Process Technology Tytan Instruction Manual

TM

TYTAN

Inline Water Heater

Instruction Manual

7010 Lindsay Dr., Mentor, OH 44060 Phone: [phone] Fax: [phone] USA/CN: 800-621-1998

www.process-technology.com

TABLE OF CONTENTS:

RELATED DOCUMENTS ...............................................................................................3

INTRODUCTION............................................................................................................. 4

SYSTEM SPECIFICATIONS .......................................................................................... 6

MODEL NUMBER.........................................................................................................10

MODEL NUMBER EXPLANATION.........................................................................................................11

FACILITY REQUIREMENTS ........................................................................................13

WATER PLUMBING REQUIREMENTS..................................................................................................14

ELECTRICAL REQUIREMENTS............................................................................................................14

INSTALLATION............................................................................................................ 15

INSPECTION AND UNCRATING ...........................................................................................................15

POSITIONING AND MOUNTING..................................................................................17

PLUMBING..............................................................................................................................................18

WIRING ...................................................................................................................................................20

RC1, RC2 COMMUNICATIONS (OPTIONAL)........................................................................................22

RC3 COMMUNICATIONS (OPTIONAL).................................................................................................23

RI REMOTE INTERFACE (OPTIONAL) .................................................................................................23

OPERATIONS ..............................................................................................................25

CONTROL PANEL..................................................................................................................................25

TEMPERATURE CONTROLLER E5CN.................................................................................................26

PARAMETER SETTINGS E5CN.........................................................................................................29

CHANGING SET POINT E5CN...........................................................................................................30

HIGH ALARM E5CN............................................................................................................................30

PID TUNING E5CN..............................................................................................................................31

TEMPERATURE CONTROLLER E5CK (RC OPTIONS).......................................................................32

PARAMETER SETTINGS E5CK.........................................................................................................35

CHANGING SET POINT E5CK...........................................................................................................36

HIGH ALARM E5CK............................................................................................................................37

PID TUNING E5CK..............................................................................................................................38

OVER TEMPERATURE CONTROLLER: FDC-L91................................................................................39

SYSTEM START UP...............................................................................................................................42

SYSTEM SHUT DOWN...........................................................................................................................42

MAINTENANCE............................................................................................................ 43

WARRANTY .................................................................................................................44

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

2

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.

OMRON E5CN INSTRUCTION MANUAL – To be used to access features of the E5CN
temperature controller. (Secure appropriate manual for any optional temperature
controller used in place of the E5CN).

OMRON E5CK INSTRUCTION MANUAL (for units with RC1, RC2 or RC3 option) –

To be used to access features of the E5CK temperature controller.
ANY – State or local building codes that would cover the electrical, mechanical, or

physical installation of electrical heating equipment.

National Electric Code
NFPA 1999 Copyright
National Fire Protection Association
Quincy, Mass. 02269

→

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

3

INTRODUCTION:

The following symbols and warning labels appear on the unit and in the instruction
manual. The table below provides an explanation of each one.

DESCRIPTION

DANGER indicates an imminently hazardous

situation which, if not avoided, will result in
death or serious injury. This signal word is to
be limited to the most extreme situations.

WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.

CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used
to alert against unsafe practices.

DANGER: HAZARDOUS VOLTAGE
ENCLOSED
Voltage or current hazard sufficient to cause
shock, burn or death. Disconnect and lock
out power before servicing.

WARNING: HAZARDOUS VOLTAGE
Contact may cause electric shock or burn.
This unit to be serviced by trained personnel
only.

PICTORAL DESCRIPTION

CAUTION: HOT SURFACE. DO NOT

TOUCH
Heater column may be hot. Allow unit to cool
before servicing.

PROTECTIVE EARTH (GROUND)

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

Table 1: TYTAN Warning Labels

4

INTRODUCTION (Continued):

The TYTAN water heater is designed for inline heating of de-ionized (DI) water, city
water, reverse-osmosis (RO) water, and filtered seawater. It can perform both as a
recirculating heater or a single-pass heater.

TEMPERATURE PERFORMANCE: The TYTAN water heater is designed to provide a
specified temperature increase at a given flow rate. Table 2 shows the maximum
temperature increase (∆T) that can be achieved for continuous flow conditions at the
specific heater power ratings varying from 24 kW to 144 kW (Higher wattage systems
available upon request). The temperature control system provided with the heater will
modulate the power to the heating columns in order to maintain your specific outlet
temperature setting.

