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QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL

PAGE 41

WARRANTY

See the Trebor Standard Limited Warranty at

http://www.treborintl.com/TechnicalSupport.aspx

Содержание Trebor QA1V208P12-AA

Страница 1: ... S 6479094B2 U S 6544583B2 10 25 07 MQTM D U S 6580061B2 U S 6663914 U S 6674053B2 ADDITIONAL PATENTS PENDING Phone 800 669 1303 or 801 561 0303 Fax 801 255 2312 e mail treborservice idexcorp com QUANTUM DI WATER HEATER Operation Maintenance Manual ...

Страница 2: ... 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 ...

Страница 3: ...osed tip of the titanium temperature sensor included with the fast response option the DI water is exposed only semiconductor grade quartz PTFE and PFA wetted surfaces Trebor s patented heating module technology is constructed to provide excellent process control by minimizing hold up volume and thermal heat capacitance while maximizing the heat transfer While heating the system can ramp to a proc...

Страница 4: ...also complies with the requirements of the Management Methods for Controlling Pollution of Electronics Information Products known as China RoHS Figure 1 2 China RoHS Electronic information product pollution control symbol Trebor will use an EFUP Environmental Friendly Use Period of 25 years which is consistent with the industry mean The EFUP label is located next to the main system nameplate and a...

Страница 5: ...added to any metallic coating See SJ T 11363 2006 for definition of homogeneous materials X This substance is present at a concentration above the limit in SJ T 11363 2006 in at least one of the homogenous materials for this part or it has been intentionally added to a metallic coating See SJ T 11363 2006 for definition of homogeneous materials Notes concentration limits of 1000 ppm 0 1 by weight ...

Страница 6: ...n 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 Safety messages contain...

Страница 7: ...f this section describes equipment safety features Emergency Off Push button EMO Process Interlocks Main Power Disconnect Switch Lockout Tagout Information Equipment Safety Labels 2 3 EMERGENCY OFF EMO The EMERGENCY OFF button EMO is located on the front of the door When the EMO circuit is activated by pushing the button in the equipment will be placed into a safe shutdown condition The EMO will d...

Страница 8: ...eater If the indicator LED s remain illuminated then one or more faults are still active Refer to Section 8 Troubleshooting CAUTION The interlock circuit does not remove hazardous voltage from the circuit breakers contactor and the control transformer Only authorized qualified trained personnel should service this equipment 2 4 a Low Pressure Switch Interlock The pressure switch will disengage pow...

Страница 9: ...age power and alarm If this occurs check element continuity before continuing normal operation See Section 7 1 a 2 4 d Leak Sensor The Leak Sensor will disable heater power immediately when water is detected in the leak tray Fix any leaks and dry the leak sensor and leak tray prior to turning power on to the system 2 4 e Overpressure Burst Fitting The overpressure burst fitting Relief Drain is con...

Страница 10: ... which can be securely fastened to an energy isolating device in accordance with established company procedure ensures that the energy isolated device and the equipment being controlled may not be re energized or operated until the tagout device is removed This table lists the Lockout Tagout information for the system Energy Type Electrical Hazard Electrocution electrical burns and shock Magnitude...

Страница 11: ...l hand tools are removed from the equipment and that it is ready for start up 2 Notify personnel in the area that you are going to start up the equipment 3 Open the lock and remove the locking energy isolation device lock from the hole in the actuating handle of the Main Disconnect Switch 4 Move the actuating handle to the ON up position 5 Press the machine start button The machine should start 2 ...

Страница 12: ... equipment 3 Insert and rotate the key in the rotary disconnect lock top left of rotary disconnect device Remove the key 4 Move the rotary disconnect shaft to the ON of 1 up position 5 Press the machine start button The machine should start 2 6 SEISMIC PROTECTION It is the user s responsibility to adequately secure and anchor the equipment to comply with local regulatory agency seismic requirement...

Страница 13: ... 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 3 3 HOOK UP All utility hook ups associated with the DI water heater are easily accessible and are referenced in the Appendix After positioning heater at operating location adjust the four leveling feet until the heater is level and stable Connect the cold DI supp...

Страница 14: ...t drain line is not installed the system will be difficult to drain should repairs be needed CAUTION Depending on installation and routing of water supply lines a trip hazard may be created It is the responsibility of the facility installation personnel to eliminate or minimize any and all trip hazards or identify such hazards with visual warning signs Lockout and Tagout facility power connection ...

