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Summary of Contents for Processor Technology LUFRAN LUF Series
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INSTRUCTION MANUAL LUFRAN Fluoropolymer Inline Water Heater LUF-Series 38809 Mentor Ave., Willoughby, Ohio 44094 PHONE: 440-974-1300 | USA/CN: 800-621-1998 Please supply your product model and serial numbers when FAX: 440-974-9561 ordering spare parts or when requesting technical assistance. processtechnology.com MODEL NO.: SERIAL NO.:...
RELATED DOCUMENTS: The following documents are to be used in conjunction with this manual: → ANSI/NFPA70 – National Electric Code , latest edition. To be used to determine appropriate electrical service, wire sizing, routing and protection. SEMI S2 – Semiconductor Equipment Safety Guidelines, latest edition. To be used in conjunction with safe operation, access and decommissioning procedures.
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INTRODUCTION (Continued): The following symbols and warning labels may appear on the unit and in the instruction manual. The table below provides an explanation of each one. PICTORAL DESCRIPTION DESCRIPTION DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
ENGINEERING INFORMATION: This system features the patented DAC control system operating from a PLC with a touch-screen operator interface. The DAC control system provides superior temperature control and faster response to changes in conditions versus a typical PID temperature control system. Figure 1: DAC Performance Graph +/- 1°C Steady State M-43-46...
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ENGINEERING INFORMATION (Continued): The maximum possible temperature rise through the heater is dependent upon the wattage of the unit and the water flow rate through the unit. The following table illustrates the maximum temperature rise of various models based upon the water flow rate through the unit.
ENGINEERING INFORMATION: SYSTEM SPECIFICATIONS: Product LUFRAN fluoropolymer Inline Water Heater, LUF Series, Approvals (Pending) Pending 24 kW – 312kW Available Wattages Refer to model number label for the wattage of any specific unit 380V-480V, 50/60Hz, three phase only Available Voltages (Lower voltages available with special construction, consult factory for details) Cabinet dimensions and...
ENGINEERING INFORMATION: MODEL NUMBER: Process Technology model numbers 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 interface screen. Refer to figure 42 (page 49) to see the location of this label. Figure 2: Model/Serial Number Label Provided below is an example of a typical model number along with an explanation of each part.
ENGINEERING INFORMATION: MODEL NUMBER (Continued): Heater Voltage. The first character following the heater Wattage will describe the rated Voltage of the heater. Please note that all heaters are rated for Three-Phase power. Heater Rated Heater Rated Model Voltage Model Voltage Number Number...
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ENGINEERING INFORMATION: MODEL NUMBER (Continued): Flow Meter Device. The ultrasonic flow meter device is part of the DAC temperature control system. The flow meter is selected based upon total wattage of the heater and operating flow rate range. This device does not require routine maintenance or re-calibration.
ENGINEERING INFORMATION: FACILITY REQUIREMENTS: Before installing the LUFRAN fluoropolymer inline water heater confirm the facility requirements listed below. Space Requirements: The LUFRAN fluoropolymer inline water heater is constructed in a freestanding enclosure. This cabinet includes the common framework for the heating column(s) as well as the electrical components. No additional support is required. Figure 3: Clearance Dimensions The dimensions of the specific model are based upon the unit wattage.
ENGINEERING INFORMATION: FACILITY REQUIREMENTS (Continued): Water Plumbing Requirements: This unit is typically supplied with a single inlet and outlet water connection located just inside the rear of the cabinet. The connections are arranged vertically and do not offset from the horizontal center of the unit. The inlet plumbing should also include a means to drain the unit for service.
ENGINEERING INFORMATION: CUSTOMER INTERFACE: Below is a table containing the remote communications options, their associated connection type and their connection label on the interface plate. Customer Connections / Protocols Process Customer Customer Physical Technology Communications Communications Interface Interface Protocol Connection All Units Ordering Label Unit 1...
ENGINEERING INFORMATION: OPERATOR CONTROLS: Operator Interface Buttons: There are two push buttons are located on the front panel of the unit. POWER OFF POWER ON RED BUTTON GREEN BUTTON Figure 4: Operator Interface Buttons Power On Button: When depressed, this button enables the main power safety contactor (1CON) and readies the system for operation.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Startup Menu: Figure 6 Startup Menu Startup Menu Information Description Panel This button will display a keypad to enter a password. After entering the password the MANUFACTURE display will show a manufacturer settings for system setup. There is no need for a user SETTINGS or operator to access these settings.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Main Menu: This is the display menu for normal operation. It provided overall information and allows the operator to navigate to a number of other menus. Pressing on any of the animated heating columns will pull-up a smaller image which will provide some temperature information for that specific heating column.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Main Menu (Continued): Main Menu Information Description Panel Displays the temperature measured from the process sensor located at the outlet of OUTLET the heater. Displays the output load of the heating elements needed to provide the desired outlet OUTPUT % temperature.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): General Settings Menu: The GENERAL SETTINGS MENU allows the operator to adjust the date and time. It also displays details about the supply voltage and heater current draw when the power meter is included with the unit. Figure 9: General Settings Menu General Settings Information Description...