Flow Rate 12 18 24 36 48 72 96 120 144

GPM Maximum Theoretical Temperature Rise (°F)

1 80.8 121.2 - - - - - - ­2 40.4 60.6 80.8 121.2 - - - - ­4 20.2 30.3 40.4 60.6 80.8 121.1 - - ­6 13.5 20.2 26.9 40.4 53.8 80.8 107.7 134.6 -

8 10.1 15.1 20.2 30.3 40.4 60.6 80.8 101.0 121.2
10 8.0 12.1 16.1 24.2 32.3 48.4 64.6 80.8 96.9
12 6.7 10.1 13.4 20.2 26.9 40.4 53.8 67.3 80.8
14 5.7 8.6 11.5 17.3 23.0 34.6 46.1 57.7 69.2
16 5.0 7.5 10.1 15.1 20.2 30.3 40.4 50.5 60.6
18 4.5 6.7 8.9 13.4 17.9 26.9 35.9 44.8 53.8
20 4.0 6.0 8.0 12.1 16.1 24.2 32.3 40.4 48.4
22 3.6 5.5 7.3 11.0 14.6 22.0 29.3 36.7 44.0
24 3.3 5.0 6.7 10.1 13.4 20.2 26.9 33.6 40.4

Heater Power (Kilowatts)

Table 2: Maximum Temperature Rise

SAFETY DEVICES: The TYTAN water heaters include a comprehensive system of
safety controls and devices to insure safe and long-lasting operation. The list of
safeties is included in Table 3: system specifications provided on the following page.

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

5

SYSTEM SPECIFICATIONS:

Product TYTAN inline titanium water heater

Standards UL, cUL standard
CE, SEMI S3 optional (-SC)

Available Wattage Range

Available Voltages

Cabinet dimensions: Width Depth Height Weight

12kW – 48kW 28.5-in (75 cm) 13.5-in (34 cm) 36-in (91 cm) 145 lbs. (66 kg)

72kW 37.5-in (95 cm) 13.5-in (34 cm) 36-in (91 cm) 230 lbs. (104 kg)

96kW – 144kW 28-in (71 cm) 17-in (43 cm) 63-in (160 cm) 300 lbs. (136 kg)

Wetted surfaces:

Heating elements CP2 titanium standard, (316SS optional [-S option])

Columns and plumbing CP2 titanium standard, (316SS optional [-S option])

PRV Valve PVDF

Operating temperatures:

Process inlet

Process outlet Up to 194°F (90°C), depending upon operating conditions

Temperature accuracy +/- 1°F, depending upon operating conditions

Ambient air temperature 86°F (30°C) maximum

Water pressure range
Minimum water flow rate:

12kW - 24kW 0.5 gpm (2 lpm)

36kW – 48kW 1.0 gpm (4 lpm)

72 kW 1.5 gpm (6 lpm)

96kW 2.0 gpm (8 lpm)
120kW 2.5 gpm (10 lpm)
144kW 3.0 gpm (12 lpm)

Standard Safety Devices: EMO Pushbutton

12kW – 144kW
Refer to model number label for the wattage of any specific unit
208V – 600V, 50/60Hz, 3 phase standard
(Some voltages available in single phase or with special construction,
consult factory for details)

Minimum 10 psi (69 kPa, 0.69 bar)
Maximum 100 psi (690 kPa, 6.9 bar)

Pressure Relief Valve (PRV), connected to inlet manifold
Electrically grounded heating chamber construction
Ground Fault Protection (GFP)
Safety Limit Control (SLC)
Bimetallic heater over temperature sensor(s)
Heater outlet overtemperature alarm
Solid state relay (SSR) overheat bimetallic sensor
Sensor failure detection
Control circuit fuse protection

Table 3: TYTAN Specifications

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

6

SYSTEM SPECIFICATIONS (Continued):

Figure 1: Dimensional Drawing, 12kW – 48kW Units

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

7

SYSTEM SPECIFICATIONS (Continued):

Figure 2: Dimensional Drawing, 72kW Unit

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

8

SYSTEM SPECIFICATIONS (Continued):

Figure 3: Dimensional Drawing, 96kW – 144kW Units

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

9

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 on the front of the unit, near the bottom (see
figures 1-3).

Figure 4: Model/Serial Number Label

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

10

Model Number (Continued):

Model Number Explanation:

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:

TY-072-480-3-SC-RI

c d e f g

c Heater Seri es. The beginning of each model number will designate the product

line. In this case, the TYTAN inline titanium water heater.

d Heater Wattage. The numerical portion of the model number will always begin

with the wattage of your heater. The table provided below identifies the standard
available wattage ratings and the number of heater columns needed to provide
that amount of Wattage.

