QUANTUM DI HEATER OPERATION / MAINTENANCE MANUAL CONTENTS
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 ..................................................................... 35
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.
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