Heateflex FLUIDIX User manual

World Leaders in Ultra-Pure Heating Revision 10
www.heateflex.com 01/17/13
405 E. Santa Clara St.
Arcadia, CA 91006-7218
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FLUIDIX
SERIES
Ultra-Pure D.I. WATER
HEATING SYSTEM

World Leaders in Ultra-Pure Heating Revision 10
www.heateflex.com 01/17/13
405 E. Santa Clara St.
Arcadia, CA 91006-7218
Tel: [phone] Fax: [phone]

World Leaders in Ultra-Pure Heating Revision 10
www.heateflex.com 01/17/13
405 E. Santa Clara St.
Arcadia, CA 91006-7218
Tel: [phone] Fax: [phone]
INDEX
Section I –Fluidix Instruction Manual
Table of Contents
Preface
Theory of Operations
System Control
Safety Systems
Preventive Maintenance and Servicing
Installation and Start-up Procedures
Servicing Policies
Section II - APPENDIX
Touch Screen Displays
External Flow Sensors
Temperature Dead Band Signal
Equipment Specification
Factory Default Parameters
Quality Assurance Checklist
Pressure Relief Valve Calibration
Drawings
Flow Meter Configuration Document
Parameter Log
Ethernet Communications
Instruction Manual Revisions
ASME Data Report (if applicable)

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TABLE OF CONTENTS
Section I
1.0 General Information
1.1 Introduction
2.0 Theory of Operation
2.1 System Overview
2.2 How the Process is Heated
2.3 How the Temperature is Controlled
2.4 Ancillary Systems
3.0 System Control
3.1 Temperature-Control Overview
3.1.1 Temperature-Control Specifics
3.2 Touch-Screen Display
3.2.1 Main Menu
3.2.2 System Status
3.2.3 Recalibration
3.2.4 Temperature Trending
3.2.5 Alarm Menu and Alarm Screens
3.2.6 Date and Time Set Up
3.2.7 Alarm History
3.3 The Remote Control Panel
3.4 Input/Output Functions
4.0 Safety Systems
4.1 Overview
4.2 Shellside (Steam) Safety Mechanisms
4.2.1 Shellside Over-Pressure
4.2.2 Shellside Over-Temperature
4.3 Tube Side (Process) Safety Mechanisms
4.3.1 Process Over-Temperature
4.3.2 Process Over Pressure
4.3.3 Low Process Pressure
4.3.4 Low Process Temperature
4.3.5 Hot Valve Over-Temperature
4.3.6 Low D.I. Flow Rate
4.4 Auto-Isolation System
4.4.1 Loss of D.I. Water Line Pressure/Auto Isolation
4.5 Shellside/Vessel Flooding
4.6 Water Leak
4.7 Summary of Alarm Conditions and System Reponses
4.8 Use of Emergency Off (EMO) Switch
4.9 Door Interlock

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TABLE OF CONTENTS
5.0 Preventative Maintenance and Servicing
5.1 Process Control System
5.1.1 Thermocouple Temperature Sensors
5.1.2 Temperature Switches
5.1.3 Pressure Transducer
5.1.4 Flow Sensor
5.2 Process Exchanger Mechanicals
5.2.1 Repairing a Tube Failure
5.2.2 Repairing a Leaking Fitting
5.2.3 The Mixing Valves
6.0 Installation and Start-up Procedures
6.1 Facilities Hook-Up
6.2 Initial Heat-Up
6.3 Adjusting Temperature Control Parameters
7.0 Servicing Policies
7.1 Self Service
7.2 Factory Service
7.3 Warranty
Section II
8.0 Appendix
8.1 Important Touch Screen Notes
8.2 Touch Screen Displays
8.2.1 Main Menu
8.2.2 Date/Time Set Up
8.2.3 System Status
8.2.4 Recalibration
A. Recalibration Instructions
B. Factory Adjustable Parameters Menu
C. Factory Adjustable Parameters
D. Temperature Dead Band
8.2.5 Temperature Control Trending
8.2.6 Alarm Menu
A. D.I. Pressure Relief Venting Alarm
B. D.I. Pressure Relief Venting Diagnostic Information
C. Hot Valve Over Temperature Alarm
D. Hot Valve Over Temperature Diagnostic Information
E. Low Flow Rate Alarm
F. Low Flow Rate Diagnostic Information
G. Low Process Pressure Alarm
H. Low Process Pressure Diagnostic Information