HEATER

MODEL

NUMBER

012
018

WATTAGE

HEATER

WATTAGE

(W)

12,000 1 12,000
18,000 1 18,000

NUMBER

OF HEATER

COLUMNS

PER
HEATING
COLUMN

(W)

HEATER

MODEL

NUMBER

072
096

HEATER

WATTAGE

(W)

72,000 3 24,000
96,000 4 24,000

NUMBER

OF HEATER

COLUMNS

WATTAGE

PER
HEATING
COLUMN

(W)

024
036
048

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

24,000 1 24,000
36,000 2 18,000
48,000 2 24,000

120
144

Table 4: Wattage and Column Table

11

120,000 5 24,000
144,000 6 24,000

Model Number Explanation (continued):

TY-072-480-3-SC-RI

c d e f g
e Heater Voltage. The first character following the heater Wattage will describe

the rated Voltage of the heater.

f Heater Phase. This character will specify if this unit is designed for single

phase (-1) or three phase (-3) power.

g Options. The remaining characters will specify any options included in this

system. Many of these options can be combined on a single Tytan water heater.
Only a few options are mutually exclusive.

Model Number Option

-CB

-SC Built to SEMI S3 standards, CE compliant version

-PLC PLC temperature controller, in place of the standard PID

-RI Remote interface. This will allow the user to start, stop,

-RC1 RS485 communications interface with the Omron PID

Include circuit breaker with disconnect switch.

(Includes –CB option)

controller

reset the unit and monitor the safety circuit remotely.

temperature controller (requires optional E5CK
controller)

-RC2 RS232 communications interface with the Omron PID
temperature controller (requires optional E5CK
controller)

-RC3 4-20mA process output (requires optional E5CK
controller)

-S

-X

-##

Wetted surfaces to be passivated 316 stainless steel.
Special option, consult factory
Special construction design, consult factory for details

Table 5: TYTAN Options

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

12

FACILITY REQUIREMENTS:

Before installing the TYTAN inline water heater confirm the facility requirements listed
below.

Space Requirements:

The TYTAN inline water heater is constructed in a wall-mounted or freestanding
enclosure. The dimensions of this enclosure are based upon the wattage of the unit.
This enclosure includes the common framework for the heating column(s) as well as the
electrical components.

The enclosure requires adequate ventilation. Locate equipment so that ventilation
provisions on the bottom and sides of the enclosure are not obstructed. The ventilation
fan exhausts air through these openings which prevents overheating of the interior. Be
sure to provide adequate clearance for normal operation and maintenance of this
heater.

The standard dimensions of the various models are shown in Table 3 (see appendix for
custom made units). Allow additional space on all sides of the unit for the control
ventilation and service access. (all dimensions are in inches).

Figure 5: Clearance Dimensions for Wall-Mounted Units (72kW Model Shown)

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

13

Facility Requirements (continued):
Water Plumbing Requirements:

The customer supplied inlet and outlet plumbing must be rated to withstand
temperatures up to 275°F (135°C) at pressures up to 100 psi (6.9 Bar).

The wall-mounted TYTAN units are supplied standard with 1-inch MNPT threaded pipe
connections for the plumbing inlet and outlet. These connections extend from the right
side of the unit, with the inlet near the bottom and the outlet near the top (see figures 1-

2). There is also a ½-inch FNPT threaded pipe connection for the PRV valve on the
right side of the enclosure which must be plumbed to a non-pressurized drain. Special
plumbing connections are available as an option. Refer to your specific unit for any
special connections.

The free-standing TYTAN units are supplied standard with 2-inch MNPT threaded pipe
connections for the plumbing inlet and outlet. These connections extend from the back
of the unit, with the inlet near the bottom and the outlet near the top (see figure 3).
There is also a ½-inch FNPT threaded pipe connection for the PRV valve on the back of
the enclosure, which must be plumbed to a non-pressurized drain. Special plumbing
connections are available as an option. Refer to your specific unit for any special
connections.

Do not reverse the plumbing connections of
this unit. Failure to observe the correct
plumbing orientation will result in high­temperature conditions and heater failure.

Electrical Requirements:

NOTE: Ensure electrical power fusing and disconnects meet local jurisdictional

requirements. Fuse ratings noted in this document are for reference only.
Ensure external electrical components comply with local requirements before
operating this unit.

Reference the model/ serial number label to identify the electrical power requirements of
this unit (see figure 4). Verify that the incoming electrical service is rated and fused for
the required amperage draw.

Do not exceed the rated voltage. Irreparable
damage to the heating column or control
circuitry may result.

M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07

14