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Process Technology LUFRAN Instruction

Fluoropolymer inline water heater
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TM
LUFRAN
Fluoropolymer Inline Water Heater
www.processtechnology.com
7010 Lindsay Dr., Mentor, OH 44060 Phone: 440-974-1300 Fax: 440-974-9561 USA/CN: 800-621-1998

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  • Page 1 LUFRAN Fluoropolymer Inline Water Heater www.processtechnology.com 7010 Lindsay Dr., Mentor, OH 44060 Phone: 440-974-1300 Fax: 440-974-9561 USA/CN: 800-621-1998...

  • Page 2: Table Of Contents

    SHUTDOWN ....................53   ...................... 54 RAINING   ALARM CONDITIONS ................55   REMOTE INTERFACE ................58   REMOTE TOUCH-SCREEN INTERFACE (-ROI OPTION) ....... 61   M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 2 -...
  • Page 3   MAINTENANCE ..................67   SPARE PARTS..................97   CLEANING ....................99   TROUBLESHOOTING ................100   WARRANTY .................... 103   APPENDIX I ....................1   M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 3 -...

  • Page 4: Introduction

    The cleanliness report is available upon request. The Lufran fluoropolymer inline water heaters are available in wattages from 24kW to 288kW. These units consist of one or more heating columns combined with a control system and all necessary power distribution circuitry in a freestanding enclosure.
  • Page 5 51.4 Figure 2: Maximum Temperature Rise Table The Lufran fluoropolymer inline water heaters include a comprehensive system of safety controls and devices to insure safe and long-lasting operation. The list of safety devices includes but is not limited to the following: ...
  • Page 6 CAUTION: HOT SURFACE. DO NOT TOUCH Heater column may be hot. Allow unit to cool before servicing. EIP: Electronic Information Product Pollution Control Logo. PROTECTIVE EARTH (GROUND) M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 6 -...
  • Page 7 INTRODUCTION (Continued): 24 kW – 144 kW Units 157 kW – 288 kW Units Figure 3: Warning Label Locations M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 7 -...

  • Page 8: System Specifications

    SYSTEM SPECIFICATIONS: Product Lufran fluoropolymer inline water heater Standards CE, ETL, Semi S2/S3 24kW – 288kW Available Wattages Refer to model number label for the wattage of any specific unit 380V – 600V, 50/60Hz, 3 phase only Available Voltages (Lower voltages available with special construction, consult factory for...
  • Page 9 Chinese RoHS Compliance Table M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 9 -...

  • Page 10: Model Number

    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 17 (page 31) to see the location of this label.
  • Page 11 65,000 36,000 36,000 144,000 72,000 52,500 52,500 157,500 52,500 65,000 65,000 195,000 65,000 72,000 72,000 210,000 52,500 72,000 36,000 260,000 65,000 208V) 105,000 52,500 288,000 72,000 M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 11 -...
  • Page 12 Pillar Tube Fitting 13mm (1/2-inch) Pillar Tube Fitting 19mm (3/4-inch) Pillar Tube Fitting 25mm (1-inch) Socket Fusion Union (Standard) 25mm (1-inch) Super 300 Pillar 25mm (1-inch) M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 12 -...
  • Page 13 Some of these options are described in greater detail in the OPERATION section of this manual. More than one option may be included in an individual Lufran heater. Please refer to the table below for a brief listing of the available options.

  • Page 14: 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.

  • Page 15: Water Plumbing Requirements

    A source of purge gas, nitrogen (N ) or clean dry air (CDA) is required for the heater element purge system. All Lufran fluoropolymer inline water heaters use 6.4-mm (0.25- inch) compression fittings as the purge gas inlet and outlet connections.

  • Page 16: Installation

    ATTEMPT to move or lift the unit without the appropriate material handling equipment. Inspection and Uncrating: The Lufran fluoropolymer inline water heater is shipped in a horizontal position. The unit must be raised to a vertical orientation before it can be removed from the shipping crate.
  • Page 17 Serious personal injury or equipment damage may result. 8) Visually inspect the unit itself for damage. If there is evidence of damage, notify Process Technology and the freight carrier immediately. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15...
  • Page 18 With the –C2 communications option, a 6 m (20 ft) DeviceNet cable is included to connect the Lufran heater to a DeviceNet network. The cable has the connector plug for the heater on one end and loose lead wires at the other end. Please refer to the electrical prints for your heater (provided with this instruction manual) for an explanation of the wire numbers and functions.

  • Page 19: Positioning The Unit

    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.
  • Page 20 The customer can decide whether to install the bottom half of the brackets to face inward or outward, as shown below. Bottom facing outward Bottom facing inward Figure 9: Seismic Bracket Assembled, two possible orientations M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 20 -...