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Alarms Menu: The ALARMS MENU displays the status of the various alarm settings for the LUF heater. All of the alarm fields in this menu are read-only. Any alarm that has been activated will change color to red. Pressing the alarm button will bring-up a small inset view with a description of the alarm.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Alarm Log Menu: The ALARM LOG MENU lists each alarm event detected along with the date and time at which it occurred. Figure 12: Alarm Log Menu Alarm Menu Information Description Panel PAGE UP, PAGE DOWN, These buttons allow the operator to scroll up and down through the list of alarm LINE UP,...
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Maintenance Menu: The MAINTENANCE MENU displays the list of maintenance tasks that should be performed per the prescribed timeframe. When it is time for one or more of the maintenance tasks to be performed, the MAINTENANCE button on the main menu will turn yellow.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): IO Menu: The IO MENU provides a display of the input and output connections for the PLC controller. This display will be unique for the specific layout of a specific model. Pressing on the image of the PLC base shows the IO points on the PLC base and their current state. Pressing each card will display “PLC IO Card”...
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Stack Light Test Menu: The STACK LIGHT TEST MENU allows the operator to test the condition of the indicator lamps. Two stack lights will be accessible if equipped as a dual out unit. Figure 15: Stack Light Test Menu Display Stack Light Test Menu Description...
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Trend Graph Menu: The TREND GRAPH displays the graph of current datalog values. This display includes the fields to adjust the sampling rate and the switch to stop or start datalogging. The datalog values will be automatically saved to a USB drive that is installed in the HMI unit. However if the USB drive has been removed and the operator attempts to activate the datalog then the message in yellow will appear.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Unit # Configuration Menu: The configuration menu contains a number of internal calibration settings. A password must be entered in order to access this menu. The factory default engineering password is 1234. Figure 17: Configuration Menu Configuration Menu Description Information Panel...
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ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI): Configuration Menu (Continued): Configuration Menu Description Information Panel Displays the LOW FLOW SETPOINT. This setting will disable heater operation when the flow rate through the heater falls below this setting (liters per minute). The controller will provide a warning message when the flow rate has dropped below this setting, but it will not enter an alarm state.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Temperature Monitor Menu: The temperature monitor menu provides a number of internal temperature measurements. Figure 18: Temperature Monitor Menu Temperature Monitor Menu Description Information Panel Displays the current temperature measured by the sensor which monitors the COLUMN # ELEMENT TC heating element for the heating column # specified.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Comms Menu: The COMMS MENU is a diagnostic menu which provides a display of the devices that are communicating with the PLC controller. This display will be unique for the specific layout of a specific model. An internal communications fault between these devices will be highlighted in red, as shown in the figure below.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Heater Calibrate # Menu: The HEATER CALIBRATE # MENU allows the operator to calibrate the heater unit # specified. The calibration procedure will be different depending upon whether or not the unit includes a power monitor. Refer to the Heater Calibration section of this manual for the procedures.
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Flow Calibrate # Menu: The FLOW CALIBRATE # MENU allows the operator to calibrate the flow rate for the unit # specified. Refer to the Flow Calibration section of this manual for the procedures. Figure 22: Flow Calibrate # Menu Flow Calibrate # Menu Description...
ENGINEERING INFORMATION: HUMAN MACHINE INTERFACE (HMI) (Continued): Adjust Offsets Menu: The ADJUST OFFSETS MENU allows the operator to change the offset value on a number of internal temperature sensors. Press the offset field and a keypad will appear to enter an adjustment value. Figure 23: Adjust Offsets Menu Adjust Offsets Menu Description...
ENGINEERING INFORMATION: HEATER CALIBRATION PROCEDURE: This calibration procedure should be performed the first time the unit is operated. While this unit was tested and calibrated prior to shipment, this procedure will help correct for some offsets caused by variations in nominal supply voltages. While the DAC control system will compensate for these differences, performing this procedure will improve heater response.
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ENGINEERING INFORMATION: Heater Calibration Procedure (Continued): Figure 25: Heater Calibration Menu Displays (with power monitor) Calibration Procedure with Power Monitor: 1) Once the installation and startup procedures are complete, adjust the water flow to the maximum expected operating flow rate. 2) Access the HEATER CALIBRATION menu through the SECURE MENU on the operator-interface panel (HMI).
