QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
CONTENTS
CONTENTS
1
INTRODUCTION ........................................................................................................................................3
2
SAFETY ......................................................................................................................................................6
2.1
SAFETY MESSAGE CONVENTIONS ............................................................................................6
2.1.a
Danger ...........................................................................................................................6
2.1.b
Warning ..........................................................................................................................6
2.1.c
Caution ...........................................................................................................................7
2.2
EQUIPMENT SAFETY ...................................................................................................................7
2.3
EMERGENCY OFF (EMO) .............................................................................................................7
2.4
PROCESS INTERLOCKS ..............................................................................................................8
2.4.a
Low Pressure Switch Interlock ........................................................................................8
2.4.b
Liquid Level Sensor Interlock ..........................................................................................9
2.4.c
Element Over Temperature Protection ...........................................................................9
2.4.d
Leak Sensor ...................................................................................................................9
2.4.e
Overpressure Burst Fitting ..............................................................................................9
2.5
LOCKOUT / TAGOUT ....................................................................................................................9
2.5.a
Preliminary .....................................................................................................................9
2.5.b
Definitions .................................................................................................................... 10
2.5.c
Machine Shutdown with door closed ............................................................................. 11
2.5.d
Machine Start-Up with door closed ............................................................................... 11
2.5.e
Machine Shutdown with door open ............................................................................... 11
2.5.f
Machine Start-Up with door open .................................................................................. 12
2.6
SEISMIC PROTECTION .............................................................................................................. 12
3
INSTALLATION ........................................................................................................................................ 13
3.1
UNPACKING ................................................................................................................................ 13
3.2
LOCATION ................................................................................................................................... 13
3.3
HOOK-UP .................................................................................................................................... 13
3.3.a
Ethernet Communication .............................................................................................. 15
3.3.b
Changing Heater IP Address ........................................................................................ 16
4
OPERATION ............................................................................................................................................. 17
4.1
GENERAL .................................................................................................................................... 17
4.2
DIAGNOSTIC DISPLAY ............................................................................................................... 17
4.2.a
Main Page .................................................................................................................... 17
4.2.b
Alarm Status Page ....................................................................................................... 18
4.2.c
Module Status Page ..................................................................................................... 20
4.2.d
Process Plot Page ........................................................................................................ 20
4.2.e
Configuration Page ....................................................................................................... 21
4.2.f
Log Reports .................................................................................................................. 23
4.2.g
Security Status Page .................................................................................................... 26
4.3
REMOTE OPERATION OVER A NETWORK .............................................................................. 28
4.3.a
Ethernet Interface ......................................................................................................... 28
4.3.b
Modbus Protocols ......................................................................................................... 28
4.3.c
Modbus/TCP ................................................................................................................ 29
4.3.d
Modbus Communication ............................................................................................... 29
5
START-UP ................................................................................................................................................ 31
5.1
PRE-START INSPECTION .......................................................................................................... 31
5.1.a
Verify Shipping Condition ............................................................................................. 31
5.1.b
Hazardous Power Terminals ......................................................................................... 31
5.1.c
Electrical Inspection ..................................................................................................... 31
5.1.d
Plumbing Leak Check ................................................................................................... 31
5.2
SYSTEM ON ................................................................................................................................ 32
5.3
HEATER MODULE POWER ........................................................................................................ 32
5.4
PROCESS ALARMS .................................................................................................................... 32
6
SHUT DOWN............................................................................................................................................ 33
7
MAINTENANCE ........................................................................................................................................ 34
7.1
REPAIR INSTRUCTIONS ............................................................................................................ 34
7.1.a
Heater Element Check ................................................................................................. 34
7.1.b
Heater Replacement ..................................................................................................... 34
7.1.c
Liquid Level and Leak Sensor Calibration ..................................................................... 35
7.1.d
Fuse Replacement ....................................................................................................... 36
7.1.e
Draining the System ..................................................................................................... 36
7.1.f
Leaks............................................................................................................................ 37
7.1.g
Overpressure Relief Replacement ................................................................................ 37
7.2
PREVENTIVE MAINTENANCE SCHEDULE................................................................................ 38
8
TROUBLESHOOTING .............................................................................................................................. 40
9
WARRANTY ............................................................................................................................................. 41
See Appendix for specific system requirements.