  • Page 21: Plumbing

    3) Before the outlet service shutoff valve, install a tee fitting to the outlet side of the heater. The tee portion of the fitting should be closed. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 21 -...
  • Page 22 Failure to properly secure the plastic piping when tightening the plumbing connections may result in internal damage to the plumbing of this unit. Such damage is not covered under our product warranty. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 22 -...
  • Page 23 25mm union half (nut) of the fitting. 7) Attach the male and female union halves to create the inlet connection and tighten the union halves securely, until the connections are fully tightened. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 23 -...
  • Page 24 25mm (1-inch) flared 3.39 N-m (30in-lbs). 5.1 N-m (45 in-lbs). Do NOT tighten fitting nuts at elevated temperatures. Irreparable damage to the plumbing connections will result. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 24 -...
  • Page 25 Continue tightening the union nut until the bosses make full contact with the gauge ring. Figure 13: Super 300 type Pillar fittings tightening procedure M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 25 -...
  • Page 26 4) Insert the tubing into the compression fitting. Tighten securely. NOTE: There is no exhaust connection for the purge gas. The purge gas is exhausted inside the cabinet and released into the air. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 26 -...

  • Page 27: Wiring

    The power wires and ground wire must be connected to the main circuit breaker, per the electrical prints, which are provided with this manual. Figure 14: Electrical Access Panel M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 27 -...
  • Page 28 2) Push the disconnect switch down, past the OFF position to the RESET position. 3) Hold the switch in the RESET position and open the two doors. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 28 -...
  • Page 29 CIRCUIT BREAKER (1CB) DISTRIBUTION BLOCK (1PD) PRIMARY: SECONDARY: SECONDARY: POWER FUSES (7FU-9FU) SAFETY CONTACTOR (1CON) SOLID STATE RELAYS (1SSR-2SSR) INPUT: OUTPUT: Figure 16: Torque Specifications Table M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 29 -...

  • Page 30: Operation

    OPERATION: The Lufran fluoropolymer inline water heater can be operated from the front of the unit, remotely through the interface cable provided with the unit, or through an optional remote operator interface panel (ROI). This section deals with controlling the heater locally from the front of the unit.
  • Page 31 Power Off Button: When depressed this button disables heater operation by disengaging the main power safety contactor. It illuminates to indicate the main power is off. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 31 -...

  • Page 32: Touchscreen Display

    The rectangular fields with dark borders that are located in the navigation area (at the bottom of the screen) are used to navigate between different screens and menus. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 32 -...
  • Page 33 The run-time application can be terminated in the SYSTEM SERVICE menu by selecting the SHUTDOWN APPLICATION pushbutton.  Menu Name. The name of the current menu is always provided at the very top of the display. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 33 -...
  • Page 34 This section of the display is explained for each of the menu screens in the following pages of this section. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 34 -...

  • Page 35: Touchscreen Menu Overview

    SYSTEM SETUP SYSTEM OPERATIONS ACCESS SERVICE ALARM CONTROL HEATER ALARM ACCESS GRAPH HISTORY (LOCKED) SYSTEM HEATER REMOTE S P DATALOG FACTORY PARAMETERS CALIBRATION CALIBRATION PARAMETERS DEFAULTS M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 35 -...

  • Page 36: Operations Menu

    Operations Menu: The operations menu provides current performance statistics of the Lufran fluoropolymer inline water heater. It is the default menu that appears following the startup screen. The navigation keys at the bottom of the screen provide access to the other menus available.

  • Page 37: System Setup Menu

    This button will forward the operator to the FACTORY DEFAULTS FACTORY DEFAULTS menu. REMOTE S. P. This button will forward the operator to the REMOTE SET POINT (S. P.) menu. CALIBRATION M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 37 -...

  • Page 38: System Parameters Menu

    M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 38 -...
  • Page 39 The default value will provide the quickest rate of temperature rise with no temperature overshoot above the process setpoint. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 39 -...

  • Page 40: Heater Calibration Menu

    100(%). If, during initial startup, the heater is having difficulty in reaching the process setpoint, this value may be adjusted (in 1% increments) up or down in order to improve the precision of the unit. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 40 -...

  • Page 41: Remote S. P. Calibration Menu

    ENTER THE 20mA This button allows adjustment to the highest setpoint value provided VALUE IN DEGREES C remotely by the customer control. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 41 -...

  • Page 42: Datalog Menu

    This button in the command panel will enable the datalog feature of ENABLE DATALOG the controller. Once enabled, this function button will change to DISABLE DATALOG. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 42 -...