ENGINEERING INFORMATION: FLOW METER CALIBRATION PROCEDURE: This calibration procedure has been performed at the factory prior to shipment. Flow meter calibration is only needed if the flow meter is replaced. Figure 26: Flow Calibrate # Menu 1) Turn off heater operation by pressing the HEAT ON/OFF button on the MAIN MENU. Access the FLOW CALIBRATION # menu.
ENGINEERING INFORMATION: ALARMS: The following section describes each of the alarm conditions that may occur on the LUFRAN fluoropolymer inline water heater. Alarms Alarm History Menu Description Menu A ground fault has occurred somewhere in the unit. This may be caused Ground Fault Ground Fault by a failed component.
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ENGINEERING INFORMATION: ALARMS (Continued): Alarms Alarm History Menu Description Menu The thermostat on one of the heat sinks for the SSRs has tripped, indicating a high temperature on the heat sink. This may be caused by a malfunctioning fan, high ambient air SSR Fault SSR Heatsink Fault temperature, inadequate air circulation through the cabinet, or a tripped...
INSTALLATION: Note: Carefully read this entire section before installation. The installation of this unit must be performed by qualified technicians. En raison du poids de l'appareil, NE PAS ESSAYER de Due to the weight of the unit, DO NOT ATTEMPT to move or déplacer ou de soulever l'appareil sans l'équipement de lift the unit without the appropriate material handling manutention de matériel approprié.
INSTALLATION: POSITIONING THE UNIT: 1) Once the LUFRAN fluoropolymer inline water heater has been removed from the crate and the unit passes the damage inspection, it can be moved to the service location. Move the unit using either the lifting hooks located on top of the enclosure or by lifting the unit from underneath using a fork truck or other suitable handling equipment.
INSTALLATION: INSTALLING SEISMIC BRACKETS (optional): This unit includes four seismic brackets in the event such brackets are a requirement for the installation of this unit. The top-half of these brackets have already been installed on the unit. If the heater installation requires that the seismic brackets be used, the bottom-half of these seismic brackets may be secured to the floor and then fastened to the bracket halves on the cabinet.
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INSTALLATION: PLUMBING (Continued): The various plumbing connections are located as follows: Figure 31: Plumbing Connections (stack light option shown) Refer to the facilities print for your specific heater model to identify the exact size and type of plumbing connections that are provided on your unit.
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INSTALLATION: PLUMBING (Continued): Water Inlet, Outlet Connections: When tightening all connections on this unit, be sure to support the internal plastic piping as close as possible to 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.) do not require very much force to properly seal.
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INSTALLATION: PLUMBING (Continued): Inlet/Outlet Connections; Flared Compression Tube Fittings: Please note that the procedure specified below should only be performed once, when the tubing is first connected to the fittings. Once properly tightened, the fittings will not need to be re-tightened. 1) Remove the protective plastic caps from the flared fittings on the Inlet and Outlet piping of the heater assembly.
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INSTALLATION: PLUMBING (Continued): Inlet/Outlet Connections; Super 300 Type Pillar™ Tube Fittings: Super 300 Type Pillar Fittings use a “gauge ring” which is used to determine the proper tightness of the fitting connections. 1) Remove the protective plastic caps from the fittings on the Inlet and Outlet piping of the heater assembly.
INSTALLATION: PLUMBING (Continued): Purge Gas Supply Connection (6mm (1/4-inch) compression fitting): 1) Loosen and remove the compression nut. Remove the sealing cap from plumbing connection and discard. 2) Test fit the tubing to ensure proper length. 3) Slide the compression nut over the tubing. 4) Insert the tubing into the compression fitting.
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INSTALLATION: WIRING (Continued): Opening the front cabinet doors: 1-2 column (24kW – 156 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 position to the RESET position and pull the door open.
INSTALLATION: OPERATION: The LUFRAN fluoropolymer inline water heater can be operated from the front of the unit. It can also be operated remotely through an optional or customer-provided interface cable. This section deals with controlling the heater locally from the front of the unit. For an explanation of controlling the unit remotely, refer to the ENGINEERING section of this manual.
OPERATION: SHUTDOWN PROCEDURE: 1) Press the HEATER OFF button on the main menu screen. Continue water flow through the heater to allow the heating columns to cool down. 2) Continue water flow through the heater until the outlet temperature display indicates 95°F (35°C) or less. Le chauffe-eau doit être désactivé...
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MAINTENANCE SCHEDULE: CATEGORIES OF ELECTRICAL HAZARDS Type Description Equipment is energized, but live circuits are covered or insulated to prevent accidental shock. Equipment is energized and energized circuits of less than 24 VDC, 240 VA and 20 joules are exposed to accidental contact.
MAINTENANCE PROCEDURES: M1: Liquid Level Sensor, Top Half Plumbing There is one liquid level sensor located at the top of heating column 1, and for heaters with 3-4 heating columns there is another liquid level sensor at the top of column 4. These are capacitive sensors that must be inspected for proper adjustment every 6 months.
