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M-43-01

Lufran Single Outlet Manual

Revision - Date: 08 – 04/06/15

- 3 -

OPTIONAL COMMUNICATIONS .............................................................. 63

THERNET

OMMUNICATIONS

(-C1

PTION

) ................................................................... 63

EVICE

OMMUNICATIONS

(-C2

PTION

) ................................................................. 64

NTEGER

OINTS

........................................................................................................... 65

MAINTENANCE ......................................................................................... 67

SPARE PARTS.......................................................................................... 97

CLEANING ................................................................................................ 99

TROUBLESHOOTING ............................................................................. 100

WARRANTY ............................................................................................ 103

APPENDIX I ................................................................................................. 1

Содержание LUFRAN

Страница 1: ...LUFRAN TM Fluoropolymer Inline Water Heater www processtechnology com 7010 Lindsay Dr Mentor OH 44060 Phone 440 974 1300 Fax 440 974 9561 USA CN 800 621 1998...

Страница 2: ...TING 16 POSITIONING THE UNIT 19 PLUMBING 21 WIRING 27 OPERATION 30 TOUCHSCREEN DISPLAY 32 TOUCHSCREEN MENU OVERVIEW 35 OPERATIONS MENU 36 SYSTEM SETUP MENU 37 SYSTEM PARAMETERS MENU 38 HEATER CALIBRAT...

Страница 3: ...Revision Date 08 04 06 15 3 OPTIONAL COMMUNICATIONS 63 ETHERNET COMMUNICATIONS C1 OPTION 63 DEVICENET COMMUNICATIONS C2 OPTION 64 INTEGER POINTS 65 MAINTENANCE 67 SPARE PARTS 97 CLEANING 99 TROUBLESHO...

Страница 4: ...vailable in wattages from 24kW to 288kW These units consist of one or more heating columns combined with a control system and all necessary power distribution circuitry in a freestanding enclosure The...

Страница 5: ...0 45 7 6 11 4 16 5 20 6 22 9 33 3 41 3 45 7 66 7 82 5 50 6 9 10 3 14 9 18 6 20 6 30 0 37 1 41 1 60 0 74 3 82 3 55 6 2 9 4 13 5 16 9 18 7 27 3 33 8 37 4 54 5 67 5 74 8 60 5 7 8 6 12 4 15 5 17 1 25 0 31...

Страница 6: ...s situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be...

Страница 7: ...M 43 01 Lufran Single Outlet Manual Revision Date 08 04 06 15 7 INTRODUCTION Continued 24 kW 144 kW Units 157 kW 288 kW Units Figure 3 Warning Label Locations...

Страница 8: ...2123mm 83 57 in 341 kg 750 lbs 157kW 288kW 1220mm 48 in 769mm 30 25 in 2123mm 83 57 in 682 kg 1500 lbs Wetted surfaces Heating elements PTFE fluoropolymer Columns and plumbing PVDF o rings Chemraz Ope...

Страница 9: ...M 43 01 Lufran Single Outlet Manual Revision Date 08 04 06 15 9 Chinese RoHS Compliance Table...

Страница 10: ...are designed to offer some description of the heater construction including features and options The model number can be found on the model serial number label located directly above the operator int...

Страница 11: ...s the standard available wattage ratings and the number of heater columns needed to provide that amount of Wattage Heater Model Number Heater Wattage W Number of Heater Columns Wattage per Heater Colu...

Страница 12: ...e same designation for both the inlet and outlet connections Please refer to the table below to see the specific plumbing connections provided with the heater Heater Model Number Plumbing Connection T...

Страница 13: ...ne water heater Some of these options are described in greater detail in the OPERATION section of this manual More than one option may be included in an individual Lufran heater Please refer to the ta...

Страница 14: ...e unit wattage The cabinet assembly requires ventilation Locate equipment so that ventilation fans on the top and bottom of the enclosure and louvers on the sides are not obstructed The ventilation fa...

Страница 15: ...trical service is rated and fused for the required amperage draw Do not exceed the rated voltage Irreparable damage to the heating column or control circuitry may result NOTE Ensure electrical power f...

Страница 16: ...heater is shipped in a horizontal position The unit must be raised to a vertical orientation before it can be removed from the shipping crate 1 Inspect the shipping crate for evidence of damage If an...

Страница 17: ...e with the enclosure 6 Remove any braces used to hold the unit in place during shipping 7 Using a fork truck or other suitable lifting device lift the unit from underneath and remove from the crate Do...