  • Page 43: Factory Default Menu

    This button will reset all controller settings to the factory default RESET TO DEFAULT settings listed in the information panel. CANCEL This button will return the display to the SYSTEM SETUP menu. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 43 -...

  • Page 44: System Service Menu

    Depress the APPLY button to shut down the DAC control system. This button will appear if the SHUTDOWN APPLICATION button is CANCEL depressed. Depress the CANCEL button return to the SYSTEM SERVICE menu. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 44 -...

  • Page 45: Control Access Menu

    (◄┘) key on the LOGIN display to enter the login code, which will then change the control mode. CANCEL This button will return the display to the CONTROL ACCESS menu. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 45 -...
  • Page 46 DNET DeviceNet cable connection only. The DeviceNet network can access and change settings remotely. MODBUS MODE. This selection will only appear if the Lufran heater includes the C5 MBUS communications option. This control mode allows heater control through the Modbus cable connection only.
  • Page 47 The system can be locked while in any of the operating modes. Changing control modes will automatically unlock the control system. ULOCK This control mode will disable the lock function. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 47 -...

  • Page 48: Alarms Menu

    Alarms Menu: This menu provides a display status of all alarm conditions in the Lufran fluoropolymer inline water heater. When one of the alarms trip, the Alarms menu will automatically appear. The alarm setting(s) that has tripped will flash. Note: To silence the audible alarm during an alarm event, press the POWER OFF button on the front of the unit.

  • Page 49: Alarm History Menu

    This button will clear all of the entries in this menu. These two buttons will allow the operator to scroll up and down through the ▲ ▼ alarm history. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 49 -...

  • Page 50: Startup Procedure

    Note: Steps 8 and 10 can also be accomplished through the remote control interface or on the ROI. Refer to the REMOTE INTERFACE section of this manual for more information. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 50 -...
  • Page 51 14) Allow enough time for the heater to ramp up to the process setpoint and to stabilize. Depending upon the flow rate and the wattage of the unit, this may take several minutes. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 51 -...
  • Page 52  Boost deadband  Error compensation Failure to turn the HEATER CALIBRATION setting off will result in poor temperature control and may result in over-temperature conditions. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 52 -...

  • Page 53: Shutdown

    Failure to maintain the purge will result in shortened heating element life. Note: For extended shut down periods, drain the heating columns and dry the columns internally with nitrogen or another inert gas. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 53 -...

  • Page 54: Draining The Unit

    9) When the unit is finished draining, shut off the optional pressurized gas and close the fitting on the TEE fitting. 10) Shut off the purge gas supply. Apply lockout/tagout devices as necessary. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 54 -...

  • Page 55: Alarm Conditions

    Alarm Conditions: 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 by a failed component. The cause of the...
  • Page 56 (1 thru 4) – Htr 1 thru Htr 4 The operator does not have access to view or adjust this setting. Contact PROCESS TECHNOLOGY for further details. When the element temperature falls below this setting the unit can be reset.
  • Page 57 Refer to the SHUTDOWN section on page 53 of this manual for the appropriate procedure. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 57 -...

  • Page 58: Remote Interface

    REMOTE INTERFACE: The remote interface is used for communication between the Lufran fluoropolymer inline water heater and a customer-supplied control device. The remote interface will allow remote operation of heater start/stop, adjustment of the process setpoint and remote monitoring of the alarm system.
  • Page 59 EMO Output, System condition. Enabled Dry contacts Open contacts indicate the EMO has been tripped or the unit has been shut down. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 59 -...
  • Page 60 Fault Dry Contacts The unit can not be reset remotely. Closed contacts indicate all of the safety devices are in normal operating mode. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 60 -...

  • Page 61: Remote Touch-Screen Interface (-Roi Option)

    REMOTE TOUCH-SCREEN INTERFACE (-ROI Option): The remote touch-screen interface (ROI) is used for communication between the Lufran fluoropolymer inline water heater and a remote touch-screen device. The remote touch- screen will allow remote operation of heater in the same manner as the touch-screen device mounted within the heater cabinet.
  • Page 62 ROI screen when the heater is not in ROI mode. Figure 37: ROI Screen “OPERATIONS MENU” Figure 38: ROI Screen “ALARMS MENU” LOCAL MODE Figure 39: ROI Screen “ALARMS MENU” ROI MODE M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 62 -...

  • Page 63: Optional Communications

    OPTIONAL COMMUNICATIONS: Ethernet (-C1 option): The –C1 communications option adds Ethernet communications to the PLC controller. The network can interface with the Lufran heater through the RJ45 connector included with the unit. ETHERNET CONNECTOR PLUG (RJ45) REMOTE INTERFACE CONNECTION Figure 40: Ethernet RJ45 connector plug The Lufran heater is provided with the following default IP Address: 128.1.105.100.

