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Copyright © 2020 White Knight Fluid Handling  |  A Graco company
P: 626.599.8566  |  

[email protected]

  |  

https://wkfluidhandling.com

Aquarius DIW Heaters Owner’s Manual

Ver. 1.0.0  |  29 Apr 2020  |  P. 4

Subject to change without notice

The following tests are performed on all Aquarius

®

 systems after assembly and before 

shipping. The units are tested with DIW supplied to the unit and discharged to drain.

1. A high potentiometer test procedure is performed on the heaters used in Aquarius

®

 

systems. The test procedure includes a leak, thermocouple, and resistance test. For 
detail, reference SOP 1201 High Pot Test Procedure.

2. Voltage, Flow, and Pressure readings on the controller are calibrated as follows:

a. Incoming voltage is measured on the input side of the contactor by a voltmeter. If the 

measured voltage reading does not match the voltmeter reading on the screen, the 
voltage value is adjusted accordingly by adjusting the voltage calibration parameter 
which is located on the 

System Calibration

 screen of the 

System Set Up Menu

.

b. An external flow meter is plumbed in-line with the DIW heater. The flow reading on 

the touch screen should match the reading indicated on the external flow sensor. If an 

adjustment is required the flow meter value is adjusted accordingly by adjusting the 

flow calibration parameter which is located on the 

System Calibration

 screen of the 

System Set Up Menu

.

c. An external pressure meter is plumbed in-line with the DIW heater. The pressure 

reading on the touch screen should match the reading indicated on the external 

sensor. If an adjustment is required the pressure value is adjusted accordingly 
by adjusting the pressure calibration parameter which is located on the 

System 

Calibration

 screen of the 

System Set Up Menu

.

  For more detailed information on the Aquarius

®

 control system and operation screens 

please refer to the PF3000 controller manual.

3. The Aquarius

®

 control system is monitored and controlled by a Programmable Logic 

Controller (PLC) and related hardware of the Aquarius

®

 and checked for functionality.

  a. The inputs and outputs of the Safety PLC are checked and verified.

  b. All components and sensors are checked and tested.

  c. Control system functionality are checked and tested.

4. Aquarius

®

 DIW heating systems are tested to operate with the “

Process Temperature 

Set Point

” parameter set to the maximum temperature possible according to the 

equation below. This test will insure that all heater modules are operating and full heater 
power is available.

a. Proper flow rate is calculated with the formula:
b. The calculated flow rate is introduced to the DIW heater and the unit is turned on. The 

DIW heater is allowed to reach the process temperature set point.

c. At 95°C, the unit may trigger the 

High Temperature Alarm

.  

High Temperature Alarm indicates that adjustments are possibly required.  
Make adjustments as indicated in the TROUBLESHOOTING GUIDE.

3. Factory Performance Test 

KW x 3.79

GPM = 

95°C – TEMP INPUT D.I. (°C)

Содержание Heateflex Aquarius

Страница 1: ...anty Declaration of Conformity to CE Shipping Information 1 Receiving Procedures 1 2 Introduction 2 3 Factory Performance Test 4 4 Basic Safety Precautions 7 5 Pre Installation Preparation 10 6 Installation Instructions 11 7 System Shut Down Procedure 14 8 Suggested Operational Inspection 15 9 Decontamination and Decommissioning 15 10 Aquarius with Auto Purge Optional 16 11 Aquarius with Recircula...

Страница 2: ...arry that manufacturer s warranty period This expressed warranty is in lieu of and excludes all other representations made by advertisements or by agents There are no implied warranties for the equipment Heateflex agrees to correct any defect in workmanship or material which may develop under normal handling and proper usage during a period of one year from the date of shipment or by its option to...

Страница 3: ...ng as to the damage please contact our Customer Service Department for return authorization at 626 599 8566 If writing for return authorization please indicate your purchase order number We will either repair or replace the unit depending upon the extent of the damage It is your responsibility to follow the above instructions or the carrier will not honor any claims for damage If there are any sho...

Страница 4: ...s flow rate by measuring the flow rate of the fluid as it enters the heaters measuring the temperature at various stages in the heating process and adjusting the proportion of power applied to each heating zone based on those measurements This integrated control method is advancement to previous methods of temperature control that reacts quickly and robustly to any variations in flow providing a s...

