is accomplished.
1. Ensure the air oiler has the proper amount of air tool oil.
2. Make sure cables and hoses are not contacting steam piping.
3. Check the mode switch is in manual on the control panel and power it up.
4. Make sure supply “plant air” pressure is regulated to 40-125 psig. Prior to pneumatic air set, regulate
open and close regulators to 20-30 psig. If needed, the outgoing pressure to the motor can be
increased to a maximum of 40 psi.
CAUTION – To prevent damage and voiding of the warranty, do not exceed 40 psi air to the
air motor as this can cause damage to components.
5. With these pressures, the drive motor will rotate

at approximately 1.5 RPM measured on the
drive shaft. To adjust the motor speed, a simple
adjustment to the speed adjustment screws
(shown in the photo to the right) is required.
Turning the adjustment screws clockwise will
decrease the speed and turning it counter-
clockwise will increase the speed. Note that
there is independent adjustment for opening and
closing. These screws are labeled Port 2 and Port
4 and are located on the main air solenoid block
as shown in the photo below.
Figure 20: Flow Adjustment Screws

K600 1.4
PRODUCT MANUAL 1.4
Shut Off
Flow Control
Valve
Figure 21: Air Panel Assembly
4.5.4 Maintenance of Oiler

In order to assure proper operation and prevent damage to the air motor, the air system oiler should be
filled and maintained with oil to true proper level.
Hydro-Thermal recommends air tool oil (10w) for this purpose.
Oil usage and maintenance cycle will vary depending on plant operation. We recommend checking it daily
for the first 30 days of operation which will give a benchmark of how much oil is being used. Once this is
determined, a regular maintenance schedule can be determined.

K600 1.4
4.5.5 Emergency Operation (Air System Failure)
In the event of a complete failure of the air supply, the Autopilot will not operate as it needs air pressure
to move the motor which drives the CTA open or closed. In this situation, manual operation of the CTA is
required.
First, remove the idler gear (or any one of them). Once this is removed, the hex on the drive shaft of the
CTA can be rotated with a wrench to move the CT open and closed.
4.6 Autopilot Control Panel

4.6.1 General Description
Control of the Hydro-Thermal Autopilot system is performed by the control panel supplied with the
Autopilot System in conjunction with the customer DCS.
A brief description of the Autopilot’s System’s control components and their functions in 4.6.2 Description
of Control Panel Switches and Displays and are shown in Figure 22 and Figure 23. For further information
please contact the Hydro-Thermal Service Department direct at (262) 548-8900.
4.6.2 Description of Control Panel Switches and Displays

Man/Auto Switch: This switch designates whether the PLC will attempt to match the pressure drop across
the heater to the target set point. In Manual, the Autopilot will only move the combining tube if the Closed/
Open switch is toggled.
Combining Tube Closed/Open Switch: This is a 3-position spring return switch that allows the Combining
Tube to be opened or closed manually. It is only active when the Manual/Auto switch is in the Manual
position. While the switch is manually engaged, the combining tube will traverse in the indicated direction.
Emergency Stop: The Emergency Stop button disengages the master control relay, removing power from
and to all field output devices.
Control Power On: Engages the master control relay in the control panel and enables the output device
circuit.
Differential Pressure (DP): A 4-20 mA signal of measured differential pressure (slurry inlet pressure minus
slurry discharge pressure). This must be scaled the same range as the pressure drop signal (0-100 psi) and
is shown on the digital readout.
NOTE – If your pressure differential exceeds 100 psi, additional programming will be needed in your DCS
and Autopilot control panel.
CTA Position Sensor: A 4-20mA signal indicating the position of the combining tube relative to its zero
point.

K600 1.4
PRODUCT MANUAL 1.4
4.6.3 Alarm Lights (Quick Reference Table)

Table 8: Alarm Lights & Sequence
Alarm Problem Light Sequence
CTA position is less than 0% 1/4 sec. pulse followed
Valve Position
or greater than 100% by 1/2 sec. pulse
CTA position out of range 1/4 sec. pulse followed
(above or below 4-20mA) by 1/2 sec. pulse
Pressure differential out of range 1/4 sec. pulse followed
Analog Out
(above or below 4-20mA) by 1/2 sec. pulse
of Range
Pressure differential setpoint 1/4 sec. pulse followed
out of range (above or below by 1/2 sec. pulse
4-20mA)
1/4 sec. pulse followed
Wrong direction
Reverse Movement by 1/2 sec. pulse
No movement 1/2 sec. pulse
Control Panel - Old Control Panel - New
Figure 22: K5 Autopilot Panel

K600 1.4
4.6.4 K5 Autopilot Panel Alarm Lights and Reset Button
The following section pertains to alarms that the Autopilot System is programmed to generate. These lights
are shown in Figure 22. If at any time you have questions, please do not hesitate calling the Hydro-Thermal
Service Department at (262) 548-8900.
1. Valve Position Alarm (CT Position)

The Autopilot PLC reads that the CT is closed too far (zero % or a negative value) or open greater than
100%.
If the CT is at 0%, it can be manually opened to clear the alarm. Other possible reasons for this alarm
include incorrect zeroing of the system or a loose connection.
2. Analog Out of Range Alarm

The Autopilot system uses three different analog signals. If any of these are not within 4-20 mA, this will
cause the alarm. Under this condition, the air enable solenoid is disabled, thus preventing movement of the
CT until it is cleared.
Possible Solutions:
1. The CTA position. Review the three analog inputs: If this value is negative, or out of range, the
alarm will be activated.
2. Differential Pressure: A negative, or out of range, value for this reading will enable the alarm.
3. Pressure differential set point (input from plant DCS): If a zero or out of range value is
inadvertently entered for this, the alarm will be triggered.
3. Reverse Movement Alarm

This alarm is caused by either lack of movement (for a set period) or movement in the opposite direction.
Under this condition, the air enable solenoid is disabled, thus preventing movement of the CT until the
alarm is cleared.
Possible Solutions:
1. The CT is moving in the opposite direction from the command. The position sensor could be out
of scale or installed backwards, or the air motor might be piped backwards or electrically wired
backwards.
2. The CT may be stuck or jammed. In this case, the controls will try to operate, but will not move
the CT. The alarm will be activated if the motor is energized (either open or close) and the CTA
position sensor does not detect movement for eight seconds or more.
CAUTION – If the cause of the alarm is no movement, the K600 Hydroheater will likely need servicing.
Do not attempt to force the CTA/CT or damage to the unit could result.

K600 1.4
PRODUCT MANUAL 1.4
The alarm reset button only resets the “analog out of range” alarm. If either or both of the other two alarm
lights (valve position or reverse movement) are flashing, the condition that must be corrected before the
alarm will clear. Those alarms will clear only after the condition is rectified.
This is the K5 Autopilot Electrical Panel Inside
MicroLogix 1200 Programmable Controller Power Supply MCR
06-Open 07-Close 08-Enable Analogs
Figure 23: K500 Series Autopilot Panel

K600 1.4
Breakers Power Supply
Analog Expansion
Q:7 Enable
Power Q:5 Open Analogs
Q:6 Close
Figure 24: K600 Series Electrical Panel

K600 1.4
PRODUCT MANUAL 1.4
4.6.5 I/O’s: Discrete and Analog Description
System Enable Contact:

A custom dry contact on K-6 controls. When closed, the contact allows the unit to operate in Automatic
mode provided the local switch is also in Automatic. Without this Dry Contact, the unit will remain in manual
mode – even when the control panel switches it to “Automatic.”
Discrete Outputs
Customer Alarm Output:

A signal indicating the unit is in an alarm state. This may be 120VAC or high/normal/low alarm
depending on the model.
Air Motor Forward:

A signal (24VDC or 120VAC) to engage the forward solenoid in the 4-way air solenoid valve.
Air Motor Reverse:

A signal (24VDC or 120VAC) to engage the reverse solenoid in the 4-way air solenoid valve.
Alarm Light (Red):

A light indicating the system is in a fault condition.
Analog Inputs to the Control Panel

Measured Pressure Drop:
A 4-20mA signal from the customer indicating the actual measured pressure drop across the
Hydroheater. The signal scale must be 0-100 psid.
Pressure Drop Set Point:

A 4-20mA signal, from the customer, indicating the desired pressure drop across the Hydroheater. The
signal scale must match the measured pressure drop scale.
CT Position Sensor:

A 4-20 mA signal indicating absolute position of the combining tube relative to its zero point. The upper
range of this signal will differ depending on the heater to which it is attached. See Table 9 for CT travel.
4.6.6 Control Logic

The function of the Autopilot is to maintain a constant process differential pressure across the combining
tube (CT). Closing the CT will increase pressure drop; opening the CT will decrease pressure drop. Some
customers have found that a 40 psig differential was optimal. Other customers have found that an even
higher or lower differential is optimal for their conditions. Hydro-Thermal recommends that the plant be
benchmarked at various differential pressures for operations.
The control logic compares the differential pressure (DP-PV) across the chamber to the set point (DP-SP).
The set point (DP-SP) comes from customer DCS as 4 to 20mA value. The opening and closing of the CT
may interact with the flow or tank level control loop for product supply. To avoid continuous hunting of
pressure and flow conditions in the system, the program uses a ‘window’ around the pressure differential
set-point (DP-SP). If the measured pressure differential is within the upper and lower limits of this window,

K600 1.4
only minor adjustments are made (pulse signal to the solenoid), and the effect of the adjustment monitored
before making any additional adjustments (‘pulse-and-wait’ logic). A dead band will operate inside of the
pulse logic causing no CT movement inside a smaller limit around the set point. When the differential
pressure is outside of the dead band the pulse logic will then enable and pulse. Outside this window, a
continuous adjustment is made in order to bring the pressure within the limit window. The pulse waveform
below shows the pulse-and-wait logic in a graph.
Set Point
Measured Pulse window (operates continually Dead band

Differential outside this range; Pulse-and-wait (no CT adjustments
Pressure within this range within this range)
On
Off Autopilot Close Command
On
Autopilot Open Command Off
Figure 25: Pulse-and-Wait Logic

K600 1.4
PRODUCT MANUAL 1.4
4.6.7 Interconnections
MicroLogix 1200 Programmable Controller
This Picture is An Enlarged View
Input #10 On
If wired properly, when the

DCS is in ‘Auto,’ Input #10
should be shown as ‘On.’
Figure 26: K6 Autopilot MicroLogix1200 Controller

K600 1.4
4.6.8 Interconnection Diagrams
Hydro-Thermal Supply
Figure 27: Interconnection Drawing - Autopilot

K600 1.4
PRODUCT MANUAL 1.4
Figure 28: Interconnection Drawing - Autopilot Lite

K600 1.4
4.7 Autopilot Lite Controls
4.7.1 Recommended Control Logic
K6 Autopilot Lite interconnections are shown on Figure 28.
Outputs from the DCS:

Signal Type Function Function
Discrete* System Enable (for the supply air blocking solenoid)
Discrete* Combining Tube (CT) Open solenoid
Discrete* Combining Tube (CT) Close solenoid
* Solenoid voltage specified by customer 24 VDC or 120 VAC
Input to DCS:
Signal Type Function
4-20mA Analog CT position
4.7.1.1 Automatic Combining Tube Adjustment

Closing the CT will increase pressure drop; opening the CT will decrease pressure drop. Some customers
have found that a 40 psig differential was optimal while other customers have found that an even higher
differential is optimal for their conditions. Hydro-Thermal recommends that the plant be benchmarked at
various differential pressures and operated at the optimal DP for the plant, taking into account the various
factors. For example, enzyme usage, conversion efficiency, and pump head can all have an impact on
system performance.
Opening and closing the CT may interact with the flow or tank level control loop in the product supply.
To avoid continuous hunting of pressure and flow conditions in the system we recommend programming
a ‘window’ around the pressure differential set-point. If the measured pressure differential is within the
upper and lower limits of this window, only a minor adjustment is made (pulse signal to the solenoid), and
the effect of the adjustment monitored before making any additional adjustments (‘pulse-and-wait’ logic).
Outside this window, a continuous adjustment is made in order to bring the pressure differential to within
the upper and lower limit window. See Figure 25 for the pulse-and-wait logic shown graphically.
4.7.1.2 Manual Combining Tube Adjustment

Logic should be implemented allowing the CT adjustment to be placed in manual mode. This allows the
operator to toggle the open/close solenoids from the DCS screens independent from what the pressure
set-point is and move the CT in any direction. Having this also helps in troubleshooting should any
malfunctions occur.
4.7.2 Alarm Logic

Safety precautions should be programmed in order to prevent damaging the equipment. The following
sections briefly describe the alarms the Hydro-Thermal recommends at a minimum for safe operation of the
K600 Hydroheater.

