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Phone: 800-669-1303 or 801-561-0303
Fax: 801-255-2312
e-mail: [email protected]
QUANTUM
DI WATER HEATER
Operation / Maintenance
Manual
SERIAL NUMBER:
PATENTS: U.S. 5971402, U.S. 6433319, U.S. 6479094B2, U.S. 6544583B2, 03/11/11 – M3QTM-A
U.S. 6580061B2, U.S. 6663914, U.S 6674053B2;
ADDITIONAL PATENTS PENDING
Page 2
CONTENTS
1 INTRODUCTION ........................................................................................................................................3
2 SAFETY ......................................................................................................................................................6
2.1 SAFETY MESSAGE CONVENTIONS ............................................................................................6
2.1.a Danger ...........................................................................................................................6
2.1.b Warning ..........................................................................................................................6
2.1.c Caution ...........................................................................................................................7
2.2 EQUIPMENT SAFETY ...................................................................................................................7
2.3 EMERGENCY OFF (EMO) .............................................................................................................7
2.4 PROCESS INTERLOCKS ..............................................................................................................8
2.4.a Low Pressure Switch Interlock ........................................................................................8
2.4.b Liquid Level Sensor Interlock ..........................................................................................9
2.4.c Element Over Temperature Protection ...........................................................................9
2.4.d Leak Sensor ...................................................................................................................9
2.4.e Overpressure Burst Fitting ..............................................................................................9
2.5 LOCKOUT / TAGOUT .................................................................................................................... 9
2.5.a Preliminary .....................................................................................................................9
2.5.b Definitions .................................................................................................................... 10
2.5.c Machine Shutdown with door closed ............................................................................. 11
2.5.d Machine Start-Up with door closed ............................................................................... 11
2.5.e Machine Shutdown with door open ................................ ............................................... 11
2.5.f Machine Start-Up with door open .................................................................................. 12
2.6 SEISMIC PROTECTION .............................................................................................................. 12
3 INSTALLATION ........................................................................................................................................ 13
3.1 UNPACKING ................................................................ ................................................................ 13
3.2 LOCATION ................................................................................................................................... 13
3.3 HOOK-UP .................................................................................................................................... 13
3.3.a Ethernet Communication .............................................................................................. 15
3.3.b Changing Heater IP Address ........................................................................................ 16
4 OPERATION ............................................................................................................................................. 17
4.1 GENERAL .................................................................................................................................... 17
4.2 DIAGNOSTIC DISPLAY ............................................................................................................... 17
4.2.a Main Page .................................................................................................................... 17
4.2.b Alarm Status Page ....................................................................................................... 18
4.2.c Module Status Page ..................................................................................................... 20
4.2.d Process Plot Page ........................................................................................................ 20
4.2.e Configuration Page ....................................................................................................... 21
4.2.f Log Reports .................................................................................................................. 23
4.2.g Security Status Page .................................................................................................... 26
4.3 REMOTE OPERATION OVER A NETWORK .............................................................................. 28
4.3.a Ethernet Interface ......................................................................................................... 28
4.3.b Modbus Protocols ......................................................................................................... 28
4.3.c Modbus/TCP ................................................................................................................ 29
4.3.d Modbus Communication ............................................................................................... 29
5 START-UP ................................................................................................................................................ 31
5.1 PRE-START INSPECTION .......................................................................................................... 31
5.1.a Verify Shipping Condition ............................................................................................. 31
5.1.b Hazardous Power Terminals ......................................................................................... 31
5.1.c Electrical Inspection ..................................................................................................... 31
5.1.d Plumbing Leak Check ................................................................................................... 31
5.2 SYSTEM ON ................................................................................................................................ 32
5.3 HEATER MODULE POWER ................................ ........................................................................ 32
5.4 PROCESS ALARMS .................................................................................................................... 32
6 SHUT DOWN............................................................................................................................................ 33
7 MAINTENANCE ........................................................................................................................................ 34
7.1 REPAIR INSTRUCTIONS ............................................................................................................ 34
7.1.a Heater Element Check ................................................................................................. 34
7.1.b Heater Replacement ..................................................................................................... 34
7.1.c Liquid Level and Leak Sensor Calibration ..................................................................... 36
7.1.d Fuse Replacement ....................................................................................................... 36
7.1.e Draining the System ..................................................................................................... 36
7.1.f Leaks............................................................................................................................ 37
7.1.g Overpressure Relief Replacement ................................................................................ 37
7.2 PREVENTIVE MAINTENANCE SCHEDULE................................................................................ 38
8 TROUBLESHOOTING .............................................................................................................................. 40
9 WARRANTY ............................................................................................................................................. 41
See Appendix for specific system requirements.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL CONTENTS
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1 INTRODUCTION
QUANTUM DI WATER HEATER
TREBOR’s Quantum deionized 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.
Trebor’s DI water heater uses a revolutionary heating technology to
provide exceptional process purity and control. Heat is generated using
resistive heating elements conducted to the fluid through quartz tubes
using convective heat transfer. This conductive / convective heating
method allows the heating element to operate at a much cooler
temperature than IR heating systems and provides the basis for a
responsive heating control system.
The Quantum heater modules have smooth surfaces with minimal cracks
and crevices, reducing particle traps. Furthermore, no pipe threads or
elastomeric O-rings are used. With the exception of the exposed tip of
the titanium temperature sensor (included with the fast response option),
the DI water is exposed only semiconductor grade quartz, PTFE, and
PFA wetted surfaces.
Trebor’s patented heating module technology is constructed to provide
excellent process control by minimizing hold-up volume and thermal heat
capacitance while maximizing the heat transfer. While heating, the
system can ramp to a process temperature in a “no flow” condition. The
ability to withstand these extreme transient conditions allows the heater to
operate without the need of flow monitors or flow switches to protect the
heaters. This also reduces the consumption of DI water by minimizing
temperature transition time and bypass to drain requirements.