  • Page 64: Device Net Communications (-C2 Option )

    The Lufran heater is provided with the following default node assignment: 63. Once connected to the network, the customer must assign a new node to the Lufran heater. Assigning the node or performing other networking tasks with the Lufran heater will require the use of DNI Utilities software, available from Allen-Bradley.

  • Page 65: Integer Points

    OPTIONAL COMMUNICATIONS (Continued): Integer Points: The following table describes the standard integer points of the Lufran water heater. These integer points are the same for both Ethernet (-C1) and DeviceNet (-C2) communications Integer Data Signal Description Point type Inlet water...
  • Page 66 When the N50:11 point (°C) input system is in REMOTE control mode, this value should be matched by integer point N48:05. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 66 -...

  • Page 67: Maintenance

    MAINTENANCE: The Lufran fluoropolymer inline water heater requires only a routine inspection every 6 months to check the operation of the various operation and safety devices. maintenance procedures listed here should only be performed by qualified technicians. Many of these devices require the control system to remain operational during inspection, while others may be checked while the unit is completely powered down.

  • Page 68: Maintenance Schedule

    Pressure relief valve (PRV), bottom-half plumbing PRV sensor Cabinet cooling fans SSR heat sink cooling fans Circuit breaker Audible alarm Indicator lights Remote Interface Safety Contactor M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 68 -...
  • Page 69 Notice the LED is red when operating properly. The liquid level sensor should be about 3.5mm (0.125-inch) away from the outlet manifold. Figure 42: Liquid Level Sensor M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 69 -...
  • Page 70 4) Repeat the inspection procedure above. If the sensor again fails to trip and/or reset from alarm mode, repeat the calibration procedure or replace the liquid level sensor. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 70 -...
  • Page 71 11) If the sensor passes the inspection, the unit may be restarted and returned to service. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 71 -...
  • Page 72 3) Open the rear cabinet door. Locate the outlet process temperature sensor located in the TEE fitting directly in front of the outlet plumbing connection. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 72 -...
  • Page 73 10) Reconnect the connector plugs for these sensors. Press the FAULT RESET button on the command panel of the touch screen display to clear the fault condition. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 73 -...
  • Page 74 9) Close the drain and allow water to flow through the unit. Check for leaks. If the fitting is not leaking, the unit may be restarted. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 74 -...

  • Page 75: Leak Detector N 1 M3

    The CAB LEAK alarm will flash on the display. 5) Press the FAULT RESET button on the command panel of the touch screen display to clear the fault condition. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 75 -...
  • Page 76 12) Restore power to the unit. 13) Perform procedure M3-1: leak detector inspection procedure. 14) If the sensor passes the inspection, the unit may be restarted and returned to service. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 76 -...

  • Page 77: Purge Gas Flow Switch N 2 M4

    3) Turn off the purge gas supply to the unit. Verify that the purge gas supply is shut off, and any necessary lockout/tagout devices are properly installed. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 77 -...
  • Page 78 16) Perform procedure M4-1: Purge Gas Flow Switch Inspection Procedure. 17) If the purge gas flow switch passes the inspection, the unit may be restarted and returned to service. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 78 -...

  • Page 79: Humidistat Purge Exhaust

    Figure 45: Purge Gas Control 4) Locate the ¼-inch tubing connected between the top of the heating column and the humidistat. The outlet of the purge column is labeled EXHAUST. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 79 -...
  • Page 80 Proceed to the humidistat replacement procedure on the next page. 11) Replace the black plastic enclosure cover of the humidistat. 12) Close the rear cabinet door. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 80 -...
  • Page 81 11) Replace the black plastic enclosure cover on the humidistat. 12) Replace the rear cabinet panel. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 81 -...

  • Page 82: Pressure Relief Valve (Prv), Bottom-Half Plumbing N 1 M6

    6) Inspect the discharge tubing of the PRV. Confirm that there is no liquid in the discharge tube. If the PRV is leaking it must be replaced. 7) Confirm that the weep hole of the PRV is not leaking. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 82 -...
  • Page 83 9) Re-connect the ½-inch discharge tubing to the PRV. 10) Start flow of water to the unit and check for leaks. 11) Close the rear cabinet door. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 83 -...

