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Phone: 800-669-1303 or 801-561-0303
Fax: 801-255-2312
e-mail: treborservice@idexcorp.com
SERIAL NUMBER:
PATENTS: U.S. 5971402, U.S. 6433319, U.S. 6479094B2, U.S. 6544583B2,
U.S. 6580061B2, U.S. 6663914, U.S 6674053B2;
ADDITIONAL PATENTS PENDING
QUANTUM
DI WATER HEATER
Operation / Maintenance
Manual
10/25/07 – MQTM-D
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Related Manuals for Idex Trebor QA1V208P12-AA
Summary of Contents for Idex Trebor QA1V208P12-AA
- Page 1 Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com QUANTUM DI WATER HEATER Operation / Maintenance Manual SERIAL NUMBER: 10/25/07 – MQTM-D PATENTS: U.S. 5971402, U.S. 6433319, U.S. 6479094B2, U.S. 6544583B2, U.S. 6580061B2, U.S. 6663914, U.S 6674053B2; ADDITIONAL PATENTS PENDING...
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Page 2: Table Of Contents
CONTENTS INTRODUCTION ............................3 SAFETY ..............................6 SAFETY MESSAGE CONVENTIONS ....................6 2.1.a Danger ...........................6 2.1.b Warning ..........................6 2.1.c Caution ...........................7 EQUIPMENT SAFETY ........................7 EMERGENCY OFF (EMO) ......................7 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... -
Page 3: Introduction
INTRODUCTION QUANTUM DI WATER HEATER TREBOR’s Quantum deionized water heater will meet your most stringent application requirements for process cleanliness and temperature control. Our unique heater design virtually eliminates the potential for metal contamination due to potentially exposed metal heating elements in immersion style heaters, while process control and reliability are designed to outperform and outlast other available quartz heating systems. - Page 4 Figure 1-1: 89/392/EEC “European Machinery Directive” 89/336/EEC “European EMC Directive” Conformity of the equipment with the above guidelines is attested by the CE mark. This equipment also complies with the requirements of the “Management Methods for Controlling Pollution of Electronics Information Products”, known as “China RoHS”.
- Page 5 Table [表] Part Name Table of Hazardous Substances and Elements [部件名称] [产品中有毒有害物质或元素的名称及含量] Lead Mercury Cadmium Hexavalent Polybrominated Polybrominated Chromium biphenyl diphenyl ether [铅] [汞] [镉] [六价铬] [多溴联苯] [多溴二苯醚] (Pb) (Hg) (Cd) (Cr (VI)) (PBB) (PBDE) QA1V208P12-AA QA1V380P10-AB QA1V415P10-AB QA1V480P10-AD QA1V480P12-AB O = This substance is present at a concentration below the limit in SJ/T 11363-2006 in all of the homogeneous materials for this part, and it has not been intentionally added to any metallic coating.
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Page 6: Safety
SAFETY This section describes information that is important for safe equipment operation. Included is a listing of message conventions used in this manual, as well as equipment safety interlocks, push buttons, and labels. The equipment described in this manual uses hazardous voltage electricity that can be dangerous. -
Page 7: Caution
2.1.c Caution A Caution message indicates a potentially hazardous situation, which, if not avoided, could result in minor or moderate injury. It may also be used to alert against unsafe practices. Following is a typical example of a Caution message as it could appear: Caution Hot Surface Do not touch. -
Page 8: Process Interlocks
Figure 2-1 On power up or after the EMO has been pushed, the heater must be reset by pressing the blue RESET button to reactivate the controls. This must be done at the machine. PROCESS INTERLOCKS The process fault interlocks are latched into the logic controller (PLC) memory. -
Page 9: Liquid Level Sensor Interlock
2.4.b Liquid Level Sensor Interlock The Liquid Level Sensors will disengage power to the system if the heater modules are not full of water or if boiling in the heating module occurs. The heater will reengage if fluid is present within a 30 second time period. -
Page 10: Definitions
2.5.b Definitions Lockout: the placement of a lockout device on an energy isolating device, in accordance with established company procedures, ensures that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed. Tagout: a prominent warning device such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with established company procedure, ensures that the... -
Page 11: Machine Shutdown With Door Closed
2.5.c Shutdown with door closed Machine Perform the following sequence of events in the order listed for electrical energy isolation of the tool: 1. Notify personnel in the area that you are going to shut down the equipment. 2. Shutdown the system in an orderly fashion. 3. -
Page 12: Machine Start-Up With Door Open
2.5.f Machine Start-Up with door open Perform the following sequence of events in the order listed for electrical re-energization of the tool: 1. Ensure that all hand tools are removed from the equipment and that it is ready for start-up. 2. -
Page 13: Installation
INSTALLATION UNPACKING Remove heater system from crate and inspect heater cabinet for any signs of damage (dented panels, paint scratches, etc.). Shock indicators on the heater cabinet should be checked for rough handling during shipment. Any damage to the system should be reported to the carrier immediately. - Page 14 Recommendation: Either insulate the hot DI water process line or place a Hot Surface hazard warning (example shown below) on the tubing every 20 feet. Conform to local codes while evaluating hot water line routing. Caution Hot Surface Do not touch. Can cause skin burns upon contact.