Страница 5: ...unaway heating condition occurs 6 Safety PLC Programmable Logic Controller Safety PLC monitors high limit thermocouples GFCI and Thermal Cut off Sensor status using redundant force guided relays and controls the Heater Master Relay which controls the heater contactor and the Heater Safety Relay which controls the SCR output signals to the heater 7 Pressure Relief Valves Pressure relief valves are ...

Страница 6: ... Menu c An external pressure meter is plumbed in line with the DIW heater The pressure reading on the touch screen should match the reading indicated on the external sensor If an adjustment is required the pressure value is adjusted accordingly by adjusting the pressure calibration parameter which is located on the System Calibration screen of the System Set Up Menu For more detailed information o...

Страница 7: ...en i Modify the current Low Flow Alarm Set Point located on the System Set Up Alarm Set Points screen ii Set the Low Flow Alarm Set Point value to just above the FLOW RATE reading on the System Status screen The Low Flow Alarm will trigger and the controller will disable the heaters and send the unit into STANDBY mode iii Return the Low Flow Alarm Set Point to the original setting c Pressure Senso...

Страница 8: ...nd Aquarius control system are verified and checked for functionality c The pump safeties and or alarms are tested This includes the Water Leaks Alarm which is standard on the Aquarius system to ensure that the supply of DIW to the unit is shut off in the case that a critical leak condition is present d The unit is allowed to operate with the controller Process Temperature Set Point set to a value...

Страница 9: ...hould be selected to match the application s environment and be able to withstand worst case failures especially in hazardous locations Avoid fire hazards Electric heaters and their components can develop temperatures that produce an auto ignition source Avoid mounting heaters in atmospheres containing combustible gases vapor or dust Article 501 of the National Electrical Code NEC requires that th...

Страница 10: ...oming power has been disconnected from a remote source prior to opening or servicing the unit This is advised to prevent user exposure to high voltage and current and reduce the risk of electric shock The function of this unit is to heat process fluid for use in ultra pure operations Therefore during normal operation the unit will accumulate heat within the plumbing and the heater compartment It i...

Страница 11: ...ool fluid before opening 3 Danger Electrical Arc Flash Danger label for electric arc flash hazard Wear protective equipment when diagnosing an energized system 4 Air Supply with option 01 Label for maximum air supply pressure 5 Serial Number Plate Plate with system model serial electrical and pressure information 6 Incoming Power Label Label for incoming power information for voltage amps phase an...

Страница 12: ...ements will be detailed on respective drawings and be clearly visible and marked on the back of each Aquarius systems It is the responsibility of the user to provide these types of energy sources i e pneumatic CDA and DIW and appropriate isolation of all energy sources including electrical power if not provided as an option To further ease the installation process lifting lugs have been mounted on...

Страница 13: ...oming electrical power from main fusible disconnect customer supplied to electrical compartment prior to being powered on For point topoint connections see the electrical schematic drawings in SECTION II of this manual All switches must remain in the OFF position See the equipment specifications section on the Quality Control Documentation for current rating operating voltage and type rating a Cus...

Страница 14: ...ght 2020 White Knight Fluid Handling A Graco company P 626 599 8566 info heateflex com https wkfluidhandling com Aquarius DIW Heaters Owner s Manual Ver 1 0 0 29 Apr 2020 P 12 Subject to change without notice ...

Страница 15: ...ss Temperature Set point Low High set points for Temperature Flow Rate Pressure and Resistivity if the option is available These values can be found on the Alarm Set Points screen To modify these parameters simply press the data display key to the right of the parameter description to be changed If key is grayed out the user will need to log in with appropriate log in credentials to modify these p...

Страница 16: ...ly the responsibility of the user to verify and provide adequate isolation of all energy sources i e electrical power pneumatic air CDA and DIW The process fluid within this system may become pressurized from outside flow sources It is the user s responsibility to verify that pressure within the system has been relieved externally prior to servicing in order to prevent exposure to hazardous fluid ...

Страница 17: ...d level sensor pressure sensor or thermocouple Note Opening the cabinet will cause the Door Interlock to trigger shutting down all power to the unit and preventing the unit from starting up Contact the factory for additional information The controller should sound an alarm signal indicating an open analog sensor or open thermocouple Reconnect the sensor to the correct terminal after testing Test t...