  • Page 84: Prv Sensor N 1 M7

    7) If the red LED fails to illuminate and the unit fails to enter alarm mode, then the level sensor must be recalibrated. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 84 -...
  • Page 85 4) Repeat the inspection procedure above. If the sensor again fails to trip and/or reset from alarm mode, repeat the calibration procedure or replace the sensor. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 85 -...
  • Page 86 11) Perform procedure M7-2: PRV sensor calibration procedure followed by procedure M7-1: PRV sensor inspection procedure. 12) If the sensor passes the inspection, the unit may be restarted and returned to service. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 86 -...

  • Page 87: Cabinet Cooling Fans N 1 M8

    Figure 47: Cabinet Cooling Fans Procedure M8-1: Cooling Fan Inspection Procedure: Verify that the cooling fans are operating. If a cooling fan has stopped, it must be replaced. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 87 -...
  • Page 88 9) Connect the connector plug for the cooling fan to the multi-port sensor/actuator box. 10) Remove lockout-tagout items. Power up the unit. Confirm that the replacement fan is operating. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 88 -...
  • Page 89 6) Attach the replacement fan and fan guard to the side of the cabinet. 7) Re-connect the cooling fan wires to the terminal blocks. 8) Remove lockout-tagout items. Power up the unit. Confirm that the replacement fan is operating. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 89 -...
  • Page 90 Procedure M9-2: SSR Cooling Fan Replacement Procedure: Refer to the instructions provided with the replacement SSR module for the replacement procedure. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 90 -...

  • Page 91: Circuit Breaker N 2 M10

    5) Press the TEST button on the front of the circuit breaker. When this button is pressed, the entire unit will shut off. 6) Reset the circuit breaker and turn on the unit. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 91 -...

  • Page 92: Audible Alarm N 1 M11

    6) Attach the lead wires to the back of the audible alarm. 7) Close the front door. Once this procedure is complete, the unit may be restarted. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 92 -...

  • Page 93: Indicator Lights N 1 M12

    The light will go out when the button is released. This will not trip an alarm event. 5) If one of the indicator lights fails to illuminate when tested, the light should be replaced. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 93 -...
  • Page 94 5) Twist and remove the green light from the base. 6) Replace the failed lamp color, and reassemble the unit. 7) Once the indicator light assembly is re-assembled, the unit may be restarted. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 94 -...

  • Page 95: Remote Interface N 1 M13

    This will not trip an alarm event. 4) If the remote interface signals fail to toggle, there may be a problem with the PLC or the software. Contact the Process Technology Technical Service Department for further assistance.
  • Page 96 (low ohms). Depress buttons here Figure 51: Safety Contactor 8) If no continuity is detected while the button is depressed, the contactor must be replaced. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 96 -...

  • Page 97: Spare Parts

    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.
  • Page 98 (72kW, 208V) 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.

  • Page 99: Cleaning

    CLEANING: The Lufran fluoropolymer inline water heater was thoroughly cleaned prior to shipment. The inlet/outlet plumbing connections were sealed and the heating columns were charged with nitrogen gas prior to shipment. PROCESS TECHNOLOGY recommends that, at a minimum, the following steps be taken to remove any contamination that may have been added to the system during installation.

  • Page 100: Troubleshooting

    If the The thermocouple is working properly it is possible that the PLC input card may be damaged and need replaced. Consult the factory for the appropriate replacement component. M-43-01 Lufran Single Outlet Manual Revision - Date: 08 – 04/06/15 - 100 -...
  • Page 101 The cause of the liquid level fault must be identified and corrected before the unit can be reset. The sensor can be recalibrated. Please reference the Lufran manual for the proper procedure to calibrate the liquid level sensor. This will be located in the Maintenance section of the manual.
  • Page 102 NOTE: This alarm can not be reset through the PLC. Rather, this alarm must be reset by shutting down cycling the main circuit breaker off and then on powering up the unit. Refer to the SHUTDOWN of the Lufran manual for the procedure.

  • Page 103: Warranty

    At its option, PROCESS TECHNOLOGY will repair or replace any defects that are exhibited under proper and normal use.

  • Page 104: Appendix I

    Appendix I LUFRAN MAINTENANCE CHECKLIST Technician: Date: Heater Model Number: Heater Serial Number: Heater Location: : Liquid Level Sensor, Top Half Plumbing Procedure M1-1: Column #1 Liquid Level Procedure M1-2 : Recalibrated Sensor Procedure M1-3 : Replaced sensor Sensor Inspection ...
  • Page 105 Appendix 1 LUFRAN MAINTENANCE CHECKLIST : SSR Cooling Fans Procedure M9-1: SSR Module #1 Cooling Fan Inspection Procedure M9-2 : Replaced SSR module #1   Pass If fan is not moving ──────────────────────────────────► Done Procedure M9-1: SSR Module #2 Cooling Fan Inspection...

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