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Page 15: Ethernet Communication
Connect the supply grounding wire to the grounding lug and the other three lines into the top of the circuit breaker connections (L1, L2, and L3) as shown in Figure 3-1 (torque wire terminal connections to 120 in/lb). Figure 3-1: (MTD0443) Close the door and secure. -
Page 16: Changing Heater Ip Address
3.3.b Changing Heater IP Address ATTENTION: This section of the manual assumes you know the basics behind IP addressing. If you are unfamiliar with IP addressing, do not attempt to change the IP address of the heater. Incorrect assignment of an IP address could leave the Ethernet functionality of the heater unusable by your current network configuration. -
Page 17: Operation
OPERATION GENERAL The Quantum is very easy to operate. Once DI water is flowing through the system and power is turned on, a process temperature can be selected and power switched on to the heater modules. The controls will do the rest. If there is a problem with the DI water heater, the system controller will notify the operator that the heater requires attention. -
Page 18: Alarm Status Page
An enable button is provided that, when activated, will open the inlet valve and allows the heater bank to be turned on. This function is active in single and multiple output systems. This feature provides the ability to safely disable a bank of heaters in a multiple outlet system. After enabling the heater and when in local control mode, the on/off button can be used to turn the heater on or off. - Page 19 Alarm Name Function Pressure Alarm Insufficient inlet water supply pressure Liquid Level Alarm Insufficient fluid level Thermocouple Open Alarm Broken/Disconnected Thermocouple lead Fluid Leak Detected – water in base area or fluid on Liquid Leak Alarm back side of burst device (for optionally installed burst device rupture sensor) One or more elements have exceeded the Over Temperature Alarm...
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Page 20: Module Status Page
4.2.c Module Status Page Figure 4-3: Module Status Page (single & dual bank version shown) The module status page shows the temperatures of each of the heater modules. If the heater module temperature is shown in black lettering with a white background, the module is functioning properly. -
Page 21: Configuration Page
The process plot page shows a plot of the set point and process value. The set point is displayed with a blue line and the process value is displayed with a red line. The plot is refreshed approximately every two seconds. - Page 22 The current IP address and mask is displayed. Note that the field being edited is displayed in red. Press the “Enter” button when done changing the IP address or mask to apply the changes. Changes to the IP address and mask will take effect immediately. Please note that the previous IP address and mask will remain active in the system until power is cycled to the heater.
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Page 23: Log Reports
A “Config” button is present on the Config page for select heater configurations. This button allows the setup of configuration-specific settings. The buttons on the bottom of the page will take you to the other pages. 4.2.f Log Reports Log reports are generated to capture three types of data: Alarms, Events, and System. - Page 24 Figure 4-7: Example of System and Alarm logs Log reports are time stamped. System time and date settings should be updated after initial startup to ensure accurate log information (see section 4.2.e). The most recent logged event is always listed at the end of the listing and the oldest at the beginning of the log.
- Page 25 After connecting the following interface will appear: Figure 4-8: Ethernet Loaded Log Menu To view the log files in the web browser, double-click the “LOGS” directory, and double click the desired log file. Click 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.