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TABLE OF CONTENTS
I. Low Process Temperature Alarm
J. Low Process Temperature Diagnostic Information
K. Process Over Temperature Alarm
L. Process Over Temperature Diagnostic Information
M. Shellside Over Temperature Alarm
N. Shellside Over Temperature Alarm Diagnostic Information
O. Steam Pressure Relief Venting Alarm
P. Steam Pressure Relief Venting Diagnostic Information
Q. Vessel Flooding Alarm
R. Vessel Flooding Diagnostic Information
S. Water Leak Alarm
T. Water Leak Diagnostic Information
8.2.7 Alarm History
8.2.8 External Flow Sensor
8.3 Pressure Relief Valve Calibration Procedure
8.4 Quality Control Documentation
8.4.1 Equipment Specifications
8.4.2 Fluidix PC Factory Default Parameters
8.4.3 Fluidix Ultra-Pure D.I. Water Heating System Quality Assurance
Checklist
8.4.4 Freescale Fluidix Source Inspection
8.4.5 Flow Meter Configuration
8.5 Drawings
8.5.1 Facility Connections
8.5.2 Mechanical Drawing
8.5.3 Plumbing Diagram
8.5.4 Electrical Component Layout
8.5.5 Electrical Schematics
8.6 Parameter Log
8.6.1 Generic
8.7 Ethernet Communications
8.7.1 Ethernet System Values & Set Points
8.7.2 Ethernet System Status & Alarms
8.8 Manual Revisions
8.9 ASME Data Report (if applicable)

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Section I
Instruction
Manual

World Leaders in Ultra-Pure Heating Revision 10
www.heateflex.com 01/17/13
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Tel: [phone] Fax: [phone]

World Leaders in Ultra-Pure Heating Revision 10
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405 E. Santa Clara St.
Arcadia, CA 91006-7218
Tel: [phone] Fax: [phone]
1.0 General Information
_________________________________________________________
1.1 Introduction
Thank you for your purchase of the Fluidix D.I. Water Heating System. We have strived in the
engineering and redesign of the Fluidix D.I. Water Heating System to provide you with a
product that has quality, performance, reliability, serviceability, and safety. Further, it is our
goal to support you, the customer, and the equipment in as positive and professional a manner
as possible.
This manual serves as a guide to how the unit is designed and how it is to be properly operated
for maximum performance and safety. It is strongly recommended that you and others who
will work with the unit read the entire manual prior to the use of the system. It is our
recommendation that the manual be kept readily available to others who may later need to refer
to it.
Another feature of this manual is the sections dealing with servicing. We realize that the
competitive business in which this equipment will be used is very sensitive to production
downtime. One of the prime considerations in the engineering of all Fluidix systems is the
feature of user serviceability. This philosophy of user serviceability has not been designed to
shift the servicing responsibility to the customer, but rather to give the customer the servicing
capability to react quickly to virtually any possible issue that may occur. This ability allows
you to have greater control over your production environment and to have one more weapon to
preclude lengthy downtimes. We are confident that if the instructions for the proper operation
and maintenance of the system are followed the unit will have years of trouble free service.
Please read the manual carefully: the system is not difficult to operate, but does require some
detailed understanding in order for it the unit to properly function. Feel free to call Heateflex
Corporation with any questions regarding start-up or maintenance.