Many product safety features have been incorporated into the Quantum
heater. Each system has a liquid level sensor, leak sensor, grounded
heater modules, ground fault protection, and redundant control system
interlocks. An electro-mechanical contactor disengages power to the
heaters when a fault condition occurs.
This equipment is built and certified to semiconductor manufacturing
industry requirements of SEMI S2-0703. Please contact Trebor
regarding any questions.
Conformity of the equipment with the above guidelines is attested by the
TUV certification mark.
This equipment complies with the requirements of the EU guidelines:
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 3
Page 4
Figure 1-1: 89/392/EEC “European Machinery Directive”
89/336/EEC “European EMC Directive”
Conformity of the equipment with the above guidelines is attested by the
CE mark.
This equipment also complies with the requirements of the “Management
Methods for Controlling Pollution of Electronics Information Products”,
known as “China RoHS”.
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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Part Name
[部件名称]
Table of Hazardous Substances and Elements
[产品中有毒有害物质或元素的名称及含量]
Lead
[铅]
(Pb)
Mercury
[汞]
(Hg)
Cadmium
[镉]
(Cd)
Hexavalent
Chromium
[六价铬]
(Cr (VI))
Polybrominated
biphenyl
[多溴联苯]
(PBB)
Polybrominated
diphenyl ether
[多溴二苯醚]
(PBDE)
QA1V208P12-AA
X
QA1V380P10-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 at least one of the homogenous
materials for this part, or it has been intentionally added to a metallic coating. (See SJ/T 11363-2006 for definition of
homogeneous materials)
Notes: concentration limits of 1000 ppm (0.1% by weight) for lead, mercury, hexavalent chromium, polybrominated
biphenyls (PBB) and polybrominated diphenyls ether (PBDE), or 100 ppm (0.01% by weight) for cadmium.
Please refer to AeA’s website for an English translation of SJ/T 11363 -2006 (or the latest revision of this document):
http://www.aeanet.org/governmentaffairs/gajl_MCV_SJT11363_2006ENG.asp
Table [表]
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 5
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2 SAFETY
This section describes information that is important for safe equipment
operation. Included is a listing of message conventions used in this
manual, as well as equipment safety interlocks, push buttons, and labels.
The equipment described in this manual uses hazardous voltage
electricity that can be dangerous. Only personnel trained in the
procedures and safety messages outlined in this manual should install (if
applicable), operate, or maintain this equipment. Read and understand
this manual before installation or operation of the system. Follow all
recommended practices and procedures that apply to your actions and
conduct. All safeguard devices must be in place when equipment is 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 contained in this manual; Dangers, Warnings, and
Cautions, are highlighted for quick identification.
2.1.a Danger
A Danger message indicates an imminently hazardous situation that, if
not avoided, will result in death or serious injury. Messages identified by
the word Danger are used sparingly and only for those situations
presenting the most serious hazards.
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:
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Caution
Hot Surface
Do not touch. Can cause
skin burns upon contact.
Disconnect and lockout
power and allow surface to
cool before servicing.
2.1.c Caution
A Caution message indicates a potentially hazardous situation, which, if
not avoided, could result in minor or moderate injury. It may also be used
to alert against unsafe practices. Following is a typical example of a
Caution message as it could appear:
2.2 EQUIPMENT SAFETY
The rest of this section describes equipment safety features:
Emergency Off Push button (EMO)
Process Interlocks
Main Power Disconnect Switch
Lockout/Tagout Information
Equipment Safety Labels
2.3 EMERGENCY OFF (EMO)
The EMERGENCY OFF button (EMO) is located on the front of the door.
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 panel remain energized and hazardous voltages will be present on
the power supply and power supply fuses, sub panel circuit breakers and
contactors. Use the Main Power Disconnect Switch to remove power
from the panel.
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On power up or after the EMO has been pushed, the heater must be
reset by pressing the blue RESET button to reactivate the controls. This
must be done at the machine.
2.4 PROCESS INTERLOCKS
The process fault interlocks are latched into the logic controller (PLC)
memory. When a fault occurs, the user interface will display the alarm
condition and the horn will sound. Pressing the RESET button will
silence the audible horn. The system will retain the fault until it is cleared.
Pressing the RESET button may restart the heater. If the indicator LED’s
remain illuminated then one or more faults are still active. Refer to
Section 8, Troubleshooting.
Figure 2-1
CAUTION: The interlock circuit does not remove hazardous
voltage from the circuit breakers, contactor, and the control transformer.
Only authorized, qualified, trained personnel should service this
equipment.
2.4.a Low Pressure Switch Interlock
The pressure switch will disengage power if system inlet water pressure
drops below 15 psig (103 kPa). The heater will come back online if the
pressure recovers within a 30 second time period. This prevents
nuisance trips due to transient conditions in the DI water supply while still
protecting the heater. However, erratic process temperature control may
result if heater power is disengaged during the pressure transient.
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2.4.b Liquid Level Sensor Interlock
The Liquid Level Sensors will disengage power to the system if the
heater modules are not full of water or if boiling in the heating module
occurs. The heater will reengage if fluid is present within a 30 second
time period. This prevents nuisance trips due to transient conditions in
the DI water supply while still protecting the heater during startup. It is
critical that these sensors operate properly. Do not tamper with the
sensors. Damage to the system can result if the sensors are altered or
overridden.
NOTE: On the dual output option, this interlock will protect the heaters it
monitors (i.e. sensor 1 will protect the modules supplying output 1).
2.4.c Element Ove r Temperature Protection
The temperature limit controller monitors a thermocouple attached to the
heater element. In the event that the element temperature exceeds the
normal operating temperature, the system will immediately disengage
power and alarm. If this occurs, check element continuity before
continuing normal operation. See Section 7.1.a.
