Trebor Q-SERIES, Operation & Maintenance Manual

Page 1: ...U S 6479094B2 U S 6544583B2 4 21 10 MQ B U S 6580061B2 U S 6663914 U S 6674053B2 ADDITIONAL PATENTS PENDING 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 ...

Page 2: ...TEM POWER 14 4 3 HEATING WATER 14 5 HEATER OPERATION 15 5 1 BACKGROUND COLOR CONVENTIONS FOR BUILT IN GRAPHICAL USER INTERFACE 15 5 2 LOCAL OPERATION THROUGH BUILT IN GRAPHICAL USER INTERFACE 15 5 2 a Home Page 16 5 2 b Alarm page 16 5 2 c Configuration Page 18 5 2 d Plot Page 19 5 3 REMOTE OPERATION OVER AN EXTERNAL HARDWARE INTERFACE 20 5 3 a Remote Communication via Modbus RTU 20 6 PROCESS INTE...

Page 3: ...ve heating control system The heater modules have smooth surfaces with minimal cracks and crevices reducing particle traps Furthermore no elastomeric O rings are used for sealing and the DI water is exposed only semiconductor grade quartz and high purity polymers Trebor s patented heating module technology is constructed to provide excellent process control by minimizing hold up volume and thermal...

Page 4: ...380P10 AB X QA1V415P10 AB X QA1V480P10 AD X QA1V480P12 AB X 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 See SJ T 11363 2006 for definition of homogeneous materials X This substance is present at a concentration above the limit in SJ T 11363 2006 in...

Page 5: ...in operation Operators set up operators helpers or installation personnel should not alter remove or disable safety equipment When using this equipment be sure to follow the safety procedures outlined by your facility These safety procedures should cover the two primary types of hazard training 1 equipment hazards and 2 facility related hazards 2 1 SAFETY MESSAGE CONVENTIONS Safety messages contai...

Page 6: ...he EMERGENCY OFF button EMO is located on the front of the heater When the EMO circuit is activated by pushing the button in the equipment will be placed into a safe shutdown condition The EMO will de energize the heaters and process interlock devices Other devices on the electrical panel remain energized and hazardous voltages will be present at the power supply and power supply fuses sub panel c...

Page 7: ...g and a means of attachment which can be securely fastened to an energy isolating device in accordance with established company procedure ensures that the energy isolated device and the equipment being controlled may not be re energized or operated until the tagout device is removed This table lists the Lockout Tagout information for the system Energy Type Electrical Hazard Electrocution electrica...

Page 8: ... button The machine should start 2 3 e Machine Lockout with access panels removed 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 Locate the main incoming power disconnect switch actuating handle 4 Rotate the rotary disc...

Page 9: ...he ON of 1 up position 5 Press the machine start button The machine should start Figure 2 2 Lockout Key Location on Main Breaker 2 4 SEISMIC PROTECTION It is the user s responsibility to adequately secure and anchor the equipment to comply with local regulatory agency seismic requirements Mounting holes for anchors are provided at the bottom of the cabinet enclosure See Facility Layout in Appendix...

Page 10: ...utility hook ups associated with the DI water heater are easily accessible and are referenced in the Appendix After positioning heater at operating location adjust the four leveling feet until the heater is level and stable Connect the cold DI supply line to the Cold DI Inlet connection Connect the hot DI process lines to the Hot DI Outlet connection Use only hot DI compatible plumbing components ...

Page 11: ...d It is the responsibility of the facility installation personnel to eliminate or minimize any and all trip hazards or identify such hazards with visual warning signs Lockout and Tagout facility power connection switch or equivalent before connecting power lines to heater main breaker To access the electrical cabinet rotate the electrical disconnect handle to the OFF position and then remove the s...

Page 12: ...inet to any facility ground Remove Facility power Lockout Tagout Restore Facility power supply to the heater 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 13: ... normal operating temperatures resulting in damage of electrical components Tighten terminal in a clockwise direction only Do not loosen terminals before tightening as this may affect the contact area 4 1 c Electrical Inspection Refer to system schematic Visually inspect all electrical components for anything that seems unusual such as damaged wire insulation disconnected wires etc 4 1 d Plumbing ...

Page 14: ...e EMERGENCY OFF button is in the operate position 4 3 HEATING WATER Ensure minimum water pressure is provided at cold DI inlet and then press the blue RESET button located on the front of the heater near the 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 o...

Page 15: ...ing background colors to provide visual indication of the heater s Green OK status All process interlocks are cleared and the heater is ready to heat water Red Fault status A fault condition is present see sections 5 2 b and 6 The heater cannot heat water until the fault condition is cleared Orange Emergency Off status EMO The EMO button on the heater has been engaged Yellow or Light Green Reset s...

Page 16: ...f water Buttons F1 and F2 will either increase or decrease the Temperature Set Point value in 1 C increments Button F3 enables or disables the heating of water The following navigation buttons are also available for advancing to the Configuration and Alarm pages Button F4 switches the display to the Configuration page Button F5 switches the display to the Alarm page F1 F2 F3 F4 F5 Figure 5 1 Home ...