Страница 18: ...the seismic brackets are already attached to the underside of the heater cabinet The bottom half of each bracket is provided here in the event they are required for heater installation Depending upon...

Страница 19: ...g or stopping the unit Ensure that there are sufficient personnel to move the unit safely Failure to follow these instructions can result in serious personal injury and or damage to the unit 2 The uni...

Страница 20: ...on the unit Figure 8 Seismic Brackets top half Attached to Cabinet If the heater installation requires that the seismic brackets be used the bottom half of these seismic brackets may be secured to the...

Страница 21: ...t supply the means to drain the heating columns which will be necessary in the case of replacing a heating column or some other items The following describes a recommended means of column drain 1 Inst...

Страница 22: ...the plumbing connections to prevent excessive torque or strain from being applied to the internal plumbing of the unit The various plastic piping connections available Unions Flared tube fittings etc...

Страница 23: ...ated just above the access panel See figure 11 2 Remove the sealing cap from plumbing connection 3 Test fit the piping to ensure proper length 4 Support the internal piping to avoid any damage during...

Страница 24: ...ut contacts the flared tubing Tighten an additional turn Then tighten fitting nut to the maximum required torque value See the table below for proper values 4 Repeat this procedure for each of the fla...

Страница 25: ...ons 1 Remove the protective plastic caps from the fittings on the Inlet and Outlet piping of the heater assembly 2 Install appropriately sized Super 300 Type Pillar gauge ring Figure 12 Gauge ring for...

Страница 26: ...nnection 1 Remove and discard the pipe plug 2 Test fit the pipe or tubing to ensure proper length The tubing must be plumbed to a non pressurized drain 3 Cover the male pipe threads with PTFE tape or...

Страница 27: ...y installed Before the plumbing is connected to this unit verify that the electrical supply is shut off Apply any plumbing lockout tagout devices as required by factory guidelines Incoming power shoul...

Страница 28: ...et doors 1 2 column 24kW 144 kW units 1 Turn the two quarter turn latches They are located on the right side of the door near the top and bottom 2 Rotate the disconnect switch handle past the OFF posi...

Страница 29: ...e 08 04 06 15 29 Wiring Continued TORQUE SPECIFICATIONS CIRCUIT BREAKER 1CB DISTRIBUTION BLOCK 1PD PRIMARY SECONDARY SECONDARY POWER FUSES 7FU 9FU SAFETY CONTACTOR 1CON SOLID STATE RELAYS 1SSR 2SSR IN...

Страница 30: ...remotely through the interface cable provided with the unit or through an optional remote operator interface panel ROI This section deals with controlling the heater locally from the front of the unit...

Страница 31: ...ying the user of the warning condition as it occurs GREEN Indicates the system is operating with all conditions in a normal operating state Operator Interface Buttons There are two push buttons are lo...

Страница 32: ...les of these different items The simple rectangular fields with the light borders are information fields only The oval fields with the dark borders are function buttons The specific function is indica...

Страница 33: ...atures Title Panel This top section of the display provides general information about the unit and the display Time Date This is factory set prior to shipment However if the customer wants to change t...

Страница 34: ...only Message Box This box indicates the status of the water heater It will detail current system messages such as heater operation or any potential alarms Command Panel In most menus the command panel...

Страница 35: ...06 15 35 Touchscreen Menu Overview STARTUP SCREEN OPERATIONS SYSTEM SETUP SYSTEM SERVICE ALARM CONTROL ACCESS LOCKED CONTROL ACCESS ALARM HISTORY SYSTEM PARAMETERS HEATER CALIBRATION REMOTE S P CALIB...

Страница 36: ...ure measured from the process sensor located at the inlet of the heater FLOW RATE This value Is the water flow rate measurement taken from the internal flow meter PROCESS SETPOINT This button will dis...

Страница 37: ...pages Figure 22 System Setup Menu Screen System Setup Menu Information Panel Description SYSTEM PARAMETERS This button will forward the operator to the SYSTEM PARAMETERS menu DATALOG PARAMETERS This...

Страница 38: ...this setting This setting does not trigger an alarm and will not shut down the heater HIGH PROCESS SETPOINT This button allows adjustment of the HIGH PROCESS SETPOINT This setting may be adjusted as...