2.4.d Leak Sensor
The Leak Sensor will disable heater power immediately when water is
detected in the leak tray. Fix any leaks and dry the leak sensor and leak
tray prior to turning power on to the system.
2.4.e Overpressure Burst Fitting
The overpressure burst fitting (“Relief Drain”) is connected in-line with the
cold DI inlet port to provide a mechanical safeguard against possible
overpressure damage. Do not operate the heater above 414 kPa (60
psig).
If the overpressure relief device opens, the low-pressure sensor will
alarm. A periodic visual inspection of the fitting is recommended. Refer
to Section 7.1.g on replacing burst fitting.
2.5 LOCKOUT / TAGOUT
2.5.a Preliminary
Before installation or servicing the DI water heater, the facility’s power
source to the heater must be de-energized to prevent serious injury to
personnel and equipment. An authorized employee representing the
facility installing the DI water heater must follow approved company
guidelines and lockout or use suitable means to prevent re-energizing the
electrical system during installation or servicing.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 9
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Energy Type
Electrical
Hazard:
Electrocution, electrical burns, and shock
Magnitude:
480 VAC or 415 VAC or 380 VAC or 208 VAC
See system label for exact voltage.
Control Method:
Main Power
Shutdown Procedure
Switch off circuit breaker on front of system.
2.5.b Definitions
Lockout: the placement of a lockout device on an energy isolating
device, in accordance with established company procedures, ensures
that the energy isolating device and the equipment being controlled
cannot be operated until the lockout device is removed.
Tagout: a prominent warning device such as a tag 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 reenergized or operated until the tagout device is removed.
This table lists the Lockout/Tagout information for the system.
PAGE 10 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Figure 2-2: Lockout/Tagout
Page 11
2.5.c Machine Shutdown with door closed
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. Move the actuating handle to the "OFF" (down) position.
5. Apply the locking energy isolation device (lock) through the hole in the
actuating handle and secure the lock.
6. Verify that the tool has been isolated and de-energized by attempting
to turn the main power disconnect back to the “ON” position and/or by
pressing the machine start button. The machine power must not be
reapplied and/or the machine must not start.
2.5.d Machine Start-Up with door closed
Perform the following sequence of events in the order listed for electrical
re-energization of the tool:
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.
3. Open the lock and remove the locking energy isolation device (lock)
from the hole in the actuating handle of the Main Disconnect Switch.
4. Move the actuating handle to the "ON" (up) position.
5. Press the machine start button. The machine should start.
2.5.e Machine Shutdown with door open
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 disconnect shaft to the "OFF" of “0” (down) position.
5. Insert and rotate the key in the rotary disconnect lock (top left of
rotary disconnect device). Remove the key.
6. Verify that the Tool has been isolated and de-energized by attempting
to turn the rotary disconnect shaft back to the “ON” or “1” position
and/or by pressing the machine start button. The machine power
must not be reapplied and/or the Machine must not start.
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2.5.f Machine Start-Up with door open
Perform the following sequence of events in the order listed for electrical
re-energization of the tool:
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.
3. Insert and rotate the key in the rotary disconnect lock (top left of
rotary disconnect device). Remove the key.
4. Move the rotary disconnect shaft to the "ON" of “1” (up) position.
5. Press the machine start button. The machine should start.
2.6 SEISMIC PROTECTION
It is the user’s responsibility to adequately secure and anchor the
equipment to comply with local regulatory agency seismic requirements.
Mechanical anchors are provided using seismic brackets attached to the
bottom of the cabinet enclosure. See Facility Layout in Appendix for
bracket location.
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3 INSTALLATION
3.1 UNPACKING
Remove heater system from crate and inspect heater cabinet for any
signs of damage (dented panels, paint scratches, etc.). Shock indicators
on the heater cabinet should be checked for rough handling during
shipment. Any damage to the system should be reported to the carrier
immediately.
Front door keys are not shipped with the system. Keys are available
upon request. (Key, Handle, 'L' LOC, [PROLINE] #98003360/B).
CAUTION: Heavy Object. When lifting or moving the system,
follow safe heavy object handling methods to prevent injury.
Be careful to not damage the drain fitting located under the heater
cabinet when using a dolly or forklift.
3.2 LOCATION
Locate the heater near the point-of-use to reduce plumbing heat loss.
Access to the front and rear of the system will be necessary for
maintenance and hook-up.
3.3 HOOK-UP
All 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. They must be
rated at a minimum of 110°C (230°F) and 414kPa (60 psig).
NOTE: It is recommended that the hot water supply line have a bleed, or
purge, at the point-of-use to reduce the possibility of the DI water
becoming stagnated in the heaters when not in use. The amount of this
bleed is best evaluated on a case-by-case basis, taking into account
each user’s criteria and production standards.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 13
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Caution
Hot Surface
Do not touch. Can cause
skin burns upon contact.
Disconnect and lockout
power and allow surface to
cool before servicing.
Recommendation: Either insulate the hot DI water process line or
place a Hot Surface hazard warning (example shown below) on the
tubing every 20 feet. Conform to local codes while evaluating hot
water line routing.
Connect the “Over Pressure Relief Drain” to an open drain line with
no more than 30’ of ¾” tubing. Do not connect restrictive fittings or
valves in line with the drain. If an overpressure condition occurs in
the heater, a burst fitting will relieve pressure in the heater. The fitting
must be replaced (see Section 7.1.g).
Attach cabinet drain line to bottom of cabinet. If a cabinet drain line is
not installed, the system will be difficult to drain should repairs be
needed.
CAUTION: Depending on installation and routing of water supply
lines, a trip hazard may be created. 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 installing system.
Open the front door by rotating the electrical disconnect handle to the
OFF position and then rotate the door handle. This will allow access
to the electrical connections.