Page 17: ... and system shutdown due to instantaneous fluctuations in fluid pressure and liquid level During this period the heater is put in a safe state while waiting for the fault condition to clear and the alarm will be reported in the Alarm Delay state If fault condition is corrected before the timeout period elapses the heater will go back to normal operation without alarming If the fault condition is n...

Page 18: ...oint cannot be adjusted nor can the heating of water be enabled or disabled locally through the display panel as described in section 5 2 a Button F2 enables the optimal preset PID configuration for High flow or Low flow conditions Refer to Table 5 1 when deciding to select the Low flow or High flow configuration during critical process steps High Flow PID Settings Low Flow PID Settings Mod Power ...

Page 19: ...lationship to the set point value SP with dashes during 2 minutes of time in 5 second intervals The plot time starts when the page is entered and will only continue while the plot page is selected Whenever the plot page is exited and returned the plot will again start plotting The plot page will not continue to plot when not on the plot page Why That is how the plot works in the display unit The o...

Page 20: ... of alarms can be monitored remotely over an external hardware interface however the temperature set point cannot be adjusted nor can the heating of water be enabled or disabled locally through the display panel as described in section 5 2 a 5 3 a Remote Communication via Modbus RTU The default remote operation communication protocol is Modbus RTU over an RS232 hardware interface See Table 5 2 for...

Page 21: ...s Temperature 400778 Reg Short 2 R 0 120 C Remote heater Power 003112 Coil Bool 1 RW 0 1 Remote Mode 003113 Coil Bool 1 R 0 1 Remote Set Point 400786 Reg Short 2 RW 10 95 C Table 5 2 Modbus Address Mapping For example To enable the heating of water a write request must be sent to the address for the Remote Heater Power coil with a value of 1 To disable the heating of water a write request must be ...

Page 22: ...ain period of time before putting the system into an alarm state This delay is intended to eliminate alarm activation and system shutdown due to instantaneous fluctuations in fluid pressure During the delay period the heater is put in a safe state while waiting for the fluid pressure to increase above 103 kPa 15 psig If the fluid pressure increases above 103 kPa 15 psig before the delay period ela...

Page 23: ...eck element continuity before continuing normal operation see section 8 1 a NOTE Running the heater at the maximum temperature set point and at a flow rate that requires 100 power for extended periods can lead to intermittent over temperature alarms Reducing flow or temperature set point slightly will correct the problem 6 4 LIQUID LEAK SENSOR If a liquid leak is detected in the bottom of the heat...

Page 24: ...may be shut down by the following methods Select the OFF button on the display panel to put the heater in standby 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 25: ... between the two screw terminals on the left of the breaker for each pair of element circuit breakers If no continuity exists replace the suspect heater modules see Section 8 1 b Heater Replacement If there is continuity then the heater element is OK Refer to the Troubleshooting Section of this manual for other possible causes 8 1 b Heater Replacement The heater modules have been designed for quic...

Page 26: ...ater to disengage top fitting from manifold Use an absorbent cloth to remove any liquid from the leak sensor probe and leak containment well Install replacement heater module into cabinet in reverse order from above Note Carefully align the fluid fittings because they can easily be cross threaded Figure 8 1 Process T C Heater Band Clamps ...

Page 27: ...nclosure the heater may be drained into the leak tray Loosen a fitting in the upper manifold to release internal vacuum in fluid lines The system will drain through the cold DI inlet a small amount of water will drain through fluid exit port Perform required maintenance Reconnect fluid inlet and outlet to process lines and refill the system 8 1 e Leaks When a leak has been detected it is recommend...

Page 28: ...note orientation of fitting Refill system Inspect for leaks Figure 8 2 8 2 PREVENTIVE MAINTENANCE SCHEDULE Initial Start Weekly 6 Months Items Visually Inspect Tighten X X Process Control Heater Element Status X X X Plumbing Leaks X X X Overpressure Relief Drain Diaphragm X X X General Electronics X X X Solid State Relays SSR s X X X Main Circuit Breaker X X X Distribution Breakers Contactors X X ...

Page 29: ...k Main Circuit Breaker The main circuit breaker should be checked for signs of loose connections at the termination lugs Damaged lugs should be replaced The terminals should be checked for tightness Distribution Breakers Contactors The distribution breakers and contactors should be checked for signs of loose connections at termination lugs Damaged lugs should be replaced The terminals should be ch...

Page 30: ...or leak Visually inspect leak tray Thermocouple damaged Check thermocouple leads at temperature limit controller for continuity Over temperature alarm Check if heater element has failed and replace module see section 8 1 Check thermocouple leads at temperature limit controller for continuity Verify fan operation Unable to maintain set point Cause Solution Failed heater element Circuit breaker trip...

Page 31: ...Q SERIES DI HEATER OPERATION MAINTENANCE MANUAL PAGE 31 10 WARRANTY See the Trebor Standard Limited Warranty at http www treborintl com TechnicalSupport aspx ...