K600 1.4
PRODUCT MANUAL 1.4
4.7.2.1 Overtravel / Undertravel Alarm

Travel limits for safe operation should be programmed to allow operation of the CT only between 5-90%.
It is the responsibility of the purchaser to calibrate the position feedback and assure the maximum and
minimum travel is properly set (Refer to assembly under the 7.0 Maintenance). An incorrectly calibrated
position signal may cause the CT to drive into the nozzle during operation resulting in damage to the
Hydroheater.
If the undertravel alarm is active, the close solenoid should be disabled and only the open solenoid
enabled in manual mode. If the overtravel alarm is active, the open solenoid should be disabled and only
the close solenoid enabled in manual mode.
Table 9: Overtravel and Undertravel Position Signals

Heater Model Positioner Sensor
CT Travel Max Travel 0% 5% 90% 100%
K610, K611, K612, K613 1.13
1.13 4.5mA ~4.88mA ~11.97mA ~12.79mA
K614, K615, K616 1.50
This table is provided for reference and should be used for a starting point. Actual positions
will vary based on setup and surroundings The actual travel will need to be verified.
NOTE – On K614 and larger the combining tube travels at a rate of 1.3 of the position sensor.
4.7.2.2 Position Signal Out of Range Alarm

Alarm logic should be programmed so that an analog out-of-range value from the sensor (typical of a
disconnect or short circuit) prevents the automatic operation of the unit and alerts the operator for this
condition.
The air supply enable solenoid should be disabled, thus shutting off the air supply to the air motor in
automatic mode.
4.7.2.3 Reverse Movement / No Movement Alarm

The reverse movement alarm should be triggered if the open or close solenoid is energized but the
position indicator senses the opposite movement. This would be an indication for a reversed air tubing
connection to the air motor.
The no-movement alarm should be triggered if the open or close solenoid is energized but the position
sensor senses no movement. This would be an indication that the CT is sticking and should be cleaned and
maintained.
The air supply enable solenoid should be disabled, thus shutting off the air supply to the air motor in
automatic mode.

K600 1.4
4.7.3 Calibration Logic
The 0% and span reference must be programmed for the signal from the position feedback sensor to
properly represent 0-100% travel. To calibrate the 0% reference point, the CT must be manually closed to
0%. Refer to assembly under 7.0 Maintenance. When at 0%, the analog value read in the DCS represents
the 0% position reference offset value.
To calibrate the 100% reference value, the CT must be manually moved to the 100% position in the same
way it was calibrated for the 0% position. The analog value read in the DCS then represents the 100%
position reference value.
4.7.4 Filtering Logic

Based on operating conditions the signal from the position feedback sensor might not be steady.
The implementation of filtering, averaging logic, or delay in alarming is therefore advisable.

K600 1.4
PRODUCT MANUAL 1.4
5 OPERATION
CAUTION - Make sure K600 is properly installed and calibrated before use.
5.1 Startup
CAUTION – For safety reasons the pre-start check-out should be performed without steam. This should
be performed prior to initial operation or restart after extended shutdown.
CAUTION – The Hydroheater must be installed according to Hydro-Thermal Corporation’s

recommendations in this manual. Please contact the Hydro-Thermal Service Department at (262) 548-8900
for the most up to date version of the manual.
5.1.1 Pre-Start Procedures

1. Check for leaks prior to operation of the system.
2. Verify correct wiring to the system.
3. With the steam inlet isolation valve closed, apply power to the system.
4. Verify the target temperature set point in the controller.
5. Verify the operation of flow sensor.
NOTE – The flow switch trigger point may have to be adjusted according to the site specific
flow conditions.
6. Verify correct operation of the steam shutoff valve.
7. Verify the operation of the Hydroheater, by manually setting to 25%, 50%, 100% position. Verify the %
stroke on the Hydroheater actuator.
8. Confirm that the mechanical zero was performed per Assembly Instructions sections E and F in section
7.0 Maintenance.

K600 1.4
5.1.2 Additional Pre-Start Procedure for Autopilot or Autopilot Lite
1. Ensure that the oil level in the pneumatic lubricator is sufficient. The oiler on the air assembly is to be
filled with detergent SAE #10 automotive engine oil or air tool oil for lubricating.
2. Ensure that cables and hoses are not in contact with hot (steam or product) piping.
3. Ensure that the incoming plant air pressure is a minimum of 40 psig. The outgoing air pressure should be
adjusted to regulate motor speed, typically ~30 psig & 1.5 RPM on the drive shaft. The outgoing pressure
and resulting speed may be adjusted by turning the brass adjustment screws located on the flow control
valves as shown in 4.5.3 Setting the Air Pressure and Operating Speed.
4. Confirm that the mechanical zero and electrical zero was performed per Assembly Instructions sections E
and F in section 7.0 Maintenance.
NOTE – If reverse movement occurs flip the incoming air lines to the motor, or at the air supply panel
solenoids.
5. Checking for proper direction of the combining tube movement:
a. Select the mode switch to manual on the control panel.
b. Briefly engage the combining tube switch to the open position.
c. Observe the movement in the open direction on the indicator CTA position.
6. Verify zero position by opening the CT until the CTA position display reads 2%. Then close the CT until
close solenoid de-energizes. The CTA position display will indicate 0.00%. If the value continues to count
in a negative direction, STOP immediately!
Reset “Mechanical Zero” before you start the procedure again. Also open the CTA to 90% and make sure
the solenoids de-energize.

K600 1.4
PRODUCT MANUAL 1.4
5.1.3 Initial Startup Procedures

CAUTION – The CTA must be opened before initial startup or an overpressure condition could be
experienced. If an Autopilot is supplied it must be in manual mode prior to startup.
1. Verify users are aware of the start-up situation and take appropriate safety precautions.
2. Set the CTA position to 25% or site specific start-up. If an Autopilot is supplied it must be in manual
mode. Be certain that the Autopilot “run enable” from the DCS system is disabled. (I:01/10). DCS system
is in manual mode.
3. Open all manual utility isolation valves.
CAUTION – If your system is equipped with a steam trap, it will discharge condensate/steam
automatically and unannounced.
4. Blow down steam line so that dirt, welding residue and other contaminants do not enter the steam line
or K600. Begin with the steam strainer blow down valve. This will purge debris from the strainer. Then,
open the blow down valve on the bottom of the drip leg to purge the drip leg.
CAUTION – Assure that blow down is done in a manner to prevent burns.

5. Set the steam control in manual mode.
6. Establish product flow. Verify that the flow sensor operates correctly and the steam valve opens. Stop
the process flow and verify that the flow switch operates, closing the automatic steam inlet valve.
7. Establish product flow. Slowly increase the K600 steam control manually and verify temperature rise.
Once correct operation is established, manually close the heater.
8.Input and verify the temperature set point in the controller. It is recommended to begin with a lower
temperature than normal to confirm loop parameters. With product flow, place the steam control in
automatic mode and begin heating.
9. Verify the controller’s function of maintaining desired temperature. PID loop parameters may have to be
adjusted to fit your system set-up. Refer to the controller manual for details. If the system response is
erratic, place the temperature selector switch back to ‘off / reset’ before adjusting parameters.
AUTION – An inadequately tuned loop can create hazardous conditions due to temperature
C
overshooting.
CAUTION – Use extreme caution if attempting to “auto-tune.” Generally the controller will cycle between
0 and 100% output in order to learn the system response. This can create hazardous conditions. Ensure
adequate safety precautions prior to performing this function. TIP: Maximum output of the controller can
generally be limited by a user setting to enhance safety.
10. Sequence a normal shutdown and start-up to confirm correct operation.

K600 1.4
5.1.4 Additional Initial Startup Procedures for Autopilot or Autopilot Lite
This section describes in detail the procedure for starting up an Autopilot System. It is critical to follow
these steps in order, if any questions arise, please contact the Hydro-Thermal Service Department at
(262) 548-8900 for additional information.
CAUTION – Autopilot CTA control must be in manual mode.

One method of starting an Autopilot System is to start it in the Manual Mode first. Once stable operation is
reached, it can then be switched over to Auto Mode.
Adjustment of the combining tube towards the nozzle (closed) will increase the pressure drop across the
unit. See section 1.3 Principles of Direct Steam Injection (DSI).
1. Set targeted fluid pressure differential in DCS, typically 30 to 55 psi.
2. With established product flow and heating mode in automatic, observe pressure differential on the LCD
display.
3. Observe fluid pressure differential in the manual mode; at the Autopilot control panel, actuate combining
tube switch to adjust the differential pressure in 5 psi increments until the differential pressure is reached
while observing the CTA position.
NOTE – In automatic run-mode, the controller will compare the measured pressure differential to the
desired pressure differential (set point) and adjust the position of the combining tube accordingly. If the
set point is greater than actual, the combining tube will close, and vice-versa. A variable (via programming)
dead band around the set point will cause no CT movement when the differential pressure is within this
dead band in order to prevent system hunting.
4. Switch mode to auto on Autopilot control panel.
5. Place the system enable of the DCS in auto mode (activate the enable bit).
6. Further targeted pressure differential changes should be made in 2 psi increments.
7. Remove the enable bit when flow rates fluctuate, plant shutdown, or process interruption occur – this
sets the Autopilot to manual mode. When disabled, the Autopilot will remain in the current position.
Control the combining tube position via the Autopilot control panel if needed.
5.2 Shutdown
CAUTION – If an Autopilot is supplied it must be in manual mode prior to shutdown. It is best to leave it
in the normal operating position. Otherwise, dropping differential pressure will make the Combining Tube
close completely. During start-up, an overpressure condition could be experienced.
1. If the heater has an Autopilot, turn it to manual mode. From the DCS Control, remove the enabled bit
(switch to manual mode).
2. Place the steam control in manual mode and gradually lower the output to 0%.
3. Stop process flow.

K600 1.4
PRODUCT MANUAL 1.4
NOTE – For long term shutdown or for dirty fluids the system should be flushed out.
4. If applicable: Isolate the fluid flow and introduce flush water down the product line through the K600.
Gradually increase the steam control in manual mode by 5% increments until the targeted temperature
is reached. Allow the K600 to maintain temperature for the amount of time needed to clean the system.
When complete gradually lower the steam control to 0%. Stop flush water flow.
5. Disable the Auto On/Off steam valve and enable the bypass valve (If applicable).
5.3 Applications with Intermittent Heat Requirement

In some applications, the K600 is installed in piping where the process fluid is circulating, but there is no
call for heat. The K600 heater is not rated as a tight shutoff, so the steam shut-off valve should be closed.
This protects the seals and internal components which otherwise would wear rapidly. A time-out function
could be used, for example, closing the steam valve if there is no call for heat for 15 minutes.
With the process fluid circulating (under pressure), the fluid will slowly leak into the steam line up to the
check valve. Generally, fibrous materials will clear themselves once steam is reapplied. Some dirty fluids,
however, could cause clogging or sticking that would require mechanical cleaning. If the heater will be
installed in a line and will have no heating requirements for extended periods, please contact Hydro-
Thermal for operating recommendations.

K600 1.4
6 TROUBLESHOOTING
Please read the scenarios below. If these instructions do not resolve your concerns, please contact the
Hydro-Thermal help line at +1 (262) 548-8900 and ask to speak with customer service.
6.1 Insufficient Heating Capacity

1. Verify that steam is reaching the system.
2. Check that the upstream steam supply line valve is fully open.
3. Ensure the steam supply line check valve is open. Observe steam pressure on the gauge nearest the
unit.
4. Ensure that the steam strainer is not clogged. Blow out the steam strainer if it appears to be obstructed.
CAUTION – Ensure liquid flow is established before actuating the K600.