Route the wires from the electrical source (480 VAC, 415VAC, 380
VAC, or 208 VAC 3-phase) into and through the conduit opening on
the top of the enclosure. To secure an electrical conduit fitting,
remove lifting eyebolts located on top of the system and raise the
vented top panel. The conduit nut may then be secured. Reassemble
the vented top panel to the enclosure.
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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).
Figure 3-1:
Close the door and secure.
Check ground continuity on cabinet to any facility ground.
Remove Facility power Lockout/Tagout.
Restore Facility power supply to the heater.
Follow heater Pre-Start Inspection (see Section 5.1).
NOTE: Before starting the system, it is important to become familiar with
Section 4, Operation. Only trained, qualified, authorized, personnel
should operate this system.
3.3.a Ethernet Communication
For remote monitoring and control of the heater, plug an Ethernet cable
into the RJ45 connector on the lower rear connection panel of the
system.
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3.3.b Changing Heater IP Address
ATTENTION: This section of the manual assumes you know the basics
behind IP addressing. If you are unfamiliar with IP addressing, do not
attempt to change the IP address of the heater. Incorrect assignment of
an IP address could leave the Ethernet functionality of the heater
unusable by your current network configuration.
The heater ships with an IP address already assigned to it. The current
IP address of the heater can be viewed and changed from the heater
touch screen.
To view the current IP address and subnet mask of the heater, go to the
configuration screen in the touch screen. The IP address and subnet
mask are shown in the center of the screen.
To change the IP address of the heater, press the “IP Addr” button on the
right hand side of the configuration screen (see Section 4.2.e). A window
will open that will allow you to change the IP address and subnet mask of
the heater. Pressing the “Enter” button assigns the new IP address to
the heater. If you wish to cancel the changes made press the “X” button
at the top right of the window.
Please note that the new IP address is assigned as soon as the “Enter”
button is pressed. The previous IP address will also remain active until
power to the heater is cycled.
NOTE: Changing the IP settings may cause a WIN CE warning message
to appear. This warning is non-critical, and the heater will continue to
operate normally. To eliminate this warning message, do not hit “OK” or
“Cancel”. Instead, simply tap anywhere in the touch screen, outside of
the warning message.
PAGE 16 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
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4 OPERATION
4.1 GENERAL
The Quantum is very easy to operate. Once DI water is flowing through
the system and power is turned on, a process temperature can be
selected and power switched on to the heater modules. The controls will
do the rest.
If there is a problem with the DI water heater, the system controller will
notify the operator that the heater requires attention. After the fault
condition is corrected, the heater can be reset using the RESET button
located on the heater door (the fault condition will also be cleared if the
entire system power is cycled off and on). Redundant hardware relay
interlocks back up heater element temperature, leak sensor, and
component temperature faults.
4.2 DIAGNOSTIC DISPLAY
A color touch screen provides an intuitive interface to the DI water heater.
The heater can also be operated using both hardware and software
remote interfaces (depending on the heater options). The display is
divided into several pages. The pages are designed to be simple and
easy to understand. The display contains a total of six pages.
4.2.a Main Page
Figure 4-1: Main Screen (single & dual bank version shown)
The main page is the first page that is displayed after the heater is
powered on. This page is designed to show you the current status of the
heater at a glance. The set point, process value, duty cycle, alarm
conditions, heater module errors, and internal communication status are
displayed.
This page also contains a button to turn the heater on and off, a button to
change the set point and enable and disable of the heater.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 17
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An enable button is provided that, when activated, will open the inlet valve
and allows the heater bank to be turned on. This function is active in
single and multiple output systems. This feature provides the ability to
safely disable a bank of heaters in a multiple outlet system.
After enabling the heater and when in local control mode, the on/off
button can be used to turn the heater on or off.
The temperature set point can be changed by pressing the “SP” button or
by pressing the current set point value on the left hand side of the screen.
The set point value can be changed on any page by pressing the set
point value on the left hand side of the screen.
The buttons on the bottom of the page will take you to the other pages.
4.2.b Alarm Status Page
Figure 4-2: Alarm Status Page (single & dual bank version shown)
The alarm page shows the alarm status of the heater, enables the user to
change the mode of the heater and allows the option of turning the
audible alarm (horn) off from the panel.
The mode of the heater can be toggled from “Local” mode to “Remote”
mode by pressing the button on the right hand side of the screen. The
button text changes from “Go to Local” to “Go to Remote” depending on
the current mode of the heater. Local mode allows the heater to be
turned on and off from the touch screen and disables turning the heater
on and off remotely. Remote mode allows the heater to be turned on and
off remotely using a software or hardware remote interface to the heater
(depending on the heater options) and disables turning the heater on and
off from the touch screen. The mode of the heater can only be changed
from the touch screen. Note that the mode status is also displayed on the
main page.
All of the heater alarms are listed on this page. When the heater system
enters an alarm state the heater is turned off and a horn sounds. This
horn can be turned off by pressing the reset button or by pressing the
turning off audible alarm off button on the alarm page.
PAGE 18 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
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Alarm Name
Function
Pressure Alarm
Insufficient inlet water supply pressure
Liquid Level Alarm
Insufficient fluid level
Thermocouple Open Alarm
Broken/Disconnected Thermocouple lead
Liquid Leak Alarm
Fluid Leak Detected – water in base area or fluid on
back side of burst device (for optionally installed
burst device rupture sensor)
Over Temperature Alarm
One or more elements have exceeded the
protective temperature limit
Alarms can have the following states:
Alarm Ok – all alarms are off.
Alarm Delay – pressure and liquid level alarms have a timeout period.
These alarms will wait a certain period of time before putting the
system into an alarm state. During the timeout period the heater is
put in a safe state while waiting for these alarms to clear themselves
and the alarm will be in the alarm delay state. If these alarms clear
themselves before the timeout period elapses, the heater will go back
to normal operation without alarming. If these alarms do not clear
themselves before the timeout period expires, the heater will alarm.
The time delay for these alarms is set on the system configuration
page.