Страница 39: ...r Wattage Number of Heating Columns LOW FLOW SETPOINT 24Kw 72Kw 1 1 0 105Kw 144Kw 2 2 0 210Kw 288Kw 4 4 0 BOOST GAIN This button allows adjustment of the BOOST GAIN This setting improves heater perfor...

Страница 40: ...able the system calibration mode In this mode the error correction is disabled and the DAC control system will operate as an open loop control The HEATER CALIBRATION STARTUP PROCEDURE details the prop...

Страница 41: ...values used by the customer control Otherwise the primary setpoint will be incorrect Remote S P Calibration Menu Information Panel Description ENTER THE 4mA VALUE IN DEGREES C This button allows adjus...

Страница 42: ...Pressing the button again will change the time units from MIN to HR hours Pressing the button a third time will change the time units from HR back to SEC TIMER VALUE This button allows adjustment of t...

Страница 43: ...set control parameters of the DACTM control system Figure 28 Factory Default Menu Screen Factory Default Menu Command Panel Description RESET TO DEFAULT This button will reset all controller settings...

Страница 44: ...le from normal operating states TEST AMBER STACK LIGHT Depress this button to illuminate the amber light on the stack light SHUTDOWN APPLICATION When the heater is disabled this button will shut down...

Страница 45: ...button will bring up the LOGIN display on the information panel Pressing User F2 on the LOGIN display will bring up a small keyboard From the keyboard you can enter one of the available control mode l...

Страница 46: ...adjusted through the remote operator interface heater control only The customer can also access and change all other user settings either locally or remotely ENET ETHERNET MODE This selection will on...

Страница 47: ...tic behavior or over temperature conditions For this reason manual control should only be used by qualified personnel as a maintenance tool LOCK This control mode limits operator access to most operat...

Страница 48: ...til the control system has been reset To reset the safety press the FAULT RESET button located on the command panel Please note that the high wattage Lufran heaters that use 3 or 4 heating columns 157...

Страница 49: ...he information panel provides the date and time of the event as well as the type of fault that occurred Alarm History Command Menu Description CLEAR HISTORY This button will clear all of the entries i...

Страница 50: ...le ranges the main load safety contactor will engage The YELLOW indicator light will be illuminated 7 Verify that the system parameters are correct 8 Adjust the PROCESS SETPOINT in the OPERATIONS MENU...

Страница 51: ...be performed while the unit is in MANUAL or REMOTE control mode This procedure must be performed following the STARTUP PROCEDURE provided on the previous page 10 Once the startup procedure is complet...

Страница 52: ...es the PROCESS SETPOINT Once the unit outlet temperature matches the PROCESS SETPOINT the unit is calibrated Proceed to step 17 17 Turn the HEATER CALIBRATION setting OFF The image of the toggle switc...

Страница 53: ...erature reaches ambient as referenced from the Main screen 3 Press the POWER OFF button located on the front panel of the heater Note Steps 1 and 3 can also be accomplished through the remote control...

Страница 54: ...e heating columns to a non pressurized drain 7 Open the capped fitting of the customer supplied TEE fitting on the outlet of the unit The heating columns will start draining 8 Optional the customer ma...

Страница 55: ...efore attempting to reset the unit H2O Flow Low Flow Low Flow Condition The flow rate through the unit has dropped below the LOW FLOW SETPOINT This setting is located in the SYSTEM PARAMETERS menu Thi...

Страница 56: ...he appropriate procedure Elem o t 1 thru 4 Element OT soft Htr 1 thru Htr 4 This safety signal is redundant to the Element OT slc alarm signal The element temperature has risen above the internal sett...

Страница 57: ...ssure has dropped below the setting for the pressure switch This may be caused by shutting off the water supply to the unit The water pressure must increase to a level above the pressure switch settin...

Страница 58: ...red tag If the customer wants to use the remote interface these red tag jumpers must be removed The unit must be in REMOTE control mode in order to operate the unit through the remote interface Howev...

Страница 59: ...g the contacts across these pins when the controller is in REMOTE mode only This is one of the signals that has been bypassed at the factory In order to use this remote EMO feature the red tag jumper...

Страница 60: ...front of the unit has been pressed The EMO button has been pressed One of the alarms has been tripped 10 11 System Setpoint Output Dry Contacts This output will apply closed contacts across these pin...

Страница 61: ...on of heater in the same manner as the touch screen device mounted within the heater cabinet The unit must be in ROI control mode in order to operate the unit through the remote touch screen interface...