5. Manually open the K600 heater, while observing the stem position. If there is no response, determine if
the controller output is not reaching the heater or if the heater is not responding.
6. Verify that clean, dry instrument air is reaching the K600. Observe the positioner gauge pressures.
7. Note both process fluid and steam pressures and compare to design parameters. Verify it remains within
the range while the heater rises to temperature.

K600 1.4
PRODUCT MANUAL 1.4
6.2 Rough Operation

1. If condensate is not purged out of the steam supply line to the K600, operation will be rough. The unit
should have a drip leg and a condensate trap to supply dry steam to the K600.
2. The unit may be operating outside of design conditions. Review steam pressure at the heater inlet, water
pressure, inlet and discharge temperatures and water flow rate. Compare with K600 sizing provided by
Hydro-Thermal with unit.
3. The water flow rate, water temperature, and/or steam pressure may be varying too rapidly for the
temperature controller to maintain smooth, stable operation. If this is the case, temperature overshoot
and undershoot will occur. Minimize flow variations and adjust controller settings to optimize temperature
control. If Hydro-Thermal provided the controller, refer to the system control manual.
4. The process pressure after the heater is not enough to prevent flashing in the discharge piping. This
occurs at operating temperatures above 212°F [100°C]. Check Appendix A: Steam Table for the pressure
required and reset back pressure valve if necessary.
5. Temperature sensor is too far from K600. Refer to 4.0 Installation for guidelines on properly locating the
temperature sensor.
6. Excessive condensate in the steam supply. This can be worse at startup, if a drip leg is not correctly
installed or if the steam trap is undersized or unmaintained.
7. Heater components may be worn. If the unit has been in service for more than a year or has been subject
to “wet steam,” a visual inspection of the internal components and seals is recommended. If necessary,
reorder parts or schedule a service visit by contacting info@hydro-thermal.com.
8. Viscosity of the process fluid is varying.
9. Multi-phase fluid is present.
10. Combining Tube (CT) position is incorrect for the current parameters. Typically if rough operation is
occurring an adjustment closed is necessary, depending on the fluid type.
11. Heater is operating outside the design parameters. Verify the steam and process pressures are within
original design parameters.

K600 1.4
6.3 Excessive Temperature Variation
The temperature sensor should be verified for its position, function, and connection. The temperature
sensor is maybe located too far downstream from the K600. Refer to section 4.0 Installation for guidelines
on properly installing temperature sensor.
PID control parameters should be reviewed relative to the response time of the heater, actuator position
and the temperature changes and thereafter the parameters optimized.
Steam pressure trending should be observed. Rapid fluctuations in steam pressure will affect temperature
control.
Flow rate data should be captured to observe sudden flow rate variations. Typically a high temperature
reading will occur with a drop in flow if the response is too slow, and vice versa. It may become necessary
to add a recirculation loop if the flow variation becomes too excessive, to stabilize temperature variation.
Heater components may be worn. If the unit has been in service for more than a year or has been subject
to “wet steam,” a visual inspection of the internal components and seals is recommended.

K600 1.4
PRODUCT MANUAL 1.4
7 MAINTENANCE
7.1 Recommended Maintenance

Weekly:
1. Examine the Hydroheater for any steam or water leaks
Monthly:
1. Ensure all external nuts and bolts are tight. Refer to Torque Table in 7.6 Assembly
2. Examine stem for unusual scale buildup
3. Verify temperature control loop is working properly
4. Look for indirect signs of wear (such as failure to shutoff)
Annually:
1. Disassemble heater and check parts for wear
2. Replace all seals
3. Replace stem packing
It is recommended having spare internals on hand prior to disassembling

K600 1.4
7.2 Wear and Inspection
The K600 may exhibit wear on the stem plug, combining tube or seals. Wear on the stem plug may appear
as scratches, gouges or pitting. A small amount of wear may not interfere with operation, but significant
wear may prematurely wear the stem plug seals, and/or packing material which may cause the unit to leak
externally. In general, if the stem plug is fully seated, the steam leakage internally through the unit should
be very small. There should be no appreciable temperature rise at nominal flows, and if the process fluid
flow is shut off, the temperature of the process fluid should rise very slowly. If it rises quickly, there may be
wearing on the stem plug tip or nozzle, causing steam to leak past.
Inspect the length of the inside diameter for wear and

Inspect the tip, annulus and pitting, especially the first 6”of entry point.
inside angle for straightness,
rounded corners and wear pat- Inspect the outer surface Inspect the stud hole
terns. This area is the process for galling, scoring, wear or for thread damage.
fluid shear point. Depending other damage.
on the process, shear could be
very critical and affect perfor-
mance. This is especially true in
starch and grain conversation
applications. Uneven wear will
cause inconsistent shear and
mixing.
Figure 29: Combining Tube Cross-Sectional View
NOTE – Drawing is not to scale and is intended for refer-
ence only, geometry may vary.
Inspect and clean, this

is the sealing surface
Inspect threads for
between the body and head.
actuator bolting and
Inspect steam bore for packing follower.
galling and out of round.
Inspect bore for lip
seal and retaining
ring groove for wear.
Figure 30: Head Cross-Sectional View

NOTE – Drawing is not to scale and is intended
for reference only, geometry may vary.

K600 1.4
PRODUCT MANUAL 1.4
Inspect the bore for wear.

Inspect inside angle for
wear. This is theseating
Inspect the outside surface for surface for the nozzle and
wear. This area is the process stem-plug. Wear would result
fluid shear point. Depending on in steam leakage when closed
the process, shear could be very and/or poor temperature
critical and affect performance. This control.
is especially true in starch and grain
conversion applications. Uneven
wear will cause inconsistent shear
and mixing. If shear is critical,
Hydro-Thermal recommends new
parts, even for minor wear.
Figure 31: Nozzle Cross-Sectional View

NOTE – Drawing is not to scale and is
intended for reference only, geometry
may vary.
Inspect the length of the stem shaft

for scoring. If this surface does not
meet a 16 Ra finish, it is likely the
Inspect outer angle on plug seals will fail and steam leakage
for wear. This is the seating will occur. Note: stem is polished
surface for the nozzle and and should never be sand blasted Inspect steam for
stem-plug. as it will damage the surface finish. damaged threads.
Inspect plug for wear or

erosion on control angle.
Figure 32: Stem-Plug Sectional View
This surface is the steam NOTE – Drawing is not to scale and is
controlling surface. If this intended for reference only, geometry
surface is damaged, it will cause may vary.
poor temperature control and
irregular mixing. This could af-
fect performance, especially in
starch and grain conversion
applications.

K600 1.4
7.3 Inventory and Spare Parts Recommendations
NOTE – Hydro-Thermal has maintenance programs available, including on-site technician visits, to help
you keep your K600 in top running condition.
The K600 is a very robust valve for process control but requires preventive maintenance of its wear
components to maximize the life of the steam control components. Simply maintaining the disposable and
less expensive components on a regular basis will reduce the total cost of the unit during the length of its
operation.
If noise, vibration, or temperature variation occurs, maintenance may be necessary. Notify Hydro-Thermal if
this happens at: info@hydro-thermal.com or call (262) 548-8900. If possible, please have the heater’s serial
number when calling. (See 1.5.2 Location of Markings on Body).
To prevent unintended shutdowns or the potential for extended outages, Hydro-Thermal offers a range
of preventive maintenance plans. These plans range from stocking a spare heater in your plant in case of
emergency shutdown, stocking spare internal and soft parts for your heater, service technician visits and
training your maintenance staff and operators, or complete refurbishment of your unit. Call us to learn about
the various maintenance plans and options.
Hydro-Thermal Corporation recommends either a spare Hydroheater or six spare parts be kept in your
inventory at all times. While the Hydroheater is extremely reliable, it is also custom designed for your
specific facility and application. Lead times apply so please contact your Hydro-Thermal representative for
more details. It is an unnecessary risk to not retain proper inventory. If equipment breaks upstream of the
Hydroheater (on the steam or process side), parts can get lodged in the Hydroheater causing damage as
well. Proper inventory can minimize these unexpected downtimes.
Option #1 (Spare Hydroheater)

Over 50% of our customers have chosen to keep a spare Hydroheater for the following reasons:
a. One less vendor to manage during your shutdown

Your staff can swap out the units in about an hour. Then you can send the used Hydroheater to
our facility for refurbishment.
b. Refurbishment Program
Any refurbished Hydroheater receives a renewed warranty equal to a new Hydroheater.
c. Longer lasting parts

We can offer advice from noticing wear patterns and can reuse parts at our facility
(due to our manufacturing capabilities) that would have to be replaced in the field.
Option # 2 (Spare parts and Service)

If you don’t have a spare Hydroheater we recommend you keep the following six parts in stock (at all times)
in case they are needed. *The first three items are custom made parts for your specific plant.
a. *Combining Tube d. CTA Assembly

b. *Stem Plug e. CT Stud
c. *Nozzle f. Rebuild Kit

K600 1.4
PRODUCT MANUAL 1.4
Hydro-Thermal service technicians are available for start-ups, rebuilding your Hydroheater at your facility
during a shut-down, or training/troubleshooting. If you are interested in any of these options, please
contact the service team at 1-800-952-0121 or email info@hydro-thermal.com.
Table 10: Recommended Spare Parts List

Description Qty
** Combining Tube 1
** Nozzle 1
** Stem Plug 1
** CTA Stud 1
* CTA Replacement Kit 1
* Rebuild Kit 1
* Recommended 1 year spare parts
** Recommended 2-3 year spare parts
NOTE – These parts are recommended to be stocked by the
customer, in-case of an emergency and for standard service
rebuilds. Actual replacement varies upon operating conditions
and atmospheric surroundings.
7.3.1 Anti-Seize Compounds

Anti-seize compounds should be liberally applied to all threaded components of K600 when they
are reassembled after parts replacement. The recommended anti-seize compound is Loctite Nickel
Anti Seize - #77124.
7.4 General Information

The following sections explain how to disassemble and assemble the K600 Hydroheaters. For some
instances, like trouble shooting a specific area complete disassembly and assembly may not be necessary.
For example, it may be easier to remove the head, stem plug, and actuator as an assembly rather than
completely disassembling the Hydroheater. This will save a significant amount of time and effort versus
disassembling the stem plug and actuator. Examples of these circumstances are:
• Stem Plug not fully closing
• Stem Plug closing but still leaking steam
• Unstable Temperature Control, particularly at lower steam output
For inspection purposes, there is no need to disassemble the stem plug from the actuator. This allows for
inspecting the inside of the nozzle for wear/debris and the tip of the stem plug.

K600 1.4
Figure 33: K600 Exploded View

K600 1.4
PRODUCT MANUAL 1.4
7.5 Complete Disassembly

Periodically, a Hydroheater will require a full disassembly and rebuild. The following section details step-
by-step instructions to completely disassemble a K600 Series heater in preparation for rebuild. It is
required to have a rebuild kit available prior to disassembly. Please consult your Hydro-Thermal Sales
Representative for part numbers, pricing, and delivery.
If there are any questions regarding this procedure or to schedule an on-site maintenance visit, please
contact the Hydro-Thermal Service Department at (262) 548-8900 for further information.
Please follow the steps below:

1. Personally verify that steam, process inlet, and heater outlet are locked out and tagged out.
2. Mark current positions (actuator to head and head to body, etc) with a marker so you know
where to orient each assembly for reassembly. Taking pictures prior to disassembly may help
for reassembling the heater.