Alarm Active – any alarm that has not been cleared and is still active
is in this state.
Alarm On – any alarm that has not been cleared but is no longer
active is in this state.
The buttons on the bottom of the page will take you to the other pages.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 19
Page 20
4.2.c Module Status Page
Figure 4-3: Module Status Page (single & dual bank version shown)
The module status page shows the temperatures of each of the heater
modules.
If the heater module temperature is shown in black lettering with a white
background, the module is functioning properly. If a heater module
temperature is displayed with blue lettering, the heater is running too cool
compared to the other heaters in the bank. If a heater module
temperature is displayed with red lettering, the heater is running too hot.
Heaters running too hot or too cold should be checked as soon as
possible. See Section 7.1.a.
The numbered buttons bellow each temperature status box correspond to
the heater modules. These buttons enable or disable each modules
thermocouple. When enabled, the thermocouple is considered in the
temperature control algorithm and is monitored for the Thermocouple
Open Alarm condition (see Section 4.2.b).
The buttons on the bottom of the page will take you to the other pages.
4.2.d Process Plot Page
Figure 4-4: Plot Page (single & dual bank version shown)
PAGE 20 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 21
The process plot page shows a plot of the set point and process value.
The set point is displayed with a blue line and the process value is
displayed with a red line. The plot is refreshed approximately every two
seconds.
The buttons on the bottom of the page will take you to the other pages.
4.2.e Configuration Page
Figure 4-5: Configuration Page
The configuration page shows a summary of system information, and
allows changes to the heater IP Address, Serial Communications
Settings, Alarm Delay, and System Time and Date. This page also
allows access to log files described in Section 4.2.f.
Press the “Alarm Delay” button to set the pressure and liquid level alarm
delay. Enter the desired alarm delay in seconds and press enter.
Press the “IP Address” button to set the current IP address and subnet
mask of the heater. See Section 3.3.b for details.
Figure 11: IP Address Change
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 21
Page 22
The current IP address and mask is displayed. Note that the field being
edited is displayed in red. Press the “Enter” button when done changing
the IP address or mask to apply the changes. Changes to the IP address
and mask will take effect immediately. Please note that the previous IP
address and mask will remain active in the system until power is cycled to
the heater.
Press the “Serial Comm” button to change serial communications
settings. Default settings are 9600, 8, E, 1.
Figure 12: Serial Communication Setup
Press the “Time/Date” to set the system time and date.
Figure 13: Changing System Date and Time
When changing the system date or the time, each field must be changed
and apply button pressed to update the system before changing the next
field. For instance, if the month and day fields need to be changed, select
the month field. Use the up and down arrows to select the correct month.
When done, press the “Apply” button before selecting the day field. Use
the up and down arrows to select the correct day and press the “Apply”
button to initiate that change. This also applies to the time. The hour,
minute and AM/PM field must be changed separately by changing the
field and pressing the “Apply” button to apply that change.
Press the “View Logs” button to access the log reports described in
section 4.2.f.
PAGE 22 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 23
A “Config” button is present on the Config page for select heater
configurations. This button allows the setup of configuration-specific
settings.
The buttons on the bottom of the page will take you to the other pages.
4.2.f Log Reports
Log reports are generated to capture three types of data: Alarms, Events,
and System.
The Alarms log captures Pressure, Liquid Level, Thermocouple Open,
Liquid Leak, and Over Temperature alarms (see section 4.2.b for further
explanation of alarms & alarm states).
The Events log will record “Events” that occur such as, Remote On or
Off, Heater Banks running too hot or too cold, Banks being turned On or
Off, etc.
The Systems log records such things as Emergency Shut Off activated,
Reset Button depressed, changes to alarm settings, and several other
settings that affect “system” changes.
Log files can be viewed through the heater touch screen interface, or on
a remote PC via a web browser or a text editing program such as MS
Word or Notepad:
To view the log files through the heater touch screen interface, press the
“View Logs” button on the Config page (see section 4.2.e). First select
the type of log file to view and click the “Open Log” button. Note that
Alarms and Events log files will be available only after an Alarm and
Event occurrence, respectively.
Figure 4-6: Select the Log to view
Select the desired log and press the Open Log button.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 23
Page 24
Figure 4-7: Example of System and Alarm logs
Log reports are time stamped. System time and date settings should be
updated after initial startup to ensure accurate log information (see
section 4.2.e). The most recent logged event is always listed at the end
of the listing and the oldest at the beginning of the log.
Because of memory limitations, the log reports hold a finite number of
records. When the report reaches a set size, the oldest record will be
deleted each time a new record is added.
Select the “Exit” button when finished viewing.
Any of the log files can have its contents deleted by pressing the “Delete
Log” button. A deleted log will be re-started when new records are
generated.
To view the log files on a remote PC, the PC must be connected to the
heater via the Ethernet connection on back side of the Quantum heater.
The log files can be accessed through a web browser, by browsing to the
heater IP address (see section 3.3.b for information on setting and
observing the heater IP address). For example, if the heater IP address
is set to “172.16.17.8” in the heater configuration page, then it should be
entered into the address field of the web browser along with the storage
card name. For example “172.16.17.8/storage card” would be entered
without he double quotes. Note that the IP address on the remote PC
must be in the same range as the heater IP address, and the appropriate
Subnet Mask must also be the same on the remote PC. See local
computer administrator for assistance.
PAGE 24 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 25
After connecting the following interface will appear:
Figure 4-8: Ethernet Loaded Log Menu
To view the log files in the web browser, double-click the “LOGS”
directory, and double click the desired log file. Click the browser’s
“Refresh” button to update the latest changes to that log. The most
recent logged event is always listed on the top of the listing.
To save the log files on the remote PC for viewing in a text editing
program, double-click the “LOGS” directory and right-mouse-click on the
desired log. Select “Save Target As” and specify the location and file
name to be saved.