Страница 15: ...ground continuity on cabinet to any facility ground Remove Facility power Lockout Tagout Restore Facility power supply to the heater Follow heater Pre Start Inspection see Section 5 1 NOTE Before starting the system it is important to become familiar with Section 4 Operation Only trained qualified authorized personnel should operate this system 3 3 a Ethernet Communication For remote monitoring an...

Страница 16: ...ubnet mask are shown in the center of the screen To change the IP address of the heater press the IP Addr button on the right hand side of the configuration screen see Section 4 2 e A window will open that will allow you to change the IP address and subnet mask of the heater Pressing the Enter button assigns the new IP address to the heater If you wish to cancel the changes made press the X button...

Страница 17: ...ure leak sensor and component temperature faults 4 2 DIAGNOSTIC DISPLAY A color touch screen provides an intuitive interface to the DI water heater The heater can also be operated using both hardware and software remote interfaces depending on the heater options The display is divided into several pages The pages are designed to be simple and easy to understand The display contains a total of six ...

Страница 18: ... the heater enables the user to change the mode of the heater and allows the option of turning the audible alarm horn off from the panel The mode of the heater can be toggled from Local mode to Remote mode by pressing the button on the right hand side of the screen The button text changes from Go to Local to Go to Remote depending on the current mode of the heater Local mode allows the heater to b...

Страница 19: ...ut period These alarms will wait a certain period of time before putting the system into an alarm state During the timeout period the heater is put in a safe state while waiting for these alarms to clear themselves and the alarm will be in the alarm delay state If these alarms clear themselves before the timeout period elapses the heater will go back to normal operation without alarming If these a...

Страница 20: ...heaters in the bank If a heater module temperature is displayed with red lettering the heater is running too hot Heaters running too hot or too cold should be checked as soon as possible See Section 7 1 a The numbered buttons bellow each temperature status box correspond to the heater modules These buttons enable or disable each modules thermocouple When enabled the thermocouple is considered in t...

Страница 21: ...tion Page Figure 4 5 Configuration Page The configuration page shows a summary of system information and allows changes to the heater IP Address Serial Communications Settings Alarm Delay and System Time and Date This page also allows access to log files described in Section 4 2 f Press the Alarm Delay button to set the pressure and liquid level alarm delay Enter the desired alarm delay in seconds...

Страница 22: ...ime Date to set the system time and date Figure 13 Changing System Date and Time When changing the system date or the time each field must be changed and apply button pressed to update the system before changing the next field For instance if the month and day fields need to be changed select the month field Use the up and down arrows to select the correct month When done press the Apply button be...

Страница 23: ...or Off Heater Banks running too hot or too cold Banks being turned On or Off etc The Systems log records such things as Emergency Shut Off activated Reset Button depressed changes to alarm settings and several other settings that affect system changes Log files can be viewed through the heater touch screen interface or on a remote PC via a web browser or a text editing program such as MS Word or N...

Страница 24: ...og button A deleted log will be re started when new records are generated To view the log files on a remote PC the PC must be connected to the heater via the Ethernet connection on back side of the Quantum heater The log files can be accessed through a web browser by browsing to the heater IP address see section 3 3 b for information on setting and observing the heater IP address For example if th...

Страница 25: ...ick the browser s Refresh button to update the latest changes to that log The most recent logged event is always listed on the top of the listing To save the log files on the remote PC for viewing in a text editing program double click the LOGS directory and right mouse click on the desired log Select Save Target As and specify the location and file name to be saved NOTE For ease of viewing the fi...

Страница 26: ...creen it unlocks the system for a given time Initially the time is set to 10 minutes but it can be changed from 01 minute to 99 minutes must use two digits The heater is shipped with this functionality set to the Disabled position To enable the security features Open the security page by selecting the Security button and enter the correct PIN and check the Enable Security box Initial factory set P...

Страница 27: ...y tab enter your correct PIN and select the access duration time by selecting the current access duration value Note that the access duration value does not appear until after the Security Mode is Enabled is checked Enter the new 2 digit time in the keypad and press the Enter button The minimum duration is 1 minute with a maximum duration of 99 minutes Figure 4 10 Changing the Access Duration Fail...

Страница 28: ...h Modbus TCP and Modbus RTU networks Modbus TCP communication is included in all Quantum heaters Modbus RTU communication is an option on all Quantum heaters Using Modbus communication Quantum heaters can be turned on and off remotely the set point can be changed and the operation status and alarms status can be monitored The Modbus register mapping for Quantum heaters is the same for both Modbus ...

