Table of Contents
Related Manuals for Process Technology Lufran LUF Series
Summary of Contents for Process Technology Lufran LUF Series
- Page 1 LUF-Series Lufran Fluoropolymer Inline Water Heater Optional features shown. Photo may vary from actual product www.processtechnology.com 38809 Mentor Ave., Willoughby, Ohio 44094 Phone: 440-974-1300 Fax: 440-974-9561 USA/CN: 800-621-1998...
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Page 2: Table Of Contents
TABLE OF CONTENTS: RELATED DOCUMENTS ....................2 INTRODUCTION ......................2 ENGINEERING INFORMATION ..................4 ..........................6 YSTEM PECIFICATIONS ............................7 ODEL UMBER ........................... 11 ACILITY EQUIREMENTS ..........................11 PACE EQUIREMENTS ......................12 ATER LUMBING EQUIREMENTS ........................12 LECTRICAL EQUIREMENTS ........................12 URGE EQUIREMENTS ........................ -
Page 3: Related Documents
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. - Page 4 Introduction (Continued): The following symbols and warning labels appear on the unit and in the instruction manual. The table below provides an explanation of each one. PICTORAL DESCRIPTION DESCRIPTION DESCRIPTION DANGER indique situation DANGER indicates imminently dangereuse imminente qui menera à hazardous situation which,...
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Page 5: Engineering Information
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 M-43-25 LUF-Series Lufran Manual... - Page 6 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. Heater Power (Kilowatts) Flow Rate L/min...
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Page 7: System Specifications
Engineering Information (Continued): System Specifications: Product LUF-series, Lufran fluoropolymer inline water heater 24kW – 312kW 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 details) Cabinet dimensions and Width... -
Page 8: Model Number
2006. 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 33 (page 41) to see the location of this label. - Page 9 Figure 2: Model/Serial Number Label Engineering Information (Continued): Model Number (Continued): Provided below is an example of a typical model number along with an explanation of each part. This key will help you understand your model number. Model number example: LUF-130-3LL6-SK ...
- Page 10 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. Heater Model Device Water Flow Process Technology Number Brand Range Part Number Thornton...
- Page 11 Technology technical service department for assistance. CE certification Cabinet leak detector Customer-defined remote interface option. Contact the Process Technology technical service department for assistance. Stack light Customer specific design/construction (Which may or may not include some of the above options)
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Page 12: Facility Requirements
Engineering Information (Continued): 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 13: Water Plumbing Requirements
Engineering Information (Continued): 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. -
Page 14: Optional Communications
Engineering Information (Continued): Optional Communications: -C1 Option: Ethernet: –C1 communications option adds Ethernet communications controller. The network can interface with Lufran heater through RJ45 connector included with the unit. The Lufran heater is provided with the following default IP Address: 128.1.105.100. Ethernet RJ45 or The Ethernet card has a default module ID DeviceNet mini male... - Page 15 Engineering Information (Continued): Optional Communications (Continued): The following table describes the network addresses of the Lufran water heater. Network Data Signal Description Address type Inlet water Heater V3200 temperature The value provided is the measured inlet water temperature. output (°C) Outlet water The value provided is the measured outlet water temperature.
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Page 16: Operator Interface
Engineering Information (Continued): Operator Interface: 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 6: Operator Interface Buttons Power On Button: When depressed, this button enables the main power safety contactor (1CON) and readies the system for operation. -
Page 17: Main Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): Main Menu: Figure 8: Main Menu Main Menu Information Description Panel TREND GRAPH This button will go directly to the TREND GRAPH screen. Displays the process setpoint. The value appears when the unit is in LOCAL control mode. - Page 18 Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): Main Menu (Continued): Main Menu Information Description Panel Displays the temperature measured from the process sensor located OUTLET TEMPERATURE at the outlet of the heater. Displays the output load of the heating elements needed to provide HEATER OUTPUT the desired outlet temperature.