NOTE: For ease of viewing, the file extension should be changed from
the default “.log” to “.txt”.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 25
Page 26
NOTE: Alarm and Events logs may appear for heater banks that are not
available. Disregard these logs.
4.2.g Security Status Page
This heater is supplied with security features that will lock out the local
user interface. When security is enabled, any screen can be viewed at
any time but a four digit pass code is required to change the heater
variables or states. When a valid pass code is entered in the security
screen, it unlocks the system for a given time. Initially the time is set to
10 minutes but it can be changed from 01 minute to 99 minutes (must
use two digits). The heater is shipped with this functionality set to the
Disabled position.
To enable the security features: Open the security page by selecting
the Security button and enter the correct PIN, and check the Enable
Security box. (Initial factory set PIN is “1234”)
Figure 1: Security Status Page (before & after entering PIN)
To disable the security features. Open the security page by selecting
the Security page and enter the correct PIN, and uncheck the
Security Mode box.
Figure 2: Security Status Page with Security Mode off
PAGE 26 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
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To change your PIN number: Open the security page, enter the
correct PIN, and press “Change PIN” button then enter a new four
digit PIN code.
Figure 4-9: Entering new PIN Number
To change the access time, open the security tab, enter your correct
PIN, and select the access duration time by selecting the current
access duration value. Note that the access duration value does not
appear until after the “Security Mode is Enabled” is checked. Enter
the new 2 digit time in the keypad and press the Enter button. The
minimum duration is 1 minute with a maximum duration of 99
minutes.
Figure 4-10: Changing the Access Duration
Failure to provide a correct PIN will result in “Invalid Pin Number”
message.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 27
Page 28
Figure 4-11: Invalid Pin
If the user PIN number is lost: Contact Trebor for instructions to reset
the security features.
4.3 REMOTE OPERATION OVER A NETWORK
4.3.a Ethernet Interface
The heater can be operated over an Ethernet network using either
Modbus TCP or a proprietary software interface. A remote connection
over Ethernet can turn the heater on and off, change the set point, and
check the operation and the alarm status. Contact the factory for further
information regarding the Ethernet software interface.
4.3.b Modbus Protocols
Quantum heaters can communicate on both Modbus/TCP and
Modbus/RTU networks. Modbus/TCP communication is included in all
Quantum heaters; Modbus/RTU communication is an option on all
Quantum heaters. Using Modbus communication, Quantum heaters can
be turned on and off remotely, the set point can be changed, and the
operation status and alarms status can be monitored.
The Modbus register mapping for Quantum heaters is the same for both
Modbus/TCP and Modbus/RTU protocols. The register mapping is for
single, dual, triple and quadruple output Quantum heaters.
Table 1: Version 1 Modbus Mapping shows the new register mapping that
uses only Modbus registers. Table 2: Version 2 Modbus Mapping shows
the old register mapping that uses both Modbus registers and coils.
While either mapping can be used, Trebor recommends that new
installations use the new mapping in Table 1: Version 1 Modbus
Mapping.
PAGE 28 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
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4.3.c Modbus/TCP
The heater can be operated over an Ethernet network using the
Modbus/TCP protocol. Although the heater can be controlled directly
using Modbus/TCP, Trebor recommends that the heater be controlled
using a communication library written by Trebor. The Trebor
communication library abstracts the details of Modbus/TCP. Currently,
the library is available for Win32 platforms. If you need the library for
another platform please contact the factory.
The IP address of the heater can be configured from the “Config” page
on the heater touch screen (see Section 4.2.e).
4.3.d Modbus Communication
Table 1: Version 1 Modbus Mapping and Table 2: Version 2 Modbus
Mapping includes register mappings for single, dual, triple and quadruple
output Quantum heaters. For a standard single output Quantum heater
use the “Bank 1” addresses. Table 1: Version 1 Modbus Mapping and
Table 2: Version 2 Modbus Mapping contains the name, address, type,
data type, size, and read/write permission for each register.
The Table 1: Version 1 Modbus Mapping interface to the Quantum heater
is composed entirely of Modbus registers – no Modbus coils are used.
This means that only two Modbus functions are required to communicate
with a Quantum heater. The function 03 (read holding registers) and
function 06 (write single register) are the only two Modbus functions that
will be needed.
The Table 2: Version 2 Modbus Mapping interface is an old interface that
uses both Modbus coils and registers. This interface is for backwards
compatibility with the first generation of Quantum heaters. New
installations should use the new register mapping found in Table 1:
Version 1 Modbus Mapping.
To turn the heater on remotely, the value 1 must be written to the
“Remote Heater Power” register. The heater must be in remote mode
(see Section 4.2.b) to enable remote on/off of the heater. To turn the
heater off remotely, the value 0 must be written to the “Remote Heater
Power” register.
All of the Boolean data type registers are false when they contain the
value 0 and true when they contain any value greater than 0. When
writing to Boolean registers, false is represented by the value 0 and true
is represented by the value 1.
The float data type registers need to be converted from network format to
host format after being read. If you are using SCADA software this will
be done automatically. If you are using the C or C++ programming
languages this can be done using the C function ntohl().