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Page 26: Security Status Page
NOTE: Alarm and Events logs may appear for heater banks that are not available. Disregard these logs. 4.2.g Security Status Page This heater is supplied with security features that will lock out the local user interface. When security is enabled, any screen can be viewed at any time but a four digit pass code is required to change the heater variables or states. - Page 27 To change your PIN number: Open the security page, enter the correct PIN, and press “Change PIN” button then enter a new four digit PIN code. Figure 4-9: Entering new PIN Number To change the access time, open the security tab, enter your correct PIN, and select the access duration time by selecting the current access duration value.
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Page 28: Remote Operation Over A Network
Figure 4-11: Invalid Pin If the user PIN number is lost: Contact Trebor for instructions to reset the security features. REMOTE OPERATION OVER A NETWORK 4.3.a Ethernet Interface The heater can be operated over an Ethernet network using either Modbus TCP or a proprietary software interface. A remote connection over Ethernet can turn the heater on and off, change the set point, and check the operation and the alarm status. -
Page 29: Modbus/Tcp
4.3.c Modbus/TCP The heater can be operated over an Ethernet network using the Modbus/TCP protocol. Although the heater can be controlled directly using Modbus/TCP, Trebor recommends that the heater be controlled using a communication library written by Trebor. The Trebor communication library abstracts the details of Modbus/TCP. - Page 30 For more information regarding Modbus communication please visit www.modbus.org. Name Addr Bank 1 Addr Bank 2 Addr Bank 3 Addr Bank 4 Type Data Bytes Perm Set Point 16404 16529 16654 16779 Reg Short Process Temperature 16405 16530 16655 16780 Reg Float Duty Cycle 16429...
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Page 31: 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 32: System On
SYSTEM ON Activate the power to the system by rotating the “Main Breaker” handle to ON. If the display on the control panel does not illuminate, ensure that the EMERGENCY OFF button is in the operate position. Press the reset button to engage control power. -
Page 33: Shut Down
SHUT DOWN The DI water heater may 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. -
Page 34: Maintenance
MAINTENANCE REPAIR INSTRUCTIONS Heater modules have a finite life. Spare heating modules should be on hand in case of a failure. NOTE: If top element fails then switch off lower element for consistent temperature control. 7.1.a Heater Element Check If the control screen indicates a check heater element status bar, check the heater diagnostic display for information about heater module status. -
Page 35: Liquid Level And Leak Sensor Calibration
Remove steel band clamps, but do not remove clamps used on modules for connecting the electrical box. Loosen fluid inlet and outlet fittings on module. Disengage the inlet fitting by sliding the bottom of heater off shelf. Lower the heater to disengage top fitting from manifold. Use an absorbent cloth to remove any liquid from the leak sensor probe and leak containment well. -
Page 36: Fuse Replacement
7.1.d Fuse Replacement There are two different ratings of fuses in the electrical control box. See the Appendix and the electrical schematic for fuse locations. All fuses are CCMR type. CAUTION: Fuses must be replaced with the same type of fuse and rating. -
Page 37: Leaks
7.1.f Leaks When a leak has been detected it is recommended that the supply water be shut off along with the main circuit breaker. Allow sufficient time 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. -
Page 38: Preventive Maintenance Schedule
PREVENTIVE MAINTENANCE SCHEDULE Quantum Items Process Control / Heater Element Status Plumbing Leaks Overpressure Relief Drain & Diaphragm General Electronics Solid State Relays (SSR’s) Main Circuit Breaker Distribution Breakers & Contactors Branch Circuit Breakers See following table for details on each item. Verify torque at least every 6 months with a calibrated torque wrench. - Page 39 ITEM DETAILS Visually check DI water lines outside of heater cabinet for signs of leaks at the Plumbing connections. (A leak sensor will detect leaks, but this periodic visual check is Leaks recommended.) Also, visually check bottom of cabinet inside heater module enclosure for DI water leaks.
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Page 40: Troubleshooting
TROUBLESHOOTING Display is Not Illuminated Cause: Solution: EMO button engaged. Twist EMO in direction of arrows (see Section 2.3). No power at main circuit breaker. Review wiring procedure (see Section 3, Installation). Control fuse is blown. Replace fuse. Main breaker is OFF. Main breaker to ON. -
Page 41: Warranty
WARRANTY See the Trebor Standard Limited Warranty at http://www.treborintl.com/TechnicalSupport.aspx QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 41...