Страница 62: ...for your specific signals and pin out assignments The displays on the remote touch screen interface are the same as the cabinet mounted touch screen with the exception of the following the CONTROL ACC...

Страница 63: ...owing default IP Address 128 1 105 100 Once connected to the network the customer may wish to change the IP address Adjusting the IP Address or performing other networking tasks with the Lufran heater...

Страница 64: ...th the following default node assignment 63 Once connected to the network the customer must assign a new node to the Lufran heater Assigning the node or performing other networking tasks with the Lufr...

Страница 65: ...s the current percentage output of the heating column s N48 05 Set point C Heater output The value provided is the outlet set point of the heater When the system is in REMOTE control mode this value s...

Страница 66: ...ption N50 10 Remote start stop Heater input 0 Stop heater operation 1 Start heater operation N50 11 Heater set point C Heater input The value provided from the network to the heater will be the desire...

Страница 67: ...ians Many of these devices require the control system to remain operational during inspection while others may be checked while the unit is completely powered down Note Several maintenance tasks can b...

Страница 68: ...nance To Be Performed Every 6 Months Item to Inspect Lockout Tagout Required Y N Electrical Hazard Category 1 2 Procedure Number Outlet plumbing liquid level sensor s top half plumbing N 1 M1 Outlet p...

Страница 69: ...utton on the command panel of the OIP If the unit is in REMOTE mode disable the heater from the customer supplied remote controller This will also prevent the heaters from energizing 2 Continue water...

Страница 70: ...2 alarm will flash on the display 7 Press the FAULT RESET button on the command panel of the touch screen display to clear the fault condition 8 If the red LED fails to illuminate and the unit fails t...

Страница 71: ...uid level sensor 5 Loosen and remove the two nuts that are holding the liquid level sensor in the bracket 6 Slide the liquid level sensor out of the bracket 7 Insert the new liquid level sensor into t...

Страница 72: ...sensors should be checked for proper operation every 6 months Procedure M2 1 Outlet Process Temperature Sensor Column TC Sensor Inspection Procedure 1 If the unit is in LOCAL mode press the DISABLE H...

Страница 73: ...ter alarm mode The red light on the top of the unit will illuminate and the ALARMS MENU on the touchscreen display will appear The INLET T C alarm will flash on the display 7 Reconnect the connector p...

Страница 74: ...umn assembly A provision for draining the unit must be installed on the inlet plumbing when the unit is installed If not method of draining the unit was provided the inlet water connection must be rem...

Страница 75: ...If the unit is in REMOTE mode disable the heater from the customer supplied remote controller This will also prevent the heaters from energizing 2 Open the rear cabinet door 3 Locate the leak detecto...

Страница 76: ...usually connected to port 3 but refer to your electrical prints to confirm the correct port number 5 If needed remove the electrical connector from the leak detector to ease in the wiring removal from...

Страница 77: ...2 Purge alarm will flash on the display 3 Restart purge gas flow Verify that the purge gas supply pressure is regulated between 1 75 6 9 bar 25 100 psig 4 Press the FAULT RESET button on the command p...

Страница 78: ...ge gas flow switch Retain these fittings for use in step 10 Discard the old flow switch 10 Re tape and install these two compression fittings into the new purge gas flow switch 11 Install the new flow...

Страница 79: ...pection part of this procedure must be repeated for each heating column Inspect the purge gas exhaust tubing 1 If the unit is in LOCAL mode press the DISABLE HEATER button on the command panel of the...

Страница 80: ...the four cover screws and remove the cover from each humidistat device 7 Turn the adjustment knob on the humidistat clockwise The unit will enter an alarm condition The red light on the top of the un...

Страница 81: ...oor 5 Remove the black plastic enclosure cover on the humidistat 6 Remove female disconnect terminal connectors 7 Remove screw from the center of the humidistat switch and remove the humidistat from t...

Страница 82: ...screen If the unit is in REMOTE mode disable the heater from the customer supplied remote controller This will also prevent the heaters from energizing 2 Continue water flow through the unit for this...

Страница 83: ...when the unit is installed Verify that the electrical supply and water supply is shut off and any necessary lockout tagout devices are properly installed 4 Once the system is drained open the rear cab...

Страница 84: ...w the unit to cool to ambient inlet temperature 3 Open the rear cabinet door The PRV sensor is located next to the cabinet leak detector just inside of the PRV outlet plumbing connection The sensor is...