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 29
Page 30
Name
Addr Bank 1
Addr Bank 2
Addr Bank 3
Addr Bank 4
Type
Data
Bytes
Perm
Set Point
16404
16529
16654
16779
Reg
Short
2
RW
Process Temperature
16405
16530
16655
16780
Reg
Float 4 R
Duty Cycle
16429
16554
16679
16804
Reg
Float 4 R
Communication Status
21384
Reg
Bool 2 R
Mode
16389
16514
16639
16764
Reg
Bool 2 R
Remote Heater Power
16387
16512
16637
16762
Reg
Bool
2
RW
Heater Power Status
16384
16509
16634
16759
Reg
Bool 2 R
Alarm Status
16392
16517
16642
16767
Reg
Bool 2 R
Alarm Liquid Level
16394
16519
16644
16769
Reg
Bool 2 R
Alarm Liquid Leak
16396
16521
16646
16771
Reg
Bool 2 R
Alarm Over Temp
16397
16522
16647
16772
Reg
Bool 2 R
Alarm Thermocouple
16395
16520
16645
16770
Reg
Bool 2 R
Alarm Pressure
16393
16518
16643
16768
Reg
Bool 2 R
Name
Addr Bank 1
Addr Bank 2
Addr Bank 3
Addr Bank 4
Type
Data
Bytes
Perm
Set Point
1049
1149
1249
1349
Reg
Short
2
RW
Process Temperature
1051
1151
1251
1351
Reg
Short 2 R
Duty Cycle
1067
1167
1267
1367
Reg
Short 2 R
Communication Status
21384
Reg
Bool 2 R
Mode
449
549
649
749
Coil
Bool 1 R
Remote On
453
553
653
753
Coil
Bool
1
RW
Remote Off
454
554
654
754
Coil
Bool
1
RW
Heater Power Status
452
552
652
752
Coil
Bool 1 R
Alarm Status
457
557
657
757
Coil
Bool 1 R
Alarm Liquid Level
458
558
658
758
Coil
Bool 1 R
Alarm Liquid Leak
459
559
659
759
Coil
Bool 1 R
Alarm Over Temp
460
560
660
760
Coil
Bool 1 R
Alarm Thermocouple
461
561
661
761
Coil
Bool 1 R
Alarm Pressure
463
563
663
763
Coil
Bool 1 R
Element Status
462
562
662
762
Coil
Bool 1 R
For more information regarding Modbus communication please visit
www.modbus.org.
Table 1: Version 1 Modbus Mapping
Table 2: Version 2 Modbus Mapping
PAGE 30 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 31
5 START-UP
5.1 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.
5.1.a Verify Shipping Condition
Refer to Section 3.1, Unpacking.
5.1.b Hazardous Power Terminals
Refer to PM Schedule, Section 4.3.b. Tighten hazardous power
connections at the main circuit breaker, distribution circuit breakers,
distribution contactors and SSRs. Slightly loose connections at these
hazardous power terminals can cause arcing. This arcing can introduce
higher than 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.
5.1.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.
5.1.d Plumbing Leak Check
Refer to PM Schedule, Section 4.3.b. Inspect heater for leaks during
start-up. Open the front door and visually watch the leak tray as the
system is initially filled with water. Visually inspect heater module
fittings and heater system plumbing for leaks.
If leaks are found at the flare fittings, hand tighten fittings while they
are at ambient temperature. Do not use a wrench to tighten flare
fittings, as excessive tightening can cause damage to the fittings.
If any problems are encountered during start-up of this heater, contact
Trebor for technical support.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 31
Page 32
5.2 SYSTEM ON
Activate the power to the system by rotating the “Main Breaker” handle to
ON. If the display on the control panel does not illuminate, ensure that
the EMERGENCY OFF button is in the operate position. Press the reset
button to engage control power.
5.3 HEATER MODULE POWER
When the RESET button is pressed, the power contactors will engage.
5.4 PROCESS ALARMS
If a fault occurs, the main contactor will disengage, an indicator LED will
turn red to show the type of fault, and an audible alarm will sound.
Pressing the RESET button will silence the audible alarm. If the RESET
button is pushed and there are no active faults, the heater will restart.
PAGE 32 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 33
6 SHUT DOWN
The DI water heater may be shut down by the following methods:
Select the OFF button on the control screen to put the heater in
standby (heater element power will be disengaged).
Rotate “Main Breaker” to off position.
Turn off the facility supply.
Lockout and tagout heater for maintenance or repair. Refer to
Section 2.5.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 33
Page 34
7 MAINTENANCE
7.1 REPAIR INSTRUCTIONS
Heater modules have a finite life. Spare heating modules should be on
hand in case of a failure.
NOTE: If top element fails then switch off lower element for consistent
temperature control.
7.1.a Heater Element Check
If the control screen indicates a check heater element status bar, check
the heater diagnostic display for information about heater module status.
Visually inspect the main and auxiliary circuit breakers. Then check the
corresponding element isolation circuit breaker to see if it has tripped.
Check the continuity of the heating elements as follows:
1. Shut off power to the system.
2. Lockout and Tagout power to heater.
3. Switch off the element circuit breakers in the control enclosure.
4. Check for continuity between the two screw terminals on the left of
the breaker for each pair of element circuit breakers.
5. If no continuity exists, replace the suspect heater modules; see
Section 7.1.b Heater Replacement.
6. If there is continuity, then the heater element is OK. Refer to the
Troubleshooting Section of this manual for other possible causes.
7.1.b Heater Replacement
The heater modules have been designed for quick replacement to
minimize downtime and field service requirements. To replace a heater
module, follow these procedures:
Turn power off to system (see Section 2.5 for Lockout/Tagout
procedures).
Drain system (see Section 7.1.e, Draining the System).
Remove the rear panel of the enclosure to access heater modules.
Disconnect the electrical connector to the failed module.
Remove process thermocouple by unthreading thermocouple fitting
from top header of the module. It should be hand tight. A wrench may
be required to loosen.
PAGE 34 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 35
Process Fluid T/C
Heater Band Clamp
Heater Band Clamp
Remove steel band clamps, but do not remove clamps used on
modules for connecting the electrical box.
Loosen fluid inlet and outlet fittings on module.
Disengage the inlet fitting by sliding the bottom of heater off shelf.
Lower the heater 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 fittings because they can easily be
cross-threaded.
Return failed heater module.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 35
Figure 7-1:
NOTE: Do not disassemble the heater module. There are no user
serviceable parts inside the module. If disassembled, any product
warranties will be invalid.
Page 36
7.1.c Liquid Level and Leak Sensor Calibration
Contact factory for calibration instructions.