Страница 29: ...s no Modbus coils are used This means that only two Modbus functions are required to communicate with a Quantum heater The function 03 read holding registers and function 06 write single register are the only two Modbus functions that will be needed The Table 2 Old Modbus Mapping interface is an old interface that uses both Modbus coils and registers This interface is for backwards compatibility w...

Страница 30: ...7 16522 16647 16772 Reg Bool 2 R Alarm Thermocouple 16395 16520 16645 16770 Reg Bool 2 R Alarm Pressure 16393 16518 16643 16768 Reg Bool 2 R Table 1 New Modbus Mapping Name Addr Bank 1 Addr Bank 2 Addr Bank 3 Addr Bank 4 Type Data Bytes Perm Set Point 1049 1149 1249 1349 Reg Short 2 RW Process Temperature 1051 1151 1251 1351 Reg Short 2 R Duty Cycle 1067 1167 1267 1367 Reg Short 2 R Communication ...

Страница 31: ... than normal operating temperatures resulting in damage of electrical components Tighten 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 Plum...

Страница 32: ...rate position Press the reset button to engage control power 5 3 HEATER MODULE POWER When the RESET button is pressed the power contactors will engage 5 4 PROCESS ALARMS If a fault occurs the main contactor will disengage an indicator LED will turn red to show the type of fault and an audible alarm will sound Pressing the RESET button will silence the audible alarm If the RESET button is pushed an...

Страница 33: ...y be shut down by the following methods Select the OFF button on the control screen to put the heater in standby heater element power will be disengaged Rotate Main Breaker to off position Turn off the facility supply Lockout and tagout heater for maintenance or repair Refer to Section 2 5 ...

Страница 34: ...in the control enclosure 4 Check for continuity between the two screw terminals on the left of the breaker for each pair of element circuit breakers 5 If no continuity exists replace the suspect heater modules see Section 7 1 b Heater Replacement 6 If there is continuity then the heater element is OK Refer to the Troubleshooting Section of this manual for other possible causes 7 1 b Heater Replace...

Страница 35: ... an absorbent cloth to remove any liquid from the leak sensor probe and leak containment well Install replacement heater module into cabinet in reverse order from above Note Carefully align the fittings because they can easily be cross threaded Return failed heater module Figure 7 1 MTD0508 NOTE Do not disassemble the heater module There are no user serviceable parts inside the module If disassemb...

Страница 36: ...valve Connect fluid inlet to an open drain line Alternate If a drain line is connected to the cabinet drain on the bottom of the heater enclosure the heater may be drained into the leak tray Power system and open DI water inlet isolation valve 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 d...

Страница 37: ...for the heater and plumbing to cool down before inspection NOTE If water is leaking out of the heater module shroud a replacement module will be required 7 1 g Overpressure Relief Replacement Turn power off see Section 2 5 Drain system see Section 7 1 e Remove and replace overpressure relief fitting note orientation of fitting Refill system Inspect for leaks Turn power on see Section 5 2 and 2 5 F...

Страница 38: ...nsult factory with questions Label Part Number Description Torque Value MCB1 Circuit Breaker 3 Pole 480VAC 60A 225A 26 0 Nm 230 1 in lb MCB1 Connection Terminal Block 6 Wire 14 6AWG 6 0 Nm 53 1 in lb CB1 4 98003449 Circuit Breaker 3 Pole 480VAC 50A 5 6 Nm 49 6 in lb CONT 1 4 98003544 Contactor 50A 400V 3 Pole 24VDC 2 5 Nm 22 1 in lb SSR 1 8 98003546 SSR 90A 4 32VDC 3 7 Nm 32 7 in lb CBH 1E1 12E2 9...

Страница 39: ...ter is present in the drain plumbing the fitting should be replaced General Electronics Visually check electronics inside control enclosure for any signs of overheating deformation or corrosion 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 ...

Страница 40: ...ged If fault repeats check thermocouple leads to OTC for continuity Check T C plugs in top heater modules Plugged orifice in heater Check fluid lines in and out of manifold for flow Over temperature alarm Check if heater element has failed and replace module see section 7 1 If fault reports check T C leads to OTC for continuity Verify fan operation Check Heater Element Status Alert Cause Solution ...

Страница 41: ...QUANTUM DI HEATER OPERATION MAINTENANCE MANUAL PAGE 41 9 WARRANTY See the Trebor Standard Limited Warranty at http www treborintl com TechnicalSupport aspx ...

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