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Trebor 2472, Operation & Maintenance Manual

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2472 DI HEATER OPERATION / MAINTENANCE MANUAL 

PAGE 17

 

4 

OPERATION 

4.1  GENERAL 

The following charts show the maximum flow capacity versus available 
temperature output for the heater system.  Applications below the 
saturation curve can be controlled to within 1

C of setpoint at steady state 

flow.  Applications above the saturation curve will not allow the process 
value to reach setpoint temperature. 

The pressure loss through the heater is shown.  Lower pressure drop 
configurations are available, consult factory for further information. 

Summary of Contents for 2472

Page 1: ...A U n i t o f I D E X C o r p o r a t i o n SERIAL NUMBER 9 13 00 M2472 FB MODEL 2472 DI WATER HEATER Operation Maintenance Manual ...

Page 2: ... REQUIREMENTS 11 3 4 HOOK UP 13 3 5 REMOTE HOOK UP 16 4 OPERATION 17 4 1 GENERAL 17 5 START UP 19 5 1 PRE START INSPECTION 19 5 1 a Verify Shipping Condition 19 5 1 b High Power Terminals 19 5 1 c Electrical Inspection 19 5 1 d Plumbing Leak Check 19 5 2 SYSTEM ON 20 5 3 TEMPERATURE CONTROLLER 20 5 4 HEATER MODULE POWER 21 5 5 POWER DISTRIBUTION INDICATORS 21 6 SHUT DOWN 22 6 1 HEATER CLEANOUT 22 ...

Page 3: ...n in the extent of large process flow changes DI water contacts only high purity fluoropolymer materials PVDF PFA and PTFE The modular system design facilitates the addition or replacement of system components as the need arises Redundant built in safety features and heater diagnostics provide valuable user protection and performance feedback With proper care and maintenance the Model 2472 DI Wate...

Page 4: ...lace when equipment is in operation Operators set up operators helpers or installation personnel should not alter remove or disable safety equipment When using this equipment be sure to follow the safety procedures outlined by your facility These safety procedures should cover the two primary types of hazard training 1 equipment hazards and 2 facility related hazards 2 1 SAFETY MESSAGE CONVENTIONS...

Page 5: ...connect Switch Lockout Tagout Information Equipment Safety Labels Hazard Lights 2 3 INTERLOCKS WARNING The high voltage interlock circuit does not remove high voltage from the circuit breaker contactor and the control transformer Only authorized qualified trained personnel should service this equipment 2 3 a Over Temperature Controller Interlock OTC The OTC disengages power to the heater component...

Page 6: ...heater elements The system will require pressing HEATER ON to restart see Section 8 Troubleshooting 2 3 c Liquid Level Sensor Interlock The Liquid Level Sensor will disengage power to the system if the heater modules are not full of water and prevents them from running dry The system will require pressing HEATER ON to restart see Section 8 Troubleshooting If sensor calibration is required follow d...

Page 7: ...aused by a plumbing leak inside the heater Fix any leaks and dry the leak tray prior to turning power on to the system The heater can be reactivated by pressing the HEATER ON button and will not function until the fault condition clears Figure 2 2 2 3 f Overpressure Burst Fitting The overpressure burst fitting Relief Drain is connected in line with the cold DI inlet port to provide a safeguard aga...

Page 8: ...elines and lockout or use suitable means to prevent re energizing the electrical system during installation or servicing 2 5 b Definitions Lockout the placement of a lockout device on an energy isolating device in accordance with established company procedures ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed Tagout ...

Page 9: ...er padlocks may not adequately block access to the setscrew Verify that the circuit breaker switch cannot be repositioned to ON Attach a safety tag Use the following information to assist in writing Lockout Tagout procedures for the system For more specific instructions refer to your site s Lockout Tagout requirements and procedures This table lists the Lockout Tagout information for the system En...

Page 10: ...ods to prevent injury Be careful when using a dolly or forklift to not damage the drain fitting located under the heater cabinet 3 2 LOCATION Locate the heater near the point of use to reduce plumbing heat loss Access to the front and rear of the system will be necessary for maintenance and hook up For heater replacement access to the top and sides of the enclosure are required This access can be ...