7.1.d Fuse Replacement
There are two different ratings of fuses in the electrical control box. See
the Appendix and the electrical schematic for fuse locations. All fuses
are CCMR type.
CAUTION: Fuses must be replaced with the same type of fuse
and rating. Failure to do so could result in a safety hazard and cause
injury to personnel and equipment. Consult factory for further
information.
7.1.e Draining the System
Close heater DI water inlet isolation valve.
Connect fluid inlet to an open drain line. (Alternate: If a drain line is
connected to the cabinet drain on the bottom of the heater enclosure,
the heater may be drained into the leak tray.)
Power system and open DI water inlet isolation valve.
Loosen a fitting in the upper manifold to release internal vacuum in
the line.
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.
Draining the system with out power requires manual activation of the
inlet isolation valve by pressing the red button (see Figure 7-2:
Isolation Valve).
Figure 7-2: Isolation Valve
PAGE 36 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 37
7.1.f Leaks
When a leak has been detected it is recommended that the supply water
be shut off along with the main circuit breaker. 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.
7.1.g Overpressure Relief Replacement
Turn power off (see Section 2.5).
Drain system (see Section 7.1.e).
Remove and replace overpressure relief fitting (note orientation of
fitting).
Refill system.
Inspect for leaks.
Turn power on (see Section 5.2 and 2.5).
Figure 7-3
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 37
Page 38
Quantum
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 X
Branch Circuit Breakers
X
Label
Part
Number
Description
Torque Value
MCB1
-
Circuit Breaker, 3 Pole, 480VAC, 60A - 225A
30.5 Nm / 270 in-lb
MCB1
-
Connection Terminal Block,6Wire,14-6AWG
6.0 Nm / 53.1 in-lb
CB1-4
98003862
Circuit Breaker, 3 Pole, 480VAC, 50A
5.6 Nm / 49.6 in-lb
CONT 1-4
98003544
Contactor, 50A, 400V, 3 Pole, 24VDC
2.5 Nm / 22.1 in-lb
SSR 1-8
98004141
SSR, 125A, 4-32VDC, 48-660V
3.7 Nm / 32.7 in-lb
CBH 1E1-12E2
98003865
Circuit Breaker, 2 Pole, 480VAC, 15A
2.5 Nm / 22.0 in-lb
F1-F4
98003253
Fuse Holder, 600V, 30A, 1 Pole
1.6 Nm / 14.2 in-lb
24VDC-PS
98003781
Power Supply, 10A, 320-575VAC, 3 Phase
0.6 Nm / 5.3 in-lb
TLM 1-2
98003897
8 Channel Temperature Monitor
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
7.2 PREVENTIVE MAINTENANCE SCHEDULE
See following table for details on each item.
Verify torque at least every 6 months with a calibrated torque wrench. Do
not over tighten. Consult factory with questions.
PAGE 38 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 39
ITEM
DETAILS
Plumbing
Leaks
Visually check DI water lines outside of heater cabinet for signs of leaks at the
connections. (A leak sensor will detect leaks, but this periodic visual check is
recommended.) Also, visually check bottom of cabinet inside heater module
enclosure for DI water leaks. Tighten fitting(s) if necessary. If heater module
is leaking, contact Trebor for instructions.
Overpressure
Relief Drain &
Diaphragm
Visually check the drain line for water running from the heater. The
overpressure burst fitting can start leaking if the system has experienced
pressures above 60 PSIG. The burst fitting can be checked by inspecting the
relief port at the back of the cabinet. No water should be present in the relief
drain since it is required to be plumbed to an open drain. If water is present in
the drain plumbing, the fitting should be replaced.
General
Electronics
Visually check electronics inside control enclosure for any signs of
overheating, deformation, or corrosion.
Solid State
Relays
The SSR’s should be free of corrosion at the terminals and should not have
signs of overheating or deformation. The wires attached to the SSR’s should
be clean and in good condition. Check and tighten mounting screws for
optimum heat transfer to heatsink.
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 checked for tightness.
Branch
Circuit
Breakers
These should be checked for signs of loose connections at the termination
lugs. The terminals should be checked for tightness.
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 39
Page 40
Display is Not Illuminated
Cause:
Solution:
EMO button engaged.
Twist EMO in direction of arrows (see Section 2.3).
No power at main circuit breaker.
Review wiring procedure (see Section 3, Installation).
Control fuse is blown.
Replace fuse.
Main breaker is OFF.
Main breaker to ON.
Alarm Sounds
Cause:
Solution:
DI supply pressure.
Check water supply pressure at source.
Liquid level.
Check water supply at source.
Check overpressure relief diaphragm.
Verify flow is on.
Leak sensor.
Check manifold and heater modules for leak. Visually
inspect leak tray.
Thermocouple damaged.
If fault repeats, check thermocouple leads to OTC for
continuity. Check T/C plugs in top heater modules.
Plugged orifice in heater.
Check fluid lines in and out of manifold for flow.
Over-temperature alarm.
Check if heater element has failed and replace module
(see section 7.1).
If fault reports, check T/C leads to OTC for continuity.
Verify fan operation.
Check Heater Element Status Alert
Cause:
Solution:
Failed heater.
Circuit breaker tripped.
Heater enable.
Check if heater element has failed and replace module
(see Section 7.1).
Check and reset the main, auxiliary and element isolation
circuit breakers.
Consult Trebor if circuit breaker repeatedly trips.
Solid State Relay (SSR) may have
“frozen” open or closed.
An SSR has failed in the open mode: Shut system off
immediately and replace the failed SSR. SSR’s should be
replaced in pairs.
8 TROUBLESHOOTING
PAGE 40 QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL
Page 41
9 WARRANTY
See the Trebor Standard Limited Warranty at
http://www.treborintl.com/TechnicalSupport.aspx
QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL PAGE 41
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