K600 1.4
DISASSEMBLY
It is required to have a rebuild kit available prior to disassembly.
Step A: Actuator Support Bracket
Step 1: Disassemble Actuator Support Bracket by removing hardware shown below.
NOTE – That Actuator support is only used on some units. it is supplied with K613 (4” flange) and

larger with the use of a standard Actuator.
U Bolt
Nut Hex Hvy

Washer Flat
Actuator Support Bracket
Washer Lock
Screw Hex Head
Figure 34: Actuator Support Bracket

K600 1.4
PRODUCT MANUAL 1.4
DISASSEMBLY
Step B: Actuator Disassembly
Step 1: NOTE – There is a spring load acting on Pneumatic Actuator keeping it in the closed
position. It is recommended to relieve the spring force before taking off the Stem
Connector (if the spring is not relieved, there will be a force exerting on the Stem
Connector and will spring outward when it is removed.) If this is not done proceed with
caution, keep fingers away and use to old to remove the Stem Connector during the
following steps. Relieving the spring pressure can be done my supplying the Pneumatic
Actuator with air utilizing a regulator and regulating to the minimum air pressure as shown
on the nameplate and slowly increase until it slightly opens.
Step 2: Remove the two screws holding in the stem connector. Remove the stem connector.
Step 3: Remove the Locknut, Actuator. This is generally done with a dull chisel or punch hammer.
NOTE – On the K616 (10” flange) and larger the Pneumatic Actuator is bolted on instead
of using the Locknut, Actuator.
Step 4: Remove the Pneumatic Actuator carefully. Avoid damaging the threads on the Head
Automatic.
Air Supply
Pneumatic Actuator
Stem Connector
Locknut, Actuator
Head Automatic
Figure 00: Actuator Disassembly

Figure 35: Actuator Disassembly

K600 1.4
DISASSEMBLY
Step C: Head & Stem Plug
Step 1: Disassemble head automatic from body by removing the Nut Hex Hvy.
NOTE – If it is difficult to remove try using the Stem Plug as a slide hammer against the

inside of the head automatic, this may need to be repeated a few times to pop it loose.
Be careful of the Stem Plug the tip may be sharp. A recent design changes added two
additional tapped holes to the head automatic with two extra screw socket head. These
are jack screws that may be turned to loosen the head automatic if it’s stuck to the body.
Step 2: Then remove packing follower by removing Screw Socket Head and Washer Lock.
NOTE – Some models may use a Gland Nut instead of Screw Socket Head and Washer

Lock.
Step 3: Pull the Stem Plug out of the Head Automatic. If this can not be completed by hand a press
may be used.
Step 4: Remove the Retaining Ring with a snap ring pliers.
Step 5: Remove the remaining seals: Lip Seal, O-Ring (head) and Packing Set.
Screw Socket Head

Washer Lock
Packing Follower
Packing Set
Nut Hex Hvy

Head Automatic
O-Ring (Head)
Lip Seal
Retaining Ring
Stem Plug
Body
Figure 36: Head and Stem Plug Disassembly

K600 1.4
PRODUCT MANUAL 1.4
DISASSEMBLY
Step D: Nozzle

Disassemble the nozzle from the body by removing the Spiral Retaining Ring (K612 and smaller use
an internal retaining ring instead.)
NOTE – If the nozzle is stuck use a piece of wood or plastic rod to tap on the nozzle from the

discharge section of the body to free the nozzle. Do this carefully because if the nozzle becomes
misaligned, it will be extremely difficult to remove and damage may occur.
Nozzle
Spiral Retaining Ring
Body
Figure 37: Nozzle Disassembly

K600 1.4
DISASSEMBLY
Step E: CTA
Disassemble CTA Replacement Kit (Manual/Auto)
Step 1: Remove Screw Heavy Hex, Washer Bellville and Washer Flat
Step 2: Lift CTA Assembly off of body.
Step 3: Remove and discard O-Ring (CTA).
Step 4: Remove CT Block, HD by removing the Screw Socket Head and Nordlock Washer.
Washer Flat
Washer Bellville
CTA Screw Heavy Hex
Replacement Kit
(Manual/Auto) CTA Assembly
O-Ring (CTA)
Screw Socket Head

Nordlock Washer
CT Block, HD
Body
Figure 38: CTA Disassembly

K600 1.4
PRODUCT MANUAL 1.4
DISASSEMBLY
Step F: Combining Tube
Step 1: Disassemble the Combining Tube from the body.
NOTE – The Combining Tube is generally difficult to remove, use a piece of wood or

plastic rod to pound on the Combining Tube from the discharge section of the body, if
unsuccessful use a porta power and Bridging Assembly to push out the Combining Tube
from the discharge end of the body.
Step 2: Remove and discard the O-Ring (CT (S)) and O-Ring (CT (L)) from the Combining Tube.
O-Ring (CT (L))
Combining Tube
O-Ring (CT (S))
Body
Figure 39: Combining Tube Assembly
Bridging Assembly
Porta Power

K600 1.4
DISASSEMBLY
Step G: Inspection

Inspect all components for damage. Refer to wear and inspection at the beginning of this section
for requirements and specifications.
Figure 40: Inspection During Disassembly

K600 1.4
PRODUCT MANUAL 1.4
7.6 Assembly
Prior to assembly make sure all parts are thoroughly inspected and replace worn or damaged parts, refer
to 7.2 Wear and Inspection for a guide.
Upon completion of the disassembly procedure, the following procedure illustrates what is required to
reassemble the heater. The same procedure applies whether or not new or used internals are used.
Hydro-Thermal recommends keeping a spare set of internals (CT, stem plug, nozzle, CT adjustment, CT
stud, and seal kit) in stock. This will prevent costly down time in the event of an internal part failure. Please
consult your Hydro-Thermal Sales Representative for part numbers, pricing, and delivery.
If there are any questions regarding this procedure please contact the Hydro-Thermal Service Department
at (262) 548-8900 for further information.

K600 1.4
ASSEMBLY
Step A: Combining Tube

Step 1: Thoroughly clean the Combining Tube and Combining Tube Bore in body of burned-on
product.
Step 2: Inspect O-Ring (CT (S)) and O-Ring (CT L)) (for some heaters these will be the same size)
for cuts, nicks and elasticity before installing them. Replace if damaged. Assemble the
O-Ring (CT (S)) and O-Ring (CT (L)) into the grooves on the Combining Tube, lubricate them
with a high temperature grease.
Step 3: Assemble the Combining Tubes into the body, be sure to keep aligned as shown below
(CT Stud location to slot of body)
Align
O-Ring (CT (L))

Combining Tube
O-Ring (CT (S))
Body
Figure 41: Combining Tube Assembly

K600 1.4
PRODUCT MANUAL 1.4
ASSEMBLY
Step B: 1a: CTA Autopilot for Autopilot K614 (6” flange) and Larger
NOTE – This pertains to the Autopilot only, if a manual CTA is used skip to Step C.
Step 1: Take off the Guard, Autopilot by removing BHCS M5-0.8x12, Washer Lock and Washer Flat.
Step 2: Remove Ext. Retaining Ring. Take off the Spur Gear and Torque Key.
Torque Key
Spur Gear
Ext. Retaining Ring
Guard, Autopilot
Washer Flat
Washer Lock
BHCS M5-0.8x12
Figure 42: CTA Autopilot Assembly for K614 and Larger Sizes

K600 1.4
ASSEMBLY
Step B: 1b: CTA Autopilot K613 (4” flange) and Smaller
NOTE – This pertains to the Autopilot only, if a manual CTA is used to skip to Step C.
Step 1: Take off the Guard, Autopilot by removing BHCS M5-0.8x12, Washer Lock and Washer Flat.
Step 2: Remove E Retaining Ring. Take off the Washer Flat, Spur Gear, Torque Key and Bearing Flat.
BHCS M5-0.8x12
Washer Lock
Washer Flat
Guard, Autopilot
Bearing Flat
Torque Key
Spur Gear
Washer Flat
E Retaining Ring
Figure 43: CTA Autopilot Assembly for K613 and Smaller Sizes

K600 1.4
PRODUCT MANUAL 1.4
ASSEMBLY
Step B: 2a: Damaged CTA Replacement for Autopilot K614 (6” flange) and Larger
NOTE – This pertains to the Autopilot only, if a manual CTA is used to skip to Step C.
Step 1: Remove the Motor Mount assembly by taking off SHCS, 0.38-16x0.88 and Washer Lock
Step 2: Remove the Position Marker by taking out SHCS, M4-0.7x18 and Washer Lock
Step 3: Remove Positioner Sensor by taing out BHCS M5-0.8x 12 and Washer Lock
Step 4: Replace these items on new CTA Assembly. Make sure the Position Marker has a 1-2mm
gap from the Positioner Sensor.
M2 Screw M2 Flat Washer

M2 Belleville Washer M2 Locknut
M4 Screw Position Sensor

M4 Washer
Positioner
Marker
CTA Assembly
Figure 44: Assembly Instruction for Damaged CTA Replacement for Autopilot - Sizes K614 and Larger

K600 1.4
ASSEMBLY
Step B: 2b: Damaged CTA Replacement for Autopilot K613 (4” flange) and Smaller
NOTE – This pertains to the Autopilot only, if a manual CTA is used to skip to the next page.
Step 1: Remove the Drive Shaft Mount (manual) from the new CTA Assembly by taking off FHCS
M10-1.5x20, be sure that none of the Washer Thrust are removed.
Step 2: Remove the Driveshaft Mount (Automatic) Assembly from the old CTA Assembly by taking
off the FHCS M10-1.5x20.
Step 3: Remove the Position Sensor by taking out BHCS M5-0.8x12, Washer Int/Ext Lock and
Washer Flat (white).
Step 4: Remove Position Marker by taking out SHSS, M6-1.0x6.00.
Step 5: Replace these items onto new CTA Assembly. Make sure the Position Marker has a 1-2mm
gap from the Position Sensor.
Drive Shaft
Washer Thrust
Drive Shaft Mount (Manual) CTA Assembly CTA Assembly
FHCS M10-1.5x20
Driveshaft Mount (Automatic)
BHCS M5-0.8x12
BHCS Lock
Washer Int/Ext M5-0.8x12
Washer
Washer Int/Ext Lock
Flat (White)
Position SensorSensor
Position
Washer Lock
SHCS, M4-0.7x18
SHSS, M6-1.0x6.00
Position Marker
Position Marker
Figure 45: Assembly Instruction for Damaged CTA Replacement for Autopilot - Sizes K613 and Smaller

K600 1.4
PRODUCT MANUAL 1.4
ASSEMBLY
Step B: 3a: Shaft Locker for Manual CTA K614 (6” flange) and Larger
NOTE – This pertains to the manual K614 and larger CTA only, if an Autopilot is used to skip to
the next page. If the Autopilot is removed then this must be installed in it;s place to prevent the
Combining Tube from self adjusting during operation.
Step 1: Align the holes of the Self-Locking Plate, K614-K616 Manual CTA to the CTA Housing for
K614-K616 and fasten with Washer Lock 3/8 18-8 and SHCS, 0.38-16x0.50, 18-8SS until
snug.
Step 2: Slide the CTA Shaft Locking Clamp onto the shaft, aligning the flat side flush with the
Self-Locking Plate, K614-K616 Manual CTA. Fasten with Washer Lock M5 18-8 and BHCS
M5-0.8x12, 18-8 SS until snug.
Step 3: T
ighten the handle on the CTA Shaft Locking Clamp until snug, do not overtighten. To
adjust the Combining Tube loosen the handle and make desired adjustment. Then tighten
the handle.
CTA Housing for K614-K616

Self-Locking Plate, K614-K616 Manual CTA
BHCS M5-0.8x12, 18-8 SS
Washer Lock M5 18-8
Washer Lock 3/8 18-8
SHCS, 0.38-16x0.50, 18-8SS
CTA Shaft Locking Clamp
Figure 46: Assembly Instructions for Shaft Locker for Manual CTA - Sizes K614 and Larger