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2.0 Theory of Operation
__________________________________________________________
2.1 System Overview
The Fluidix PC Series D.I. Water Heating System combines a steam-powered PFA heat
exchanger with a process temperature-control system to provide a "turn-key" D.I. water-
heating system.
All wetted surfaces are virgin PVDF, PFA and PTFE with elastomeric PTFE for piping seals
for no measurable change in TOC, particles ≥0.06µ or bacteria, and less than 0.1 ppb ionic
contamination from the process inlet to the process outlet. Each system is computer designed
to ensure sufficiently high water velocity to prevent bacteria growth, particularly in the inlet
region of exchanger tubing where the water is warm but not yet sufficiently hot to kill the
bacteria. During a period of low or no flow, the D.I. water in the tubing quickly rises to
sterilization temperatures.
The exchanger is a kettle-type configuration with a PFA tube bundle wound helically around a
central support, which is mounted to the exchanger cover. Removal of this exchanger cover
gives complete access to the Fluidix tube bundle for inspection of all its components. The
vessel and its cover comprise a pressurized system where steam is introduced through a
flanged inlet mounted at the side of the exchanger vessel, and where steam condensate is
drained at the bottom.
The exchanger bundle utilizes a sanitary head design such that continuous lengths of tubing
pass through the vessel cover and connect to pipe headers above the exchanger cover (See
Appendix). This configuration provides that there are no welds or connections in the tubing
within the exchanger vessel, which could potentially leak. If a tube fitting on a pipe header
develops a leak, it can be easily accessed and tightened after the unit is cooled down.
Temperature control, independent of flow rate, is accomplished by means of two mixing
valves, which blend ambient-temperature water with the hot exchanger effluent water to yield
the desired output temperature. A thermocouple temperature sensor monitors the outlet
temperature whose signal along with that of a shedding-vortex flow meter is then used by the
PLC controller to position the mixing valves as needed.

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_________________________________________________________
2.2 How the Process is Heated
The heating system receives its heating power from <15 psig regulated steam supply. This
steam comprises the shellside-heating medium and completely surrounds the tube bundle
inside the pressure vessel. The steam flow into the vessel is not throttled as it is "self-
controlling". As the flow of process water inside the exchanger tubing increases or decreases,
the rate of condensation of the steam on the outside of the tubing also increases and decreases
proportionally. In the case where the flow of process water stops completely, the tubing and
process water equilibrate to the same temperature as the steam, condensation ceases, and steam
flow into the vessel ceases.
__________________________________________________________
2.3 How the Temperature is Controlled
The PC series D.I. water heating system utilizes a "mixing-valve" temperature-control system
which can deliver unmatched accuracy in output temperature, independent of the most extreme
variations in D.I. water flow rate.
D.I. water is heated in the Fluidix PFA heat exchanger to above the set point temperature and is
continuously blended in varying ratios with ambient-temperature D.I. water by means of two
PVDF mettering valves to yield the desired set point temperature. The two mixing valves are
positioned 90° from one another (one is fully open when the other is fully closed) and are
driven by a common actuator such that a 90° rotation of the actuator can produce output
temperatures anywhere from ambient to near the steam inlet temperature.
The control system uses a look-up table, which is calibrated initially at start-up, to give the
proper actuator position as a function of set point temperature and flow rate. This type of
control provides immediate adjustment in the hot / cold blending ratio over the fast changes in
flow rate associated with many semiconductor- process tools. Once the flow rate re-stabilizes,
the control system also provides a “trimmer” function to make small adjustments in the
actuator position to fine tune.
The following figure shows the basic schematic of the process components. The exchanger is
actually broken down into two or more parallel tube bundles each fitted with isolation valves
and two pressure relief valve systems (steam and D.I.), which are not shown in this simplified
diagram.

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The overall pressure drop across the system remains nearly constant, regardless of the position
of the mixing valves, due to the fact that as one of the mixing valves is opening, the other is
closing, so the combined cross-sectional area of the two valves is essentially constant.
__________________________________________________________
2.4 Ancillary Systems
The PC series D.I. water heating systems are offered with two optional systems: the Auto-
Isolation System and the Auto-Shutdown System.
The Auto-Shutdown System is used to close the steam supply valve to the unit based on
various conditions, which could harm the unit or downstream piping and equipment.
The Auto-Isolation System is used to close two isolation valves, one upstream and one
downstream of the unit, based on various conditions which could lead to a potential
contamination of the process water.
These two ancillary systems are discussed in detail in Section 4.0