Страница 18: ...us with Auto Purge Optional Item Material of construction Cabinet Carbon Steel Powder Coated Drip Pan Polypropylene PP Wire Insulation Polyvinyl Chloride PVC Tetrafluoroethylene TFE Plumbing Fluorinated Ethylene Propylene FEP Perfluoro alkoxy Alkanes PFA Polyvinylidene Fluoride PVDF Polytetrafluoroethylene PTFE O Ring Material Approved Sanitization Methods Chemraz 505 Carbon Steel Powder Coated Vi...

Страница 19: ...to send the system into the Recirculation mode 3 The Venting mode cannot be active If the above conditions are not met the system will fail to enter Recirculation mode and remain in Demand mode Please note that the presence of any critical alarms will abort recirculation by shutting off the pump and deactivating the heaters Once critical alarms are resolved recirculation will automatically resume ...

Страница 20: ...is recommended that the pump air cooling system be utilized for optimum performance Please follow the Pump Air Cooling System Set Up and Calibration procedures prior to operation of the Recirculation feature Provide a steady air supply source for the pump air cooling system as detailed below It is highly recommended that this air supply source be independent from other system requirements for air ...

Страница 21: ... Locate the pump air cooling system pressure regulator gauge in the heater compartment of the Aquarius system and take note of the air pressure reading on the pressure gauge Please refer to the Mechanical Layout Drawing in SECTION II for its specific location 4 Turn the Aquarius system ON once again with the enclosure door open 5 Verify that the Recirculation System is enabled which is indicated b...

Страница 22: ...ss temperature has exceeded the High Temperature Alarm Set Point If the High Temperature Alarm Set Point is set correctly then make an adjustment in the Control Settings screen to the Power Adjust parameter Reset this parameter to 5 counts See if this solves the issue If not continue reducing the count by five until the issue is resolved Low Flow Alarm A The flow rate has dropped below the Low Flo...

Страница 23: ... I The pump controller temperature was higher than 70 C for more than 10 minutes J The pump controller temperature is over 80 C K The pump controller has an over current issue or the power channel has been interrupted System will not enter Recirculation mode Aquarius systems only A Verify that the Recirculation feature is enabled B Verify that the Recirculation signal is being sent to the system C...

Страница 24: ...ocation of the equipment relative to the walls Acceptable results Maximum sound pressure level does not exceed 80 dB A Test Results PASS Ambient 68 8 dB A Location Front 68 6 dB A Left 68 8 dB A Right 68 7 dB A Rear 68 8 dB A Note Operation of the system adds no measurable sound pressure to the local environment High Voltage Electrical Equipment This equipment MUST only be used within the range of...

Страница 25: ...uarius systems can be customized to meet specific customer requirements Please contact us for Aquarius options and configurations that are not specified Common options include 160 mm heater modules Auto Purge pump not included Resistivity sensor Discrete interface package Analog interface package Dry contact interface package Dry signal for 2nd process set point 32 mm internal plumbing size Flow r...

Страница 26: ...to 18 0 gpm 32 mm plumbing or 0 0 to 32 0 gpm 40 mm plumbing 14 5 Discrete Interface Package This optional interface package includes Remote Purge allows the user to monitor and control the purge function of the unit provided that the Auto Purge option is selected Remote Emergency Off EMO allows the user to shut off the system from a remote location and or from other equipment associated with the ...

Страница 27: ...rements by discouraging bacteria growth from forming in the process fluid and Aquarius plumbing Active Mode Temperature Ready Dead Band Signal Main Alarm Open Sensor Alarm analog sensors Process T C and High Limit T C Low Level Alarm Door Open High Temperature Alarm Low Temperature Alarm High Flow Alarm Low Flow Alarm High Pressure Alarm Low Pressure Alarm EPO Signal Drip Leak Alarm Open Thermal C...

Страница 28: ...036 Phone 626 599 8566 Toll Free 888 796 2476 Fax 435 783 6128 support wkfluidhandling com https wkfluidhandling com support Copyright 2020 White Knight Fluid Handling A Graco company P 626 599 8566 info heateflex com https wkfluidhandling com Version 1 0 0 29 Apr 2020 Subject to change without notice Part No IM1000 1708 Heateflex Heater Patent No 4 756 781 4 835 365 4 875 957 2685505 Japan ...

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