K600 1.4
ASSEMBLY
Step C: CTA
Step 1: Assemble CT Block, HD to Combining Tube utilizing 3 Screw Socket Head and Nordlock
Washer, make sure to use Loctite 246 (high temp) on threads. Torque Screw Socket Head
to 50 Ft*Lb. NOTE – If this is not followed exactly it will void warranty.
Step 2: Heavily grease the driveshaft with a high temperature grease. Refer to Steps 3-5 below if it
is a K614 (6” flange) and larger Hydroheater, otherwise continue to Step 6.
Step 3: Inspect the threads and lead-in chamber of the Split Nut, CTA, make sure threads are
uniform for each half for proper installation.
Step 4: Insert Split Nut, CTA onto Drive Shaft. Make sure the ends of each half of the Split Nut, CTA
are flush.
Step 5: Slide Collar Split Nut over the Split Nut, CTA. The flats on the Collar, Split Nut align with the
split line of the Split Nut, CTA.
Step 6: Insert the O-Ring (CTA) into the CTA Assembly groove. Use a high temperature grease to
temporarily hold it in place.
Step 7: A
ssemble the CTA Assembly onto the Body, the proper direction is shown below. Make
sure the Collar, Split Nut and Split Nut, CTA (K610-K613 utilizes a square solid nut instead
of Collar, Split Nut and Split Nut, CTA) slides into the center slot of the CT Block, HD.
Torque Screw Heavy Hex, Washer Bellville and Washer Flat to 42 Ft* Lb.
CT Block, HD
Nordlock Washer
CTA Replacement Kit (Manual/Auto)
Screw Socket Head Collar, Split Nut

O-Ring (CTA)
Split Nut, CTA
CTA Assembly
Driveshaft
Washer Flat
Washer Bellville
Screw Heavy Hex
Detail CTA
(K614 & Larger Only)
Collar, Split Nut
Split Nut, CTA
CT Block, HD
Drive Shaft
Body Detail CTA Installed

(K614 & Larger Only)
Combining Tube
Figure 47: CTA Assembly Instructions
K600 1.4
PRODUCT MANUAL 1.4
ASSEMBLY
Step D: Nozzle
Step 1: Thoroughly clean the Nozzle and Nozzle bore in body of burned on product.
Step 2: Assemble the Nozzle into the Body. When the Spiral Retaining Ring groove is fully visible
the Nozzle will be fully seated.
NOTE – Nozzle may be difficult to assemble, it is a tight fit, but is not a press fit. Do not

force Nozzle into Body. Make sure it isn’t cocked, it may take a few tries to get it just right.
If needed use a piece of wood or plastic rod to lightly tap around the perimeter of the
Nozzle to help assist it into place.
Step 3: Install the Spiral Retaining Ring, ensure it is fully seated in the groove (K612 and smaller
use an internal retaining ring instead).
Nozzle
Spiral Retaining Ring
Body
Figure 48: Nozzle Assembly Instructions

K600 1.4
ASSEMBLY
Step E: 1a: CTA Calibration Mechanical Zero K614 (6” flange) and Larger
NOTE – Zeroing should never be adjusted while heater is running. Incorrect adjustment of the

zero position will damage the heater is running. Incorrect adjustment of the zero position will
damage the heater or it will not work properly!
Step 1: Turn the Drive Shaft in each direction to make sure the Combining Tube moves in each
direction.
NOTE – If there is an Autopilot one of the gears must be removed first (refer to Step B).
Step 2: Turn the Drive Shaft to the closed position as indicated on the Indicator Plate and visually
make sure the Indicator Pin is moving in the right direction. Keep turning it in that direction
until resistance is felt. Do not force it and make sure the Indicator Pin does not come in
contact with the end of the slot of the Guard, CTA or the Body. At this point the Combining
Tube should be touching the Nozzle.
Step 3: Turn the Drive Shaft to the open position exactly one revolution. This will be the point of
mechanical zero.
Step 4: Align the Indicator Pin with the Indicator Plate zero position. This can be done by
loosening the BHCS M5-0.8x6 and adjusting the Indicator Plate. If there isn’t enough room
in the slots, remove SHCS, M4-0.7x18 and Washer Lock. Rotate the Indicator Insert as
needed until the zero position can be aligned.
Drive Shaft
Body
Nozzle
Combining Tube
Guard, CTA
Washer Lock
SHCS, M4-0.7x18
Indicator Insert
Indicator Plate
BHCS M5-0.8x6 Indicator Pin
Washer Lock
REVERSE ISOMETRIC VIEW

CTA Replacement Kit (Manual/Auto) K614 & Larger
Figure 49: CTA Calibration Mechanical Zero for Sizes K614 and Larger

K600 1.4
PRODUCT MANUAL 1.4
ASSEMBLY
Step E: 1b: CTA Calibration Mechanical Zero K613 (4” flange) and Smaller

zero position will damage the heater or it will not work properly!
Step 1: Turn the Drive Shaft in each direction to make sure the Combining Tube moves in each
direction.
NOTE – If there is an Autopilot one of the gears must be removed first (refer to Step B).
Step 2: Turn the Drive Shaft in the closed position as indicated on the Indicator Plate and visually
make sure the Indicator Pin is moving in the right direction. Keep turning it in that direction
until resistance is felt. Do not force it and make sure the Indicator Pin does not come in
contact with the Body or end of the slot in the Guard, CTA. At this point the Combining
Tube should be touching the Nozzle.
Step 3: Turn the Drive Shaft in the open position exactly one revolution. This will be the point of
mechanical zero.
Step 4: Align the Indicator Pin with the Indicator Plate zero position. This can be done by
loosening the BHCS M5-0.8x6 and adjusting the Indicator Plate.
Body
Drive Shaft
Nozzle
CTA Assembly
Combining Tube
BHCS M2-0.8x12
Position Sensor
SHSS, M6-1.0x6.00
Position Marker
Indicator Pin
Indicator Plate
BHCS M5-0.8x6
REVERSE ISOMETRIC VIEW

CTA Replacement Kit (Manual/Auto) K613 & Smaller
Figure 50: CTA Calibration Mechanical Zero for Sizes K613 and Smaller

K600 1.4
ASSEMBLY
Step F: CTA Calibration Electrical Zero
NOTE – This pertains to the Autopilot only, if manual CTA is used skip to Step G.


zero position will damage the heater or it will not work properly!
Step 1: The CTA Assembly must be mechanically zeroed as previously shown and it must be in
the zero position.
Step 2: Make sure the Position Marker has a 1-2mm gap from the Position Sensor, otherwise an out
of range alarm will occur or position accuracy may have poor resolution.
Step 3: Slightly loosen BHCS M5-0.8x12 so that the Position Sensor can slide back and forth.
Step 4: Slide the Position Sensor back and forth until 0.00% is displayed on the CTA position
display on the electrical panel or Co-pilot (the Co-pilot is a device that allows it to be
zeroed out of line or away from the electrical panel). Once achieved tighten the BHCS-M5-
0.8x12. Make sure the reading is 0.00% after it is tightened.
NOTE – This may take a few attempts to reach exactly 0.00%.
Step 5: Assemble gear and guard back onto the Autopilot refer to Step B. 1a or B. 1b.
Step 6: When installed correctly the PLC Program will not allow the “Close” air solenoid to
energize when directed to close. The CT will only “Open” at 0.00% and will not be able to
close past 0.00%.
Step 7: Verify that new zero position by opening the CT until the CTA position display reads 2%.
Then close the CT until close solenoid de-energies. The CTA position display will indicate
0.00%. If the value continues to count in a negative direction, STOP immediately! Reset
“Mechanical Zero” before you start the procedure again.
Body
CTA Assembly
BHCS M5-0.8x12
Position Sensor
Position Marker
Figure 51: CTA Calibration Electrical Zero

K600 1.4
PRODUCT MANUAL 1.4
ASSEMBLY
Step G: Head & Stem-Plug
Step 1: Install the Lip Seal into the Head Automatic, the spring must be facing the outside. Be
sure not to bend or kink the lip seal. Grease them with a high temperature non-petroleum
based grease. The Lip Seal will be fully seated when the Retaining Ring groove is fully
visible. Then install the Retaining Ring with a snap ring with a snap ring pliers.
Step 2: Inspect stem-plug for burrs near the flats, remove if found (they would damage Lip Seal).
Install the Stem Plug into Head Automatic, be careful when sliding it into the Lip Seal make
sure not to damage them.
Step 3: Install the Packing Set (2 ropes and 3 graphite rings) between the Head Automatic & Stem
Plug. The rope will be on the top and bottom with the graphite rings in-between. Stagger
the split/end of each one 70 degrees apart.
NOTE – The Packing Follower can be used to help push them in place.
Step 4: Assemble the Packing Follower to the Head Automatic utilizing Washer Lock and Screw
Socket Head. Hand tighten the Screw Socket Head, then tighten 1 turn with allen wrench.
Step 5: Slide O-Ring (Head) onto the Head Automatic (seats on small hub), use high temperature
grease to temporarily hold it in place if necessary.
Step 6: Assemble Head Automatic to Body, make sure O-Ring Head stays in place. Apply anti-
seize to all studs. Tighten Nut Hex Hvy to torque in chart below.
NOTE – If your Hydroheater head came with an additional two Screw Socket Head, hand

tighten them into the two tapped holes near the hex nuts. These are jack screws to assist
in disassembly of the head during maintenance.
Table 11: Head Nut (18-8, B8 Class 1)

Industrial K610
K611/
K613 K614 K615
K616/
Hydroheaters K612 K617
Bolt Size 1/2-13 1/2-13 3/4-10 7/8-9 1-8 1 1/4-7 Screw Socket Head
# of Bolts 6 10 8 12 12 12 Washer Lock

Packing Follower
Torque (in. lbs) 255 255 905 1455 2180 4360 Packing Set
Torque (ft. lbs) 20 20 75 120 180 365
Lip Seal
Retaining Ring
Flats
Stem-Plug
Nut Hex Hvy
Head Automatic
O-Ring (Head)
Body
Figure 52: Head & Stem-Plug Assembly

K600 1.4
ASSEMBLY
Step H: Actuator
Step 1: Tap on the end of the Stem-Plug with a rubber mallet to ensure that it is fully seated.
Step 2: Install Pneumatic Actuator onto Head Automatic, make sure not to damage threads on
Stem-Plug. Apply anti-seize to threads on Locknut, Actuator. Tighten Locknut, Actuator.
This is generally done with a chisel and hammer.
NOTE – On the K616 (10” flange) and larger the actuator is bolted on instead of using the
actuator locknut.
Step 3: Refer to section 9.0 bench setting of K600 Hydroheater actuator and positioner.
Pneumatic Actuator
Stem Connector
Stem Plug
Locknut, Actuator
Screw Socket Head
Head Automatic
Body
Figure 53: Actuator Assembly

K600 1.4
PRODUCT MANUAL 1.4
ASSEMBLY
Step I: Actuator Support
NOTE – The actuator support is only used on some units. It is supplied with K613 (4” flange)
and larger with the use of a standard actuator.
Step 1: Assemble the Actuator Support Bracket to the Body, utilizing the hardware below. The
Actuator Support Bracket should come in contact with the Pneumatic Actuator between
the U Bolt connection in order for it to supply proper support.
U Bolt
Pneumatic Actuator
Nut Hex Hvy

Washer Flat
Actuator Support Bracket

Screw Hex Head
Body
Washer Lock
Figure 54: Actuator Support

K600 1.4
7.7 Rotating the Actuator
For some installations, the orientation of the actuator/positioner as-shipped may be inconvenient.
For example, the positioner may be located below the heater and difficult to see.
The following procedure outlines how to rotate the actuator/positioner for a more convenient orientation.
In summary, the actuator will be raised slightly using air pressure to eliminate the closing force. Then it will
be loosened from the Hydroheater, rotated and re-tightened. Please follow the steps below or consult the
Hydro-Thermal Service Department with any questions.
1. Remove the air line between the positioner and actuator.
Positioner to Actuator Airline
Figure 55: Positioner to Actuator Airline
2. Attach air supply with regulator to the actuator as shown below.
Air Pressure Air Supply with Regulator
Figure 56: Air Supply to Actuator

K600 1.4
PRODUCT MANUAL 1.4
CAUTION – To avoid applying excessive pressure, the max pressure of the regulator should
be 0-30 psi.
3. Apply air pressure of 10-15 psi to the actuator. This will open the actuator slightly, removing the
downward force on the stem plug.
CAUTION – In this condition, the actuator could close suddenly upon loss of air. Do not place
anything (hands, fingers or tools) in the area of the actuator stroke.
4. Loosen the actuator lock nut slightly, just enough to allow movement. Do not remove the actuator.
Actuator Lock Nut
Figure 57: Actuator Lock Nut
5. Rotate the actuator to the desired orientation.
6. Tighten the actuator lock nut.
7. Reduce air pressure to zero psi. The actuator will close. Then, remove the air regulator.
8. Reinstall the airline between the positioner and actuator.
7.8 Actuator “Bench Set” Procedure (Pre-Installation of Positioner)

NOTE – The first few pictures are setting the travel of the actuator only. If this procedure is being done
with the actuator still attached to the heater, loosen the two 9/16” bolts and the jam nut holding the con-
necting block together and screw the stem plug towards the actuator several turns so it does not interfere
with the travel during the setting process.
1. Note actuator ID plate pressure and travel range. Different actuators have different pressure and travel
ranges. It is important to set the actuator based on its particular ID tag values.
2. Before connecting unregulated (plant) air to actuator install an air regulator inline before the actuator.