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3.0 System Control
__________________________________________________________
3.1 Temperature-Control Overview
The temperature and flow of the D.I. water is monitored by a thermocouple and shedding
vortex flow meter, respectively. These signals are inputted to the programmable logic
controller (PLC), the values of which are indicated on the touch-screen display.
The flow signal, along with the set point temperature are used as inputs to a look-up table
which outputs the proper actuator position for the hot and cold mixing valves to yield the
desired set point temperature.
At any given flow rate, there is a specific mix-ratio of hot D.I. water exiting the heat
exchanger, blended with ambient-temperature water from a bypass line, which will yield the
proper set point temperature. These values are programmed into the PLC‟s look-up table.
When there is a sufficient change in flow rate, as sensed by the flow meter, the PLC
immediately causes the actuator, which positions the mixing valves, to move to the new value
listed in the look-up table. This response to the change in flow rate is immediate without
waiting until there is a detected deviation from set point for the process temperature as with
conventional temperature control systems.
Additionally, the PLC has a trimmer function, which is based on the temperature sensor at the
outlet of the unit to make small adjustments in the actuator position to fine tune the unit.
__________________________________________________________
3.1.1 Temperature-Control Specifics
Temperature control is a function of two inputs, D.I. Flow Rate and D.I. Temperature,
compared with the set point temperature. If the actual D.I. temperature is within ±1°C of set
point, the actuator will maintain its current position and the look-up table will not be consulted,
nor will the trimmer function make further adjustments. If the actual temperature is not within
that range, then one of two things will happen.
First, the PLC does a comparison on flow rates. If the flow rate has change by a specified
value of ±1 GPM (Factory Default) or more, then the look-up table is consulted for the proper
actuator position corresponding to the new flow rate. (This 1 GPM value can be field adjusted
during start-up as necessary depending on the actual process flows.)
If the flow rate has not changed more than ±1 GPM, and the D.I. temperature is not within
±1°C, then a trimmer function takes over. This function checks to see if the temperature is
within the desired range, and if not, the actuator is adjusted slightly to a new position. After a
specified time interval, the temperature is checked again and the actuator moves another small

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increment if needed. This process is repeated until the temperature is within ±1°C of the
specified set point. The amount of each incremental actuator movement and the specified time
between readings is user adjustable in the Recalibration screen. The time intervals are set to be
just longer than the response time for the temperature to stabilize after a move of the actuator,
typically 5 to 10 seconds.
__________________________________________________________
3.2 Touch-Screen Display
The Omron, Touch-Screen Display mounted on the front panel of the electrical enclosure is the
user interface for the unit. When the unit is powered up, the Main Menu screen will appear
with buttons to access additional screens such as the System Status screen. The System Status
screen is the main informational screen and contains the current status of the unit, as well as
touch switches for operating actuated valves and performing other functions on the unit.
Moving from screen to screen and setting switches is a simple matter of touching the surface of
the display in the area of the screen indicated. For example, pressing the box on the display
labeled “MAIN MENU” would return the display to the main menu, and pressing the box
labeled “OPEN” would open the steam valve on the unit.
The ability to operate or change any settings to the unit via the touch-screen display is
password protected to prevent unauthorized personnel from access. There are two types of
passwords, the “operational password” and the “administrative password”. The “operational
password” is located on the Main Menu screen. The “operational password” is actually two
simultaneous keystrokes; the first is located in the area above the “PRESS FOR SYSTEM
STATUS” button or to the left of the “DATE” label and the second is located above the
“PRESS FOR TEMP TRENDING” button and to the right of the “TIME” label. When these
two areas are depressed, the “operational password” will activate and then operation functions
can be made in any of the screens for a period of fifteen minutes, after which the lockout will
automatically reset. The actual position for the operational password is indicated in the
Appendix. The “administrative password” allows access to changing controller parameters,
setting the date or time, and modifying alarm set points/delay timers.
In order to enhance the lifetime of the electroluminescent screen a screen saver function is
available which will darken the screen if there is no activity for a period of ten minutes.
Touching any area on the display will return the screen to normal, illuminated operation.