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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
Q-SERIES DI WATER
HEATER
Operation / Maintenance
Manual
4/21/10 – MQ-B
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Summary of Contents for Trebor Q-SERIES
- Page 1 Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 e-mail: treborservice@idexcorp.com Q-SERIES DI WATER HEATER Operation / Maintenance Manual SERIAL NUMBER: 4/21/10 – MQ-B 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
8.1.d Draining the System ..................... 27 8.1.e Leaks..........................27 8.1.f Overpressure Relief Fitting Replacement ..............28 PREVENTIVE MAINTENANCE SCHEDULE................28 TROUBLESHOOTING ..........................30 WARRANTY ............................. 31 See Appendix for specific system requirements. Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL CONTENTS... -
Page 3: Introduction
INTRODUCTION Q-SERIES DI WATER HEATER TREBOR’s Q-Series DI 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 1-2: China RoHS - Electronic information product pollution control symbol Trebor will use an EFUP (Environmental Friendly Use Period) of 25 years, which is consistent with the industry mean. The EFUP label is located next to the main system nameplate and a declaration table is included below.
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Page 5: Safety
2.1.b Warning A Warning message indicates a potentially hazardous situation that, if not avoided, could result in serious injury. Following is a typical example of a Warning message as it could appear: Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 5... -
Page 6: Caution
After the EMO button is disengaged, the heater must be reset by pressing the blue RESET button located on the front of the heater near the EMO button to reactivate the controls. PAGE 6 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 7: Lockout / Tagout
1. Notify personnel in the area that you are going to shut down the equipment. 2. Shutdown the system in an orderly fashion. 3. Locate the main incoming power disconnect switch-actuating handle. 4. Move the actuating handle to the "OFF" (down) position. Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 7... -
Page 8: Machine Start-Up With Access Panels Installed
1. Ensure that all hand tools are removed from the equipment and that it is ready for start-up. 2. Notify personnel in the area that you are going to start-up the equipment. PAGE 8 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 9: Seismic Protection
Mounting holes for anchors are provided at the bottom of the cabinet enclosure. See Facility Layout in Appendix for mounting hole locations. Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 9... -
Page 10: Installation
Recommendation: Either insulate the hot DI water process line or place a Hot Surface hazard warning (shown below) on the tubing every 20 feet. Conform to local codes while evaluating hot water line routing. PAGE 10 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... - Page 11 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). Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 11...
- Page 12 Follow heater Pre-Start Inspection (see Section 4.1). NOTE: Before starting the system, it is important to become familiar with Sections 4 and 5. Only trained, qualified, authorized, personnel should operate this system. PAGE 12 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL...
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Page 13: 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 14: System Power
EMO. The power contactors will engage and the heater will be in standby mode, ready to heat water. See instructions in section 5 for operating the heater locally or remotely and for explanation of process interlocks. PAGE 14 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 15: Heater Operation
HEATER OPERATION The Q-Series DI water heater is very easy to operate locally via a built-in graphical user interface or remotely through an external hardware interface. Simply choose a temperature set point and let the controls do the rest. If the heater encounters a problem, the on-board controller will notify the operator that the heater requires attention (see section 6 for details of system interlocks). -
Page 16: Home Page
The alarm page displays the status of all process interlock alarms (see section 6 for details of process interlocks). The following list explains the items on the Alarm Screen: Pressure = Status of the low fluid pressure interlock PAGE 16 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... - Page 17 Button F3 ( ) switch the display to the Plot page Button F4 ( ) switches the display to the Configuration page Button F5 ( ) switches the display to the Home page Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 17...
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Page 18: Configuration Page
Low Flow (GPM) 3, 36kW 6, 72kW 3.25 1.75 0.25 12, 120kW 12, 144kW Table 5-1: Flow Settings The following navigation buttons are also available for advancing to the Home and Alarm pages: PAGE 18 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 19: Plot Page
Why? That is how the plot works in the display unit. The only navigation button defined on this page is to return to the Home page: Button F5 ( ) switches the display to the Home page Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 19... -
Page 20: Remote Operation Over An External Hardware Interface
The default remote operation communication protocol is Modbus/RTU over an RS232 hardware interface. See Table 5-2, for the heater’s register and coil address mapping. For information regarding the Modbus communication protocol please visit www.modbus.org. PAGE 20 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... - Page 21 “Remote Set Point” register. To adjust the temperature set point, a write request must be sent to the address for the “Remote Set Point” register with a value between 15 and 95. Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 21...
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Page 22: Process Interlocks
If the liquid level returns to an appropriate level before the delay period elapses, the heater will go back to normal operation without PAGE 22 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 23: Element Over Temperature Sensor
If the overpressure relief device opens, the low fluid pressure sensor will alarm. A periodic visual inspection of the fitting is recommended. Refer to Section 8.1.f for instructions on replacing the relief fitting. Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 23... -
Page 24: System Shut Down
(heater element power will be disengaged). Rotate “Main Breaker” to off position. Turn off the facility power supply. Lockout and tagout heater for maintenance or repair. Refer to Section 2.3. PAGE 24 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 25: Maintenance
Remove steel band clamps connecting heater module to cabinet, but do not remove clamps used to connect the electrical box to the module housing Loosen fluid inlet and outlet fittings on module. Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 25... - Page 26 Install replacement heater module into cabinet in reverse order from above. Note: Carefully align the fluid fittings because they can easily be cross-threaded. Process T/C Heater Band Clamps Figure 8-1 PAGE 26 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL...
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Page 27: Liquid Level Sensor Calibration
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. Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 27... -
Page 28: Overpressure Relief Fitting Replacement
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. PAGE 28 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... - Page 29 TLM 1 98004131 16 Channel Temperature Controller 0.4 Nm / 3.1 in-lb 98003505 Connection Block, NO, 24VDC 0.8 Nm / 7.1 in-lb 98003520 Connection Block, NC, 24VDC 0.8 Nm / 7.1 in-lb Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 29...
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Page 30: Troubleshooting
An SSR has failed in the open mode: Shut system off Solid State Relay (SSR) may have immediately and replace the failed SSR. SSR’s should be “frozen” open replaced in pairs. PAGE 30 Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL... -
Page 31: Warranty
10 WARRANTY See the Trebor Standard Limited Warranty at http://www.treborintl.com/TechnicalSupport.aspx Q-SERIES DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 31...
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