K600 1.4
3. Set the air regulator to 0 psig.
4. Connect an air line from the regulator to the actuator.
5. Raise regulated air to 5 psi over actuator ID plate max operating pressure. Actuator should be at max
open position.
CAUTION – Do not exceed maximum pressure of the actuator.

6. Note the position by measuring it or sliding the scale to its max open indicator mark. This point will be
the max open of the actuator from now on. Drop the air slowly so actuator starts closing. When actuator
reaches its specified travel limit, stop dropping the air. This point is important since there is still a small
amount of movement left in the actuator. Move the connecting block (screw it in or out) to match 0%
open on the metal scale.
7. If the stem plug is attached to the heater, unscrew it towards the heater until there is contact with the
nozzle (it will be much more difficult to turn at that point). The remaining physical movement left in the
actuator will be used to maintain mechanical pressure on the stem plug in the closed position (0 psig).
8. Snug up the two 9/16” bolts on the connecting block and tighten the jam nut.
9. Note the position of the connecting block and then drop the air regulator to 0 psig. The stem plug should
not move but the remaining travel of the actuator spring should continue pushing on the stem plug to
keep some mechanical pressure to keep it closed.
10. Increase the air again to 5 psi over max operating pressure and measure travel distance. It should travel
whatever the ID plate says and the connecting block should line up with the metal Scale 100% open
mark. Release the air pressure completely and verify the connecting block does line up with the 0 mark
on the scale. If not, do steps 5 – 10 until it does.
11. Dial air down to low limit (on a 3 psig to 15 psig actuator, set to 3 psig). Increase air slightly until actuator
starts to rise. Should start about 3.5 psig or so. If it doesn’t start to rise until 4 psig the actuator spring nut
needs to be adjusted (unscrew loosens tension) just enough so it does not over power the air pressure
being applied.
12. Dial air up to 14.5 psig and actuator should move to max open. If not the spring nut needs adjustment.
13. Adjust the metal scale to the travel limits of the actuator. Loosen the two Phillips head screws and slide
the scale to match the travel. Next, retighten the screws if necessary.
14. Summary:
a. The actuator should move its rated distance on the ID tag.
b. It should start opening at or just above minimum rated pressure and be to max open position just
below max rated pressure
c. The actuator/stem plug movement should be smooth

K600 1.4
PRODUCT MANUAL 1.4
Actuator Nameplate
Actuator Fully Extended

with “0” Air Pressure
Regulator Set to “0”
House Air
Figure 58: Actuator Detached from Stem Plug and Pressure Released

K600 1.4
Scale
Jam Nut Connecting

9/16” Wrench Fits Block
These Bolts
Actuator Spring
Tensioning Nut
Regulated Air
Figure 59: Actuator Connected to Stem Plug
7.9 Positioners
A positioner can be mounted onto the K600 Hydroheater in order to better control steam flow and ulti-
mately temperature. There are many types of positioners that are compatible with the K600 Hydroheater.
Sections 7.10 Installing and Calibrating a DVC 2000 Positioner, 7.11 Installing and Calibrating a DVC 6200
Positioner, and 7.12 Calibrating a Fisher DVC 6010 Positioner give instructions on how to install and calibrate
the most common kinds. If you have a different positioner than those listed or are not sure what kind you
have, please reference the positioner manufacturers’ manual or contact Hydro-Thermal at (262) 548-8900.

K600 1.4
PRODUCT MANUAL 1.4
7.10 Installing and Calibrating a DVC 2000 Positioner

7.10.1 Mounting Magnet Array for DVC 2000
NOTE – Do not use magnetized tools around the DVC 2000. Permanent damage to the magnet array
could result. The actuator max travel must be the same as the distance between the white lines on the
magnet array.
Make sure the magnet array is mounted such that the upper white line of the valid travel range on the
magnet array is 1/8” above the white line (index mark) on the rear of the body. The key is that here is
the single white line on the body should always be between the two white lines of the magnet array
throughout its full travel. Please reference the positioner manufacturers’ manual or contact Hydro-Thermal
with further questions.
7.10.2 Calibrating a DVC 2000

1. Verify the disk below the connecting block lines up with 0% open on the scale and appears to be
centered in the channel of the body.
2. If there is a signal, skip to step #6, if not continue to step #3.
3. Hook up 4 – 20 mA generator to the green power block as label indicates.
4. Hook up (0 preset pressure) air regulator and set pressure to the ID plate pressure on actuator.
5. Turn on the generator and set to 12 mA. Perform steps 6 – 11, and then positioner should follow
generator settings.
6. Take the cover off using the two Phillips head screws. Next, there should be four grey buttons/arrows in
a diamond arrangement visible. Whether the positioner is vertical or horizontal is not important. The up
button/arrow pointing at the screen is the “up” button/arrow. The button/arrow pointing away from the
screen is the “down” button/arrow. On the screen, the button/arrow on the right is the “right” button/
arrow and the opposite button/arrow is the “left”.
7. Push the down button/arrow momentarily one time, quick setup should be displayed.
8. Other choices will be displayed if the down button/arrow is chosen more than once. Do not use c – f
unless that is what specifically needs to be done. For now, use the quick setup to ensure that the
positioner is working properly and want to verify its operation.
a. Quick setup
b. Travel calibration
c. Tuning
d. Detailed set up
e. Analog input calibration
f. Local control
g. You have to push the up button/arrow to go back up to quick set up.

K600 1.4
9. Push right arrow once. Next, the screen will show valve will move - press right button/arrow for 3 sec
warning. Push right arrow and hold for three seconds.
10. Calibration then starts. Next, the screen will show finding 0% then finding 100% then finding 0% again,
than finding 50% (it takes about two minutes to complete quick setup).
11. Quick setup complete should show on the display after that with a successful setup.
12. If it did not complete, try it again and double check the magnet array in the rear of the unit. The single
white line on the body should always be between the two white lines of the array and not binding with
or touching the body anywhere through its travel. That is usually the problem (array came loose, is
binding up somewhere or is moving past the body white line). If the array is moving freely within the
lines, perform steps 6 – 11 again.
13. To abort procedure, press and hold both right and left arrows at the same time for three seconds.
Air in Output to
Supply Actuator
SD-346
Figure 60: DVC 2000 Mounted on Actuator

K600 1.4
PRODUCT MANUAL 1.4
Magnet Array
Travel Marks
Magnet Array
Travel Marks Body Index SD-346
Marks
Figure 61: Array Mounting Location
Currently Selected
Menu Option
Up Arrow
Left Arrow Right Arrow

SD-346
Down Arrow
Figure 62: DVC 2000 Showing Screen Display and Arrow Placement

K600 1.4
7.11 Installing and Calibrating a DVC 6200 Positioner
7.11.1 Mounting Magnet Array for DVC 6200
NOTE – Do not use magnetized tools or strap magnets on meters around the DVC 6200. Permanent
damage to the magnet array could result. The actuator max travel must be the same as the distance
between the white lines on the magnet array. Please reference the positioner manufacturers’ manual or
contact Hydro-Thermal with further questions.
NOTE – These instructions are written for air-to-open actuators only. Included in the mounting kit is a
plastic template that should be used for initial setup. This template is also needed when converting from a
DVC 6010 to a DVC 6200.
7.11.2 Calibrating a DVC 6200

1. Verify the actuator is fully closed and stem plug completely seated.
2. Attach the mounting bracket from the kit to the actuator.
3. Loosely attach the feedback pieces and magnet array to the valve stem connector. Before tightening any
screws, verify that the magnet array matches the actuator travel. This is done by measuring the distance
between the white lines of the magnet array and comparing that dimension to the max travel on the
actuator metal ID plate. There are several different sizes and styles of magnet arrays so it is crucial to
verify that it is the correct one. For instance, if the magnet array goes beyond the template/body index
mark, then you will not have travel control. In this situation, please contact Hydro-Thermal at
(262) 548-8900. If the magnet array does match, then proceed to the next step.
4. Using the black plastic alignment template, position the magnet array inside the retaining slot.
5. Vertically align the magnet array so that the center line/index mark of the plastic alignment template is
slightly below the top white line of the magnet array (approximately 1/8”). The key is that the single white
line on the body should always be between the two white lines of the magnet array throughout its full
travel.
6. Loosen the bolts/screws and remove the alignment template.
7. Mount the DVC 6200 to the mounting bracket, using the supplied mounting bolts.
8. Check for clearance between the magnet array and the DVC 6200 feedback slot. Verify there is
clearance throughout the full travel of the magnet array. This can be done by slowly airing up the
actuator. Once this is complete, tighten all of the bolts/screws.
9. Hook up the air supply to the DVC 6200 and from the DVC 6200 to the actuator.
10. The DVC 6200 will now need to be programmed with a HART Communicator. Please see section 7.12
Calibrating a Fisher DVC 6010 Positioner for instructions on how to program a 475 HART communicator.

K600 1.4
PRODUCT MANUAL 1.4
Feed Back
Pieces Body Index
Mark
Mounting
Bracket
Holes
Hall Sensor in Feed-

back Slot of Body
Feedback Slot
Magnet Moves In
Figure 63: Bottom View of DVC
Valid Travel
Range Marks
Magnet
Assembly
Feedback
Pieces
Valve Stem
Connector
Figure 64: Magnetic Assembly

K600 1.4
Retaining
Slot
Mounting
Bracket
Index Alignment
Marks Template
Figure 65: Alignment Template/

Mounting Bracket
7.12 Calibrating a Fisher DVC 6010 Positioner

NOTE – The following instructions are based on using a HART 475 communicator. If you have a different
communicator or have additional questions about the DVC 6010, please reference the positioner
manufacturers’ manual or contact Hydro-Thermal.
NOTE – This procedure assumes the positioner has been bench set and linkage from stem plug and
positioner has been installed properly. Double check adjustment arm pin is in feedback arm slot, and is on
top of the spring as well as set to the max actuator travel number on the feedback arm. There is a stylus on
the back side of the unit that can be used to select screen options.
NOTE – These positioners are obsolete and can no longer be purchased. There positioners have been
replaced with the DVC 6200.
1. Unscrew electrical cover and linkage cover. If there are wires already connected, disconnect them now
remembering which terminal they came from to reconnect them after this calibration.
2. Hook up HART communicator and 4 – 20mA generator (+ (RED) to + and (BLACK) to loop terminals).
3. Set 4 – 20mA generator to 12 mA (this will be the cross over point).
4. Hook up house air to regulator and set it for 5 psi above the actuator tag max operating pressure.
Then plug the air hose into the unit.