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MAINTENANCE PROCEDURES: Procedure M1-2: Liquid Level Sensor Calibration Procedure: 1) Insure the liquid level sensor is properly positioned in facing the outlet tube of the heating column. The sensor should be about 3.5mm (0.125-inch) away from the outlet manifold. 2) Using a small flat blade screwdriver, turn the sensor adjustment potentiometer on the back of the sensor clockwise until the red LED on the sensor illuminates.
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MAINTENANCE PROCEDURES: M2: Outlet Process Sensor, Column TC Sensor(s) The outlet process temperature sensor is located in the TEE fitting directly before the outlet plumbing connection. The column temperature sensor(s) are located in the top manifold of each heating column, labeled COLUMN TC. These sensors should be checked for proper operation every 6 months.
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MAINTENANCE PROCEDURES: Procedure M2-2: Outlet Process or Column TC Sensor Replacement Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position. 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) Turn OFF Power to the unit.
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MAINTENANCE PROCEDURES: Procedure M3-2: Leak Detector Replacement Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position. 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) Turn OFF Power to the unit.
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MAINTENANCE PROCEDURES: M4: Purge Gas Flow Switch, continued Procedure M4-2: Purge Gas Flow Switch Replacement Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position. If the unit is in REMOTE mode disable the heater from the customer supplied remote controller.
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MAINTENANCE PROCEDURES: M5: Humidistat Purge Exhaust, Humidistat Switch There is one humidistat device installed in a heater with 1 or 2 heating columns. Heaters with 3 or 4 heating columns will have two humidistat devices installed. These items are responsible for monitoring the purge gas exhaust for the presence of moisture.
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MAINTENANCE PROCEDURES: Procedure M5-2: Humidistat Replacement Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position. 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) Shut down the unit.
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MAINTENANCE PROCEDURES: M6: Pressure Relief Valve (PRV), Bottom Half Plumbing The PRV is located near the inlet water plumbing connection at the bottom of the heater side of the cabinet. The PRV and the inlet plumbing should be inspected every 6 months to insure that there are no leaks. Procedure M6-1: PRV Inspection Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position.
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MAINTENANCE PROCEDURES: Procedure M6-2: PRV Replacement Procedure (Continued): 5) Disconnect the ½-inch fluoropolymer discharge tube by loosening and removing the compression fitting on the PRV. 6) Unscrew and remove the PRV by turning the PRV body counter-clockwise. 7) Inspect the O-Ring located in the inlet manifold for any damage. 8) Screw the new PRV into the inlet manifold connector.
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MAINTENANCE PROCEDURES: Procedure M7-2: Cooling Fan Replacement Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position. 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) Turn OFF Power to the unit.
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MAINTENANCE PROCEDURES: M8: SSR Cooling Fans Each solid state relay (SSR) module has an aluminum heat sink with a cooling fan mounted on the underside. This fan draws cool air into the unit through the underside of the cabinet. These SSR modules are located at the bottom of the electrical side of the cabinet.
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MAINTENANCE PROCEDURES: M9: Circuit Breaker The main circuit breaker includes a test button located on its face. The circuit breaker should be inspected for proper operation every 6 months. Procedure M9-1: Circuit Breaker Inspection Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position.
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MAINTENANCE PROCEDURES: M10: Safety Contactors The safety contactors are mounted on the high-voltage section of the electrical panel. Each safety contactor should be inspected for proper operation every 6 months. Procedure M10-1: Safety Contactor Inspection Procedure: 1) If the unit is in LOCAL mode, press the HEATER ON/OFF button to the OFF position. If the unit is in REMOTE mode disable the heater from the customer supplied remote controller.
SPARE PARTS: Listed below is the spare parts list for the LUFRAN fluoropolymer inline water heater. These are items that may need replacement after some time in service. This is not the complete parts list, so there are some heater components that are not listed below.
SPARE PARTS: Recommendations: 1) One complete spare parts kit is sufficient for every 4 to 6 LUFRAN fluoropolymer inline water heaters installed in a single location. Be sure to immediately reorder any parts that are used. 2) Sensors for the inlet/outlet process water (Part # TC-DI-L2-2.25) are a required spare part for each DI Heating Column. Spare sensors have already been provided with the unit.
WARRANTY: All PROCESS TECHNOLOGY equipment, heaters and controls have been carefully inspected before shipping and are warranted to be free from defects in workmanship and materials for a period of one year from date of purchase on a pro- rated basis. At its option, PROCESS TECHNOLOGY will repair or replace any defects that are exhibited under proper and normal use.
APPENDIX: -23 CONFIGURATION This section applies only to units that include the “-23” optional configuration. This configuration adds the ability to operate the heating column(s) at a preset output during periods of no hot water demand, when there is a low “trickle flow” of DI water passing through the unit.
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