Page 11: ...psig 2 04 bars Minimum 30 psig Hot DI Outlet 3 4 Flare PFA Tube Discharge line must be restricted to create adequate backpressure 30 psig A flow restriction may be required at the point of use to limit discharge rate Overpressure Relief Drain 3 4 Flare PFA Tube 3 4 tube or equivalent 20m 60 ft length to open drain System Weight Dry Kg lbs 134 Kg 295 lbs Min Dimensions 76cm x 78cm x 48 3cm 30 H x 3...

Page 12: ...A U n i t o f I D E X C o r p o r a t i o n PAGE 12 2472 DI HEATER OPERATION MAINTENANCE MANUAL Figure 3 1 Facility Installation Layout ...

Page 13: ... OTC 2 NOT SHOWN IN SCHEMATIC REFER TO SCHEMATIC DWG P0105 IN OPERATION MANUAL R 8 120A CONTACTOR BOTTOM Figure 3 2 Electrical Component Layout 3 4 HOOK UP All utility hook ups associated with the DI Water Heater are easily accessible and are referenced in Figure 3 1 Facility Installation Layout After positioning heater at operating location raise the four leveling feet until the heater is level a...

Page 14: ...estricted to create adequate backpressure 30 psig running the system at low pressures will trip the system pressure interlock NOTE It is recommended that the hot water supply line have a bleed or purge at the point of use to reduce the possibility of stagnating the DI water in the heaters when not in use The amount of this bleed is best evaluated on a case by case basis taking into account each us...

Page 15: ...x Top or bottom conduit connections are provided see Figure 3 1 Facility Installation Layout Add supplementary insulation heat shrink to exposed conductors between the conduit opening and terminations on the circuit breaker Connect the 480 VAC supply grounding connector to the grounding lug and the other three lines into the top of the circuit breaker connections L1 L2 and L3 as shown in Figure 3 ...

Page 16: ... o r a t i o n PAGE 16 2472 DI HEATER OPERATION MAINTENANCE MANUAL 3 5 REMOTE HOOK UP If a remote control hook up is desired refer to schematic for pin outs and Amp connector part number see Figure 3 1 Facility Installation Layout ...

Page 17: ...ble temperature output for the heater system Applications below the saturation curve can be controlled to within 1 C of setpoint at steady state flow Applications above the saturation curve will not allow the process value to reach setpoint temperature The pressure loss through the heater is shown Lower pressure drop configurations are available consult factory for further information ...

Page 18: ... 10 15 20 25 30 35 40 Flow lpm Maximum Temperature C 0 0 02 0 04 0 06 0 08 0 1 0 12 0 14 0 16 0 18 0 2 Pressure Loss MPa Saturation Temperature Pressure Drop Figure 4 1 2472 Heater Capacity Assume DI Water Ambient Temperature 20 C 20 30 40 50 60 70 80 90 100 0 2 4 6 8 10 12 Flow gpm Maximum Temperature C 0 5 10 15 20 25 30 Pressure Loss psi Saturation Temperature Pressure Drop Figure 4 2 ...

Page 19: ...ghten terminal in a clockwise direction only Do not loosen terminals before tightening as this may affect the contact area 5 1 c Electrical Inspection Refer to system schematic Visually inspect all electrical components for anything that seems unusual such as damaged wire insulation disconnected wires etc 5 1 d Plumbing Leak Check Refer to PM Schedule Section 7 3 Inspect heater for leaks during st...

Page 20: ...mperature in Degrees Celsius SV 10 C factory preset Figure 5 1 Increases heater temperature setpoint Decreases heater temperature setpoint If the Temperature Controller display does not illuminate refer to Section 8 Troubleshooting If an alarm sounds check control panel for fault condition then press ALARM SILENCE and refer to Section 8 Troubleshooting CAUTION Do not attempt to change Temperature ...

Page 21: ... remain at last setting during a restart See Figure 5 1 NOTE Maximum setpoint is 90 C 5 5 POWER DISTRIBUTION INDICATORS Each 18 kW Heater Module contains three 3 6 kW resistive heating elements that are electrically fused at either end The LED indicators on the control panel will indicate the functioning of each element see Figure 3 1 Facility Installation Layout An indicator that does not illumin...

Page 22: ...m The system will not turn on after a power shutdown until the EMO is returned to the enabled position and the HEATER ON button is pressed Turn off the main system circuit breaker or the facility circuit breaker Lockout and tagout heater for maintenance or repair Refer to Section 2 5 6 1 HEATER CLEANOUT The system has been tested with high purity DI water After installation a 48 hour purge burn in...