K600 1.4
PRODUCT MANUAL 1.4
5. Turn on HART communicator.
6. Wait for HART application to display, then enter.
7. Wait for setup to display.
8. Select – setup (1). Push #1’s most of the way.
9. Select - basic setup (1).
10. Select - auto setup (1).
11. Select – setup wizard (1).
12. Select – Follow prompts to select out of service, (1 – safe mode).
13. Select – travel control, enter.
14. Select – psi value on the tag, enter.
15. Enter value 5 psi over max value on actuator tag, enter.
16. Select – Fisher enter/OK.
17. Select - 667 Type/model, enter.
18. Select – size on actuator tag enter.
19. Select – Yes if the heater has a volume booster or No if there is not a volume booster, enter.
20. Select – send, 1/enter (configuration being sent).
21. Select – factory defaults yes, enter.
22. Run auto travel calibrate – OK, yes.
23. Cross over adjust, select – manual, enter.
24. Next (0 - 100% seeking high drive stop, then 100% - 0% seeking lo drive stop, then 0 – 50% while
adjusting output bias is occurring.
N
OTE – During the bias setting portion, the 475 HART Communicator can lockup in an endless loop.
The only way out is to turn off the Milliamp generator and start over. However, if there is a volume
booster, unscrew the screw another ½ turn or so when that screen comes up. If there is not a volume
booster, tweak the air a couple psi when that screen comes up. These are the only two things that are
proven to work to get past a lockup scenario.
25. Crossover adjustment source, select analog, 1/enter.
26. Adjust the current source until feedback arm is at crossover point (verify 12mA on generator), enter.
(12mA should put feedback arm at crossover point. Feedback arm should be perpendicular to the
actuator stem at cross over point.
Cross over point is when the pin in the feedback arm changes the direction it is moving, usually mid
travel 50%).

K600 1.4
27. Seeking hi and lo drive stops
28. Move valve now to set pressure range, hi – lo yes, enter/1.
29. Calibration Complete OK, OK.
30. Select – in service to put it back in service.
31. Shut off HART Communicator.
32. Increase and decrease mA generator signal and verify indicator follows generator values. Should start
opening at 4.2 mA and should start closing at 19.9 mA.
33. If it doesn’t start opening at 4.2 mA, redo the setup again. If that still doesn’t work use the bench set
procedure and recalibrate again.
34. Remount linkage cover.
On DVC 6010HC Positioner – plug the output B hole and crank the little adjustment wheel in the proper
direction. This will make it compatible with a single acting actuator. This type of positioner can be set up for
double acting actuators.
Figure 66: 475 HART Communicator

K600 1.4
PRODUCT MANUAL 1.4
8 K500 TO K600
Hydro-Thermal maintains a policy of continuous improvement, making ongoing changes to enhance
performance and improve reliability. For this reason, the highly reliable Hydroheater is being upgraded
from model K500 to K600. This section summarizes the differences between the two models and shows
the necessary changes to ensure smooth plant start-up after conversion.
CAUTION – Damage to the Hydroheater could occur if the program in the Autopilot panel PLC is not
updated when changing from a K500 style to a K600 style heater. K600 and K500 heaters cannot be
interchanged without changing the PLC program. Customers are strongly advised to convert any spare
K500 heaters to the K600 style.
Larger
Slot
K500 K600
Figure 67: Heater Body Comparison
Note that the K600 series body is the same casting, but is machined slightly different than the K500. The
CT adjustment slot is larger on the K600 series.
For customers with K500 series bodies, these can be reworked to a K600 style. This modification must be
done at Hydro-Thermal. The one exception is the K510/K610. In this instance, a new heater will need to be
purchased.

K600 1.4
CT Assembly
The K500 Hydroheater Combining Tube (CT) uses a threaded connection between the CT and the Stud.
For customers with K500 series Hydroheaters, the CT (if in good condition) can be reworked to a K600
style. This modification must be done at Hydro-Thermal. There are two exceptions. The first is the K513/
K613 conversion—this model requires that a new CT be purchased. The second is the K510/K610 - in this
instance, a new heater will need to be purchased.
Stroke lengths for the Combing Tube are:
Table 12: K500 Series

CT Stroke Lengths
K510 0.9 inch
K511 / K512 1.25 inch
K513 1.4 inch
K514 / K515 / K516 1.9 inch
The corresponding stroke length selection is set up in the Autopilot PLC program at Hydro-Thermal prior
to shipping.
K500 Combining Tube
K500 Manual CTA Assembly K500 Autopilot Drive Mechanism
Figure 68: K500 Series Components

K600 1.4
PRODUCT MANUAL 1.4
K600 Series
The K600 Hydroheater Combining Tube (CT) uses a bolted connection (3 screws) between the
CT and the Stud.
Stroke lengths have been standardized as:
Table 13: K600 Series CT

Stroke Lengths
K610 / K611 / K612 / K613 1.125 inch
K614 / K615 / K616 1.5 inch
Note that while the CT stroke length varies as shown above, the feedback sensor movement is always
1.125”—standardizing the interface. For this reason, the Autopilot PLC always uses 1.125” as the travel
distance for 0-100%.
K600 Combining Tube
K600 Manual CTA Assembly K600 Autopilot Drive Mechanism
Figure 69: K600 Series Components

K600 1.4
Air Motor
The air motor used in the drive mechanism has been downsized for the K600. When upgrading from a
K500 to K600 Autopilot, fitting changes (3/8” to 1/4”) will be needed at the air motor. Air line sizes are still
3/8”, but will need to be re-routed slightly.
Air Set (Solenoids)

The air set will not have to change—the K600 uses the same components.
Main Air Enable Solenoid Open Regulator & Gauge

(Dump Valve)
Close Solenoid
Air Oiler
Main Air Valve
Condensate
Removal
Open Solenoid
Close Regulator & Gauge
Figure 70: Pneumatic Air Set

K600 1.4
PRODUCT MANUAL 1.4
CT Position Sensor
The position sensor used in the K500 and K600 is the same. However, zeroing is done slightly different.
The K500 must be zero calibrated when connected to the Autopilot panel; the K600 can be zero calibrated
on the bench. This feature simplifies zeroing and plant interface.
K500 Series
The position sensor is not adjustable on its bracket. Calibrating the Combining Tube zero is done by
moving the CT to 0% and capturing the position off-set to the PLC program.
The position marker for the sensor is a round magnetic target for sizes K610-K613 and a trapezoidal target
w/ plastic housing for sizes K614-K616.
Figure 71: K500 Series Position Sensor

K600 1.4
K600 Series
The position sensor is adjustable on its bracket. Calibrating the Combining Tube zero does not involve
going on-line with the PLC anymore. The CT is set to 0% open and the sensor position is adjusted to have
an output of 4.5 mA. This corresponds to read 0 at the panel.
The position marker for the sensor is a round magnetic target for sizes K610-K613 and a trapezoidal target
w/ plastic housing for sizes K614-K616.
M2 Screw M2 Flat Washer

M2 Belleville Washer M2 Locknut
M4 Screw Position Sensor

M4 Washer
Positioner
Marker
CTA Assembly
Figure 72: K600 Series Position Sensor
Autopilot Panel
The K600 is designed to operate with the same Autopilot control panel. There are no differences in
hardware.
Changes in the software include the following:

• Stroke length has been incorporated for the K600 models.
• A dead-band feature for differential pressure control has been added. If the measured differential
pressure is within +/- 2 psi of set point, the CT will not change.
K500 Series
Zeroing the CT position is done by first moving the CT to the fully-closed position. Then, the position
is captured by one of two methods: (1) using a jumper between two terminals in the PLC panel, or (2)
connecting with the PLC communication cable.
After calibration the zero offset must be saved to the EEPROM (need to be connected to the PLC) or
calibration is lost.
K600 Series
Initially the new program must be downloaded to the PLC and saved to the EEPROM. This is a one-time
program change. After this, zeroing the CT can be done without a program change.
Zeroing the CT position is done by first moving the CT to the fully-closed position. Then the sensor position
is adjusted to have an output of 4.5 mA, which corresponds to read 0 at the panel.
Note that the new calibration procedure allows the Hydroheater to be zeroed off-line, simplifying service
and start-up. A special calibration tool (Co-pilot) has been developed to assist with setting the zero.

K600 1.4
PRODUCT MANUAL 1.4
This is the K5 Autopilot Electrical Panel Inside
MicroLogix 1200 Programmable Controller Power Supply MCR
06-Open 07-Close 08-Enable Analogs
Figure 73: K500 Series Autopilot Electrical Panel

K600 1.4
Breakers Power Supply
Analog Expansion
Q:7 Enable
Power Q:5 Open Analogs
Q:6 Close
Figure 74: K600 Series Electrical Panel

K600 1.4
PRODUCT MANUAL 1.4
Steps to Change Over from K500 to K600:

1. K500 Heater body, Combining Tube and CTA or Autopilot CTA need to be retrofitted at
Hydro-Thermal
2. Install K600 heater in plant. Slight changes in the air lines and fitting will be needed for Autopilot.
Additional Steps to Change over From K500 to K600 Autopilot:

1. Hydro-Thermal Technician must be present to download the new program, save it to EEPROM
and verify functionality.
2. Verify zero position by manually adjusting CT to mechanical zero and observe the display on the
Autopilot panel to read 0%. If necessary, adjust the position sensor until the display reads zero.
After 0% is achieved, verify that a 100% on the panel matches the CTA indicator.
Additional steps to change over from K500 to K600 Autopilot Lite:

or customers that utilize the Autopilot Lite (i.e., controlling the Autopilot through the plant DCS), other
F
changes are needed.
The Autopilot Lite system uses the same mechanical components as the standard Autopilot system with
the exception of the control panel with the PLC. This requires the control logic carrying out the control
functions, alarms as well as safety measures having to reside in the plant DCS.
1. Update DCS program for the new stroke length of 1.125” of the position sensor, with a zero setting
of 4.5 mA.
2. Verify zero position by manually adjusting CT to mechanical zero and observe the display on the
Autopilot panel to read 0%. If necessary, adjust the position sensor until the display reads zero.
After 0% is achieved, verify that a 100% on the panel matches the CTA indicator.
Hydro-Thermal Co-Pilot for K600

The Co-Pilot is a calibration tool that allows convenient electrical position zeroing of the Combining Tube
in the maintenance shop environment rather than at the Heater installation site. It simulates the position
display of the Autopilot panel which shows 0% at a sensor output current of 4.5 mA. With the Combining
Tube at the mechanical zero, the location of the position sensor on the bracket can now be adjusted to
show 0% on the Co-Pilot display. Please reference the Co-Pilot sell sheet for additional information.
Figure 75: Co-Pilot

K600 1.4
9 LIMITED WARRANTY
Hydro-Thermal warrants all products provided to be free from defects in material and workmanship, and
will replace or repair at its discretion any such product or part within one year of the date of shipment. This
warranty is considered a return to factory with freight prepaid by the customer.
Hydro-Thermal reserves the right to inspect damaged parts. Hydro-Thermal bears no responsibility for loss
or damage due to the use or misuse of its products. If the Hydro-Thermal hardware product fails to work as
warranted above, Hydro-Thermal’s maximum liability under the limited warranty is expressly limited to the
lesser of the price paid for the product or the cost of repair or replacement of any hardware components
that malfunction in conditions of normal use. Except as indicated above, in no event will Hydro-Thermal be
liable for any damages caused by the product or the failure of the product or perform, including any lost
profits or savings, business interruption, loss of use or any other commercial or economic loss of any kind,
or special, incremental, or consequential damages.
Hydro-Thermal is not liable for any claim made by a third party or made by you for the third party. This
limitation of liability applies whether damages are sought, or a claim made, under this limited warranty
or as a tort claim (including negligence and strict product liability), a contract claim or any other claim.
This limitation in liability cannot be waivered or amended by any person. This limitation of liability will be
effective even if you have advised Hydro-Thermal, or an authorized representative of Hydro-Thermal, of
the possibility of any such damages or even if such possibility were reasonably foreseeable.