Страница 85: ...lat blade screwdriver turn the sensor adjustment potentiometer on the back of the sensor clockwise until the red LED on the sensor illuminates 3 Once the red LED illuminates turn the adjustment potent...

Страница 86: ...but refer to your electrical prints to confirm the correct port number 5 Loosen and remove the two nuts that are holding the liquid level sensor in the bracket 6 Slide the PRV sensor out of the bracke...

Страница 87: ...ed in the electrical side and one cooling fan is located in the plumbing side of the cabinet These cooling fans should be operating continuously while power is applied The cooling fans should be repla...

Страница 88: ...door 4 Disconnect the connector plug for the cooling fan from the multi port sensor actuator box This connector us usually connected to port 2 but refer to your electrical prints to confirm the corre...

Страница 89: ...ut off and any necessary lockout tagout devices are properly installed 3 Open the front cabinet door 4 Locate the power wires going from the cooling fan to the terminal blocks on the ground plate Refe...

Страница 90: ...operating continuously while power is applied Procedure M9 1 SSR Cooling Fan Inspection Procedure Open the front cabinet door Verify that the cooling fans are operating If a cooling fan has stopped it...

Страница 91: ...ress the DISABLE HEATER button on the command panel of the OIP If the unit is in REMOTE mode disable the heater from the customer supplied remote controller This will also prevent the heaters from ene...

Страница 92: ...n alarm event 3 If the alarm does not sound when the TEST SONALERT button is pressed the audible alarm must be replaced Procedure M11 2 Audible Alarm Replacement Procedure 1 Shut down the unit Turn of...

Страница 93: ...h screen interface 2 Press the TEST RED STACK LIGHT button on the information panel The red indicator light will illuminate The light will go out when the button is released This will not trip an alar...

Страница 94: ...he pieces may then be separated by pulling them apart 1 Shut down the unit Turn off main power Verify that the electrical supply is shut off and any necessary lockout tagout devices are properly insta...

Страница 95: ...ation 1 If the unit is in LOCAL mode press the DISABLE HEATER button on the command panel of the OIP If the unit is in REMOTE mode disable the heater from the customer supplied remote controller This...

Страница 96: ...any necessary lockout tagout devices are properly installed 3 Continue water flow through the unit for this procedure Allow the unit to cool to ambient inlet temperature 4 Open the front cabinet door...

Страница 97: ...nology Part Description Qty 9978 POWER SUPPLY 24VDC 240W 1 9750 OPERATOR INTERFACE PANEL MONOCHROME 6 TOUCH SCREEN 1 9004 BULB REPLACEMENT 1 9826 POWER OFF SWITCH ASSEMBLY pushbutton light base contac...

Страница 98: ...part 1 TC L KT 15 65 72 130 144 SENSOR heating column water temperature J type thermocouple one sensor per column 2 TC L KT 52 105 72kW 208V SENSOR heating column water temperature J type thermocouple...

Страница 99: ...um possible flow rate for one 1 hour The effluent should be directed to the drain Note In order to prevent damage to the heater coils the purge system must be operated any time there is fluid inside t...

Страница 100: ...acted by the alarm for any external water that may be leaking In most cases this leak can not be repaired and the heating column must be replaced Consult the factory for the appropriate replacement If...

Страница 101: ...ossible that the PLC input card may be damaged and need replaced Consult the factory for the appropriate replacement component Elem o t 1 thru 4 Element Thermocouple Alarm The element temperature has...

Страница 102: ...pressure must increase to a level above 15 PSI in order for the unit to return automatically to normal operation If proper water is pressure is present it may be a problem with the PLC input card and...

Страница 103: ...damage PROCESS TECHNOLOGY neither assumes nor authorizes any representative of PROCESS TECHNOLOGY or any other person to assume for it any other liabilities in connection with the sale of the products...

Страница 104: ...Replaced sensor Done Procedure M2 1 Column 2 Sensor Inspection Pass If sensor fails inspection Procedure M2 2 Replaced sensor Done M3 Leak Detector Procedure M3 1 Leak Detector Inspection Pass If sens...

Страница 105: ...ed red light Done Procedure M12 1 Amber Indicator Light Inspection Pass If amber light fails inspection Procedure M12 2 Replaced amber light Done Procedure M12 1 Green Indicator Light Inspection Pass...

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