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Summary of Contents for Trebor 2472
- Page 1 I D t i o MODEL 2472 DI WATER HEATER Operation / Maintenance Manual SERIAL NUMBER : 9/13/00 – M2472-FB...
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Page 2: Table Of Contents
HEATER CALIBRATION ....................28 TROUBLESHOOTING ......................31 TEMPERATURE CONTROLLER DOES NOT DISPLAY ..........31 ALARM SOUNDS ......................31 HEATER ELEMENT STATUS LED IS ON ..............32 WIRING SCHEMATIC ......................33 10 WARRANTY ..........................34 2472 DI HEATER OPERATION / MAINTENANCE MANUAL CONTENTS... -
Page 3: Introduction
With proper care and maintenance, the Model 2472 DI Water Heater System has proven itself reliable with many years of installed heater run time, resulting in substantial cost saving through increased productivity. -
Page 4: Safety
A Warning message indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Following is a typical example of a Warning message as it could appear: PAGE 4 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 5: Caution
LED will indicate a failure has occurred and the display of the OTC causing the fault will flash “ALR”. The OTC’s will disengage power and a manual reset will be required by pressing HEATER ON (see Section 8, Troubleshooting). 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 5... -
Page 6: Low Pressure Switch Interlock
(see Figure 2-1: Panel Interlock Locations). Replacing panels and pressing HEATER ON will be required to restart heater. Figure 2-1: Panel Interlock Locations Troubleshooting PAGE 6 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 7: Leak Sensor
If the overpressure relief device opens, the low pressure sensor can disable heater power when an alarm condition exists and the pressure fault LED will illuminate. Refer to Section 7.1.e on replacing burst fitting. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 7... -
Page 8: Emergency Off (Emo)
Always perform an electrical de-energization test before and after installation of the Lockout device by verifying the circuit breaker properly isolates the line voltage from the system. PAGE 8 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 9: Seismic Protection
It is the users responsibility to adequately secure and anchor the equipment to comply with local regulatory agency seismic requirements. Mechanical anchor locations are provided on the top and bottom of the cabinet enclosure. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 9... -
Page 10: Installation
NOTE: The DI water heater must be allowed to stabilize at installation location at ambient temperature and humidity for 24 hours before operation. Refer to Section 3.3 for system requirements. PAGE 10 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 11: Utility Requirements
Min. Dimensions: CAUTION: Use a facility power disconnect switch equipped with Lockout/Tagout capabilities, per OSHA 29 CFR, should be installed and adjusted to the heater. Refer to Section 2.5 in this manual. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 11... - Page 12 I D t i o Figure 3-1: Facility Installation Layout PAGE 12 2472 DI HEATER OPERATION / MAINTENANCE MANUAL...
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Page 13: Hook-Up
Figure 3-1: Facility Installation Layout. After positioning heater at operating location, raise the four leveling feet until the heater is level and stable. Adequate clearance of leak tray must be provided. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 13... - Page 14 Attach cabinet drain line to bottom of cabinet. If a cabinet drain line is not installed, the system will be difficult to drain for maintenance or repair and can cause water damage if a large leak occurs. PAGE 14 2472 DI HEATER OPERATION / MAINTENANCE MANUAL...
- Page 15 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. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 15...
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Page 16: Remote Hook-Up
I D t i o 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 16 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 17: Operation
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. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 17... - Page 18 0.12 0.08 0.06 0.04 Saturation Temperature 0.02 Pressure Drop Flow (lpm) Figure 4-1 2472 Heater Capacity Assume DI Water Ambient Temperature = 20°C Saturation Temperature Pressure Drop Flow (gpm) Figure 4-2 PAGE 18 2472 DI HEATER OPERATION / MAINTENANCE MANUAL...
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Page 19: Start-Up
START-UP PRE-START INSPECTION This Trebor DI Water Heater has been thoroughly tested and inspected for proper performance and operation prior to leaving the factory. Additional pre-start inspection can identify any damage or condition change that may have occurred during shipment of the heater and reduce nuisance problems during start-up. -
Page 20: System On
The only user alterable setting in the controller is the temperature setpoint. Changing any other controller values may cause damage to the heater modules and will void the system warranty. Consult factory for settings. PAGE 20 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 21: Heater Module Power
3-1: Facility Installation Layout). An indicator that does not illuminate in conjunction with others indicates a blown fuse on one side of the element or possibly a failed heater (see Section 8, Troubleshooting). 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 21... -
Page 22: Shut Down
The system has been tested with high purity DI water. After installation a 48-hour purge “burn-in” period >1 gpm is recommended to clean out the system and plumbing before use in high purity process applications. PAGE 22 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 23: Maintenance
Failure to do so could result in a safety hazard and cause injury to personnel and equipment. Consult factory for further information. Follow Lockout/Tagout procedures as referenced in the Safety section of this manual. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 23... -
Page 24: Draining The System
When a leak has been detected it is recommended that the supply water be shut off along with the facility circuit breaker. Allow sufficient time for the DI heater and plumbing to cool down before inspection. PAGE 24 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 25: Overpressure Relief Replacement
Care needs to be taken when reinstalling the heater outlet manifold so that the top surface of the heater module and the outlet manifold are flush, to ensure that the top cap can be properly replaced. If the leak is elsewhere, identify the location and contact Trebor International. ... -
Page 26: Heater Replacement
Remove necessary plumbing fittings from failed heater module and install on replacement heater module. Install replacement heater module into cabinet in reverse order from above. Return failed heater to manufacturer. PAGE 26 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 27: Spare Parts
Overpressure Relief Drain & Diaphragm General Electronics Fuse Blocks Solid State Relays (SSR’s) Main Circuit Breaker Main Contactor Distribution Block / Terminal Block See following table for details on each item. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 27... -
Page 28: Heater Calibration
The calibration method compares the output DI Water temperature to the DI heater temperature controller process value. Perform the following procedure: Turn heater power off and isolate plumbing connections to allow insertion of a temperature sensor. PAGE 28 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... - Page 29 To lock the Watlow Controller, access the “Fcty” menu again in the Factory Menus and change the “Oper” setting to “read”. Press the Home key to exit. 2. Change the heater setpoint to 30C and run for 10 minutes. 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 29...
- Page 30 I D t i o 3. Verify the calibration offset is within 2C. 4. Return heater to original configuration. PAGE 30 2472 DI HEATER OPERATION / MAINTENANCE MANUAL...
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Page 31: Troubleshooting
I D t i o TROUBLESHOOTING The following is an outline of routine troubleshooting techniques. Consult Trebor for further conditions not covered in this section. TEMPERATURE CONTROLLER DOES NOT DISPLAY CAUSES SOLUTIONS EMO button engaged Twist EMO in direction of arrows (refer to Section 2.4). -
Page 32: Heater Element Status Led Is On
Solid state relay may have “frozen” An SSR has failed in the open mode. open Shut system off immediately and replace the failed SSR. SSR’s should be replaced in pairs. PAGE 32 2472 DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 33: Wiring Schematic
I D t i o WIRING SCHEMATIC (See attached fold out sheet.) 2472 DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 33... -
Page 34: Warranty
Manual. TREBOR’s obligation under this warranty is limited to repairing or replacing, at TREBOR’s option and at the TREBOR factory, any part or parts thereof which shall, within 1 year after delivery thereof to the original purchaser, be demonstrated to TREBOR’s satisfaction to have been defective.
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