Page 23: ...lues less than indicated probably indicates a faulty element in which case a heater module replacement is necessary 7 1 b Fuse Replacement A power distribution indicator LED that does not illuminate along with the others on the control panel indicates a blown 20 Amp fuse of a failed heater Each heater module contains three 3 6 kW elements with a 20 Amp fuse at either end of the element wiring The ...

Page 24: ...on 8 Troubleshooting 7 1 c Draining the System Close heater DI water inlet isolation valve Connect fluid inlet to an open drain line Loosen a fitting in the upper manifold to release internal vacuum in the line The system will drain through the cold DI inlet a small amount of water will drain through fluid exit port Perform required maintenance Reconnect fluid inlet and outlet to process lines and...

Page 25: ...where identify the location and contact Trebor International Remove Heater Cap Inspect ferrule fittings leads and thermocouple Hand tighten snug with 5 8 wrench Inspect tube fittings and hand tighten Inspect the joints after the module has thermo cycled to ensure that the leak has been stopped If the leak persists contact Trebor International NOTE If water is leaking out of the heater leads meanin...

Page 26: ...ocedures Drain system refer to Section 7 1 c for draining procedure Remove necessary panels to access heater modules Disconnect thermocouple wires from termination point Disconnect the heater module electrical connector from the electrical enclosure Disconnect the inlet and outlet heater tube fittings from the common manifolds Loosen heater mounting clamps Remove heater module from cabinet Remove ...

Page 27: ...ommended that a spare heater module be on site when five 5 or more systems are in one location Please specify system Model Number and Serial Number when ordering spare parts Consult factory for other parts not shown above 7 3 PREVENTIVE MAINTENANCE SCHEDULE Model 2472 Initial Start Weekly 6 Months Items X X Temperature Controller Element Status X X Plumbing Leaks X X Overpressure Relief Drain Diap...

Page 28: ...uld not have signs of overheating or deformation All wire terminations on fuse blocks should be tight Any blown fuses should be replaced Solid State Relays The SSR s should be free of corrosion at the terminals and should not have signs of overheating or deformation The wires attached to the SSR s should be clean and in good condition Check and tighten mounting screws for optimum heat transfer to ...

Page 29: ... Watlow Press both the Advance key and Home key for at least 6 seconds until the Fcty prompt appears in the lower display and LOC prompt appears in the upper display If LOC prompt does not appear in the upper display press either the up or down arrow key to reach the LOC Menu Under the LOC Menu press the Advance key 3 times to reach Oper setting Change the Oper setting to Change by using either th...

Page 30: ...A U n i t o f I D E X C o r p o r a t i o n PAGE 30 2472 DI HEATER OPERATION MAINTENANCE MANUAL 3 Verify the calibration offset is within 2 C 4 Return heater to original configuration ...

Page 31: ... power at main circuit breaker Review wiring procedure see Section 3 Installation Main Breaker to ON Panel Interlock Switch Refer to Section 2 3 d Panel Interlock Switches 8 2 ALARM SOUNDS CAUSES SOLUTIONS Over temperature Check that temperature process value doesn t exceed 90 C review setpoint procedure Check Temperature Controller for proper operation Low pressure Increase supply pressure Reduce...

Page 32: ...tion 7 1 b Fuse Replacement Consult Trebor if fuse repeatedly fails Some power distribution LED indicators stay on when output 01 LED of the temperature controller goes off An SSR has failed in the closed mode Shut system off immediately and replace the failed SSR SSR s should be replaced in pairs Solid state relay may have frozen open An SSR has failed in the open mode Shut system off immediately...

Page 33: ...A U n i t o f I D E X C o r p o r a t i o n 2472 DI HEATER OPERATION MAINTENANCE MANUAL PAGE 33 9 WIRING SCHEMATIC See attached fold out sheet ...

Page 34: ... be transferred to subsequent owners The warranty period is based on the original ship date from the factory All warranty related freight costs shall be borne by the customer This warranty shall not apply to any equipment which in the judgment of TREBOR shall have been repaired or altered outside TREBOR s factory in any way so as to affect its performance or reliability subjected to misuse neglige...

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