K600 1.4
PRODUCT MANUAL 1.4
10 APPENDIX
Appendix A: Steam Table

Table 14: Steam Table
Flash Pressure Saturated Steam Table
Temperature °F (°C)
psig / Barg psig / Barg
212ºF / 100ºC 0.0 / 0.0 5.0 / 0.34
214ºF / 101ºC 0.6 / 0.04 5.6 / 0.39
216ºF / 102ºC 1.2 / 0.08 6.2 / 0.43
218ºF / 103ºC 1.8 / 0.12 6.8 / 0.47
220ºF / 104ºC 2.5 / 0.17 7.5 / 0.52
222ºF / 106ºC 3.1 / 0.21 8.1 / 0.56
224ºF / 107ºC 3.9 / 0.27 8.9 / 0.61
226ºF / 108ºC 4.6 / 0.32 9.6 / 0.66
228ºF / 109ºC 5.3 / 0.36 10.3 / 0.71
230ºF / 110ºC 6.1 / 0.42 11.1 / 0.76
232ºF / 111ºC 6.9 / 0.48 11.9 / 0.82
234ºF / 112ºC 7.6 / 0.52 12.6 / 0.87
236ºF / 113ºC 8.5 / 0.59 13.5 / 0.93
238ºF / 114ºC 9.4 / 0.65 14.4 / 0.99
240ºF / 116ºC 10.3 / 0.71 15.3 / 1.05
242ºF / 117ºC 11.2 / 0.77 16.2 / 1.12
244ºF / 118ºC 12.1 / 0.83 17.1 / 1.18
246ºF / 119ºC 13.3 / 0.92 18.3 / 1.26
248ºF / 120ºC 14.1 / 0.97 19.1 / 1.32
250ºF / 121ºC 15.1 / 1.04 20.1 / 1.38
252ºF / 122ºC 16.2 / 1.12 21.2 / 1.46
254ºF / 123ºC 17.3 / 1.19 22.3 / 1.54
256ºF / 124ºC 18.4 / 1.27 23.4 / 1.61
258ºF / 126ºC 19.5 / 1.34 24.5 / 1.69
260ºF / 127ºC 20.7 / 1.43 25.7 / 1.77
262ºF / 128ºC 21.9 / 1.51 26.9 / 1.85
264ºF / 129ºC 23.2 / 1.60 28.2 / 1.94

K600 1.4
266ºF / 130ºC 24.5 / 1.69 29.5 / 2.03
268ºF / 131ºC 25.8 / 1.78 30.8 / 2.12
270ºF / 132ºC 27.2 / 1.88 32.2 / 2.22
272ºF / 133ºC 28.5 / 1.96 33.5 / 2.31
274ºF / 134ºC 30.0 / 2.07 35.0 / 2.41
276ºF / 136ºC 31.4 / 2.16 36.4 / 2.51
278ºF / 137ºC 32.9 / 2.27 37.9 / 2.61
280ºF / 138ºC 34.5 / 2.38 39.5 / 2.72
282ºF / 139ºC 36.1 / 2.49 41.1 / 2.83
284ºF / 140ºC 37.7 / 2.60 42.7 / 2.94
286ºF / 141ºC 39.4 / 2.72 44.4 / 3.06
288ºF / 142ºC 41.1 / 2.83 46.1 / 3.18
290ºF / 143ºC 42.8 / 2.95 47.8 / 3.30
292ºF / 144ºC 44.6 / 3.08 49.6 / 3.42
294ºF / 146ºC 46.5 / 3.21 51.5 / 3.55
296ºF / 147ºC 48.4 / 3.34 53.4 / 3.68
298ºF / 148ºC 50.3 / 3.47 55.3 / 3.81
300ºF / 149ºC 52.3 / 3.60 57.3 / 3.95
302ºF / 150ºC 54.3 / 3.74 59.3 / 4.09
304ºF / 151ºC 56.4 / 3.89 61.4 / 4.23
306ºF / 152ºC 58.5 / 4.03 63.5 / 4.38
308ºF / 153ºC 60.7 / 4.18 65.7 / 4.53
310ºF / 154ºC 62.9 / 4.34 67.9 / 4.68
310ºF / 154ºC 65.3 / 4.50 70.3 / 4.85
314ºF / 157ºC 67.6 / 4.66 72.6 / 5.00
316ºF / 158ºC 69.9 / 4.82 74.9 / 5.16
318ºF / 159ºC 72.4 / 4.99 77.4 / 5.34
320ºF / 160ºC 74.9 / 5.16 79.9 / 5.51
322ºF / 161ºC 77.5 / 5.34 82.5 / 5.69
324ºF / 162ºC 80.1 / 5.52 85.1 / 5.87
326ºF / 163ºC 82.8 / 5.71 87.8 / 6.05
328ºF / 164ºC 85.5 / 5.90 90.5 / 6.24
330ºF / 166ºC 88.3 / 6.09 99.3 / 6.43
332ºF / 167ºC 91.2 / 6.29 96.2 / 6.63
336ºF / 169ºC 97.1 / 6.69 102.1 / 7.04
338ºF / 170ºC 100.1 / 6.90 105.1 / 7.25

K600 1.4
PRODUCT MANUAL 1.4
340ºF / 171ºC 103.2 / 7.12 108.2 / 7.46

342ºF / 172ºC 106.4 / 7.34 111.4 / 7.68
344ºF / 173ºC 109.7 / 7.56 114.7 / 7.91
346ºF / 174ºC 113.0 / 7.79 118.0 / 8.14
CAUTION – To avoid undesirable steam characteristics, ensure that the steam discharge
pressure is 5 psig [0.34 barg] greater than the Flash Pressure.

K600 1.4
Appendix B: Saturation Table
Figure 72: Characteristics of Saturation Pressure vs Temperature

K600 1.4
PRODUCT MANUAL 1.4
Appendix C: Table of Figures
Figure 1: How the K600 Hydroheater Works. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 2: Location of Markings on Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 3: Dimensions of K600 Hydroheater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 4: K6 Autopilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 5: Autopilot Lite. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 6: Support Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 7: Piping Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 8: Process Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 9: Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 10: Drip Leg Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 11: Typical K600 Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 12: Logic for Closing the Steam Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 13: Pneumatic Air Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 14: Air Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 15: Side View of the Pneumatic Airset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 16: From the Top View of the Air Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 17: Close Up of Valve Forward/Reverse Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 18: Close Up of Position Sensor Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 19: Close Up of Air Enable Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 20: Flow Adjustment Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 21: Air Panel Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 22: K6 Autopilot Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 23: K500 Series Autopilot Electrical Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 24: K600 Series Electrical Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 25: Pulse-and-Wait Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 26: K6 Autopilot MicroLogix1200 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 27: Interconnection Drawing - Autopilot Lite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 28: Interconnection Drawing - Autopilot Lite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 29: Combining Tube Cross-Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 30: Head Cross-Sectional View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 31: Nozzle Cross-Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 32: Stem-Plug Sectional View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 33: K600 Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 34: Actuator Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 35: Actuator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 36: Head and Stem Plug Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 37: Nozzle Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 38: CTA Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 39: Combining Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 40: Inspection During Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 41: Combining Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 42: CTA Autopilot Assembly for K614 and Larger Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 43: CTA Autopilot Assembly for K613 and Smaller Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 44: Assembly Instruction for Damaged CTA Replacement for Autopilot - Sizes K614 and Larger. . . 81
Figure 45: Assembly Instruction for Damaged CTA Replacement for Autopilot - Sizes K613 and Smaller. . 82
Figure 46: Assembly Instructions for Shaft Locker for Manual CTA - Sizes K614 and Larger. . . . . . . . . . . . . 83

K600 1.4
Figure 47: CTA Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 48: Nozzle Assembly Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 49: CTA Calibration Mechanical Zero for Sizes K614 and Larger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 50: CTA Calibration Mechanical Zero for Sizes K613 and Smaller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Figure 51: CTA Calibration Electrical Zero. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 52: Head & Stem Plug Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Figure 53: Actuator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 54: Actuator Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Figure 55: Positioner to Actuator Airline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 56: Air Supply to Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 57: Actuator Lock Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 58: Actuator Detached from Stem Plug and Pressure Released. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 59: Actuator Connected to Stem Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 60: DVC 2000 Mounted on Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 61: Array Mounting Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 62: DVC 2000 Showing Screen Display and Arrow Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 63: Bottom View of DVC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 64: Magnetic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 65: Alignment Template / Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Figure 66: 475 HART Communicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 67: Heater Body Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 68: K500 Series Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 69: K600 Series Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Figure 70: Pneumatic Air Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Figure 71: K500 Series Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Figure 72: K600 Series Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Figure 73: K500 Series Autopilot Electrical Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Figure 74: K600 Series Electrical Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Figure 75: Co-Pilot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Figure 76: Characteristics of Saturation Pressure vs Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

K600 1.4
PRODUCT MANUAL 1.4
Appendix D: Table of Contents
Table 1: Explanation of Model Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Table 2: Application Examples for the K600 Hydroheater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Table 3: Maximum Water Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 4: Min Water Discharge Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 5: K600 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 6: Approximate Weight and General Flow Rate Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 7: Stainer Sizing Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 8: Alarm Lights & Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Table 9: Overtravel and Undertravel Position Signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 10: Recommended Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table 11: Head Nut (18-8, B8 Class 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table 12: K500 Series CT Stroke Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Table 13: K600 Series CT Stroke Lengths. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Table 14: Steam Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

K600 1.4
Contact Information
Contact Hydro-Thermal with any questions or concerns. We have a full staff of engineers, trained
technicians and customer service personnel to help with all your needs. Engineering services to design
steam systems or any other process needs are available at standard engineering consulting rates.
Hydro-Thermal Corporation
400 Pilot Court
Waukesha, WI 53188 USA
+1.262.548.8900
+1.800.952.0121
f – +1.262.548.8908
http://hydro-thermal.com
info@hydro-thermal.com

K600 1.4

K600 Hydroheater Manual

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K600 Hydroheater Manual

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K600 Hydroheater®

Call - (800) 951-0121 Email - info@hydro-thermal.com Visit - www.hydro-thermal.com

Hydroheater is a trademark of Hydro-Thermal Corporation, and is registered in the United

Copyright© 2021 Hydro-Thermal Corporation, Wisconsin, USA. All rights reserved.

All rights reserved.© Hydro-Thermal Corporation 2021

All rights reserved.© Hydro-Thermal Corporation 2021

All rights reserved.© Hydro-Thermal Corporation 2021

9 LIMITED WARRANTY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

All rights reserved.© Hydro-Thermal Corporation 2021

All rights reserved.© Hydro-Thermal Corporation 2021

1.1 Thank you for your Purchase

1.2 Purpose of the Manual

This manual contains information regarding installation, operation, troubleshooting, maintenance,

All rights reserved.© Hydro-Thermal Corporation 2021

All rights reserved.© Hydro-Thermal Corporation 2021

1.4 How the K600 Works

Sonic Velocity Steam Jet

Figure 1: How the K600 Hydroheater Works

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Table 1: Explanation of Model Numbers

1.5.2 Location of Markings on Body

Body Serial Number

Figure 2: Location of Markings on Body

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1.6 Application Criteria

Table 2: Application Examples for the K600 Hydroheater

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NOTE – For accurate sizing contact a Hydro-Thermal Representative

1.7 Process and Steam Pressure Requirements

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1.7.1 Maximum Process Pressure (Heater Discharge)

Table 3: Maximum Water Pressure

Steam Max Water Steam Max Water

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Table 4: Min Water Discharge Pressure

Water Pressure Min Water Water Pressure Min Water

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1.7.3 Superheated Steam

“F” Liquid Inlet A

1.7.4 Model Capacities and Heater Sizes

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All rights reserved.© Hydro-Thermal Corporation 2021

2.1.1 Starch Applications with the Autopilot

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• Air Set to Control Panel: 2 Cables

• Position Sensor to Control Panel: 1 Cable

See the photo below with the components identified.

Pneumatic Air Set

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2.3 Autopilot Lite – Overview and Cautions

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The system components are:

NOTE – The manual CTA cannot be integrated into the autopilot.

Pneumatic Air Set

CTA Assembly Air Motor

Figure 5: Autopilot Lite

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3.1 General Safety

3.2 Specific Safety

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All rights reserved.© Hydro-Thermal Corporation 2021

4.1 General Installation

CAUTION – If your K600 cannot be installed in accordance with these recommendations,

14. For further details call Hydro-Thermal Customer Service at 800-952-0121 or

5. With these pressures, the drive motor will rotate