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Page 19: Alarms Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (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 be indicated by a blinking red light. -
Page 20: Trend Graph
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): Trend Graph: 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. Figure 10: Trend Graph Trend Graph Information Description Panel... -
Page 21: Alarm Summary
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): Alarm Summary: The ALARM SUMMARY will appear when the ALM. LOG button on the MAIN MENU is pressed. The alarm summary lists each alarm event detected and the time at which it occurred. Figure 11: Fault Log and Detail Display Alarm Summary Description... -
Page 22: Adam Setup Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): ADAM Setup Menu: This menu displays the various settings for the universal analog input module. This module provides the various analog input signals to the PLC. These values identify the input types for the various channels. All settings listed here are set at the factory and should not be changed. -
Page 23: Slc Setup Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): Safety Limit Controller (SLC) Setup Menu: This menu displays the various settings for the safety limit controller modules #1 through #8. SLC1, SLC3, SLC5 and SLC7 modules monitor the heating element sensors in heating columns 1 through 4, respectively. -
Page 24: Secure Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): 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 14: Configuration Menu (2 Screens) Configuration Menu Description Information Panel... -
Page 25: Secure Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): 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. -
Page 26: Tc1 Setup Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): TC1 Setup Menu: This menu displays the various settings for the temperature control module. This module controls the switching of the solid state relays. Figure 15: TC1 Setup Menu TC1 Setup Information Description Panel This field identifies the sensor input type. -
Page 27: Heater Calibration Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): Heater Calibration Menu: The heater calibration menu is accessed through the secure menu only. Refer to the engineering information section of this manual for the heater calibration procedure. Figure 16: Heater Calibration Menu SLC Setup Information Description Panel... -
Page 28: Flow Calibration Menu
Engineering Information (Continued): Operator Interface Panel (OIP) (Continued): Flow Calibration Menu: The flow calibration menu is accessed through the secure menu only. Refer to the engineering information section of this manual for the flow meter calibration procedure. Figure 17: Flow Calibration Menu SLC Setup Information Description Panel... -
Page 29: Heater Calibration Procedure
Engineering Information (Continued): 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. -
Page 30: Flow Meter Calibration Procedure
Engineering Information (Continued): 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 19: Flow Calibration Menu 1) Turn off heater operation by pressing the HEAT ON/OFF button on the MAIN MENU. Access the FLOW CALIBRATION display. -
Page 31: Alarms
Engineering Information (Continued): Alarms: The following section describes each of the alarm conditions that may occur on the LUF-series Lufran fluoropolymer inline water heater. Alarms Alarm History Menu Description Menu A ground fault has occurred somewhere in the unit. This may Ground Fault Ground Fault be caused by a failed component. - Page 32 Engineering Information (Continued): Alarms (Continued): Alarms Alarm History Menu Description Menu The thermostat on one of the head 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...
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Page 33: Installation
7) Using a fork truck or other suitable lifting device, lift the unit from underneath and remove from the crate. 8) Visually inspect the unit itself for damage. If there is evidence of damage, notify Process Technology and the freight carrier immediately. -
Page 34: Positioning The Unit
Installation (Continued): 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 35: Plumbing
Installation (Continued): 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. - Page 36 Installation (Continued): Plumbing (Continued): The various plumbing connections are located as follows: Figure 24: 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. Column Drain: The customer must supply the means to drain the heating columns, which will be necessary in the case of replacing a heating column or some other items.
- Page 37 Installation (Continued): 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.
- Page 38 Installation (Continued): 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.
- Page 39 Installation (Continued): 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.
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Page 40: Wiring
Installation (Continued): 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. - Page 41 Installation (Continued): 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 Torque OFF position to the RESET position and pull Specifications...
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Page 42: Operation
Operation: The LUF-series 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 unit remotely,... -
Page 43: Shutdown
Operation (Continued): 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. -
Page 44: Maintenance
Maintenance: The LUF-series Lufran fluoropolymer inline water heater requires only a routine inspection every 6 months to check the operation of the various operation and safety devices. The 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 45 Maintenance Procedures (Continued): 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 3. These are capacitive sensors that must be inspected for proper adjustment every 6 months.
- Page 46 Maintenance Procedures (Continued): 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.
- Page 47 Maintenance Procedures (Continued): 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.
- Page 48 Maintenance Procedures (Continued): 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.
- Page 49 Maintenance Procedures (Continued): 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.
- Page 50 Maintenance Procedures (Continued): 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. This will also prevent the heaters from energizing.
- Page 51 12 hours before startup is attempted. • Failed heating column: A hole in the heating element or a leaking purge gas fitting will allow water into the exhaust tube. Contact PROCESS TECHNOLOGY for possible replacement heating column. Inspect the adjustment of the humidistat: 6) Using a screwdriver remove the four cover screws and remove the cover from each humidistat device.
- Page 52 Maintenance Procedures (Continued): 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.
- Page 53 Maintenance Procedures (Continued): 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.
- Page 54 Maintenance Procedures (Continued): 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.
- Page 55 Maintenance Procedures (Continued): 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.
- Page 56 Maintenance Procedures (Continued): 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.
- Page 57 Maintenance Procedures (Continued): 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.
- Page 58 Maintenance Procedures (Continued): 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.
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Page 59: Spare Parts
This is not the complete parts list, so there are some heater components that are not listed below. Please contact PROCESS TECHNOLOGY if a more complete parts list is needed. -
Page 60: Cleaning
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 61: Warranty
At its option, PROCESS TECHNOLOGY will repair or replace any defects that are exhibited under proper and normal use. -
Page 62: Appendix
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. Low Flow Bypass Calibration Startup Procedure: This calibration procedure should be performed before the first time the unit is operated during a Low Flow Bypass, and whenever the flow rate during this bypass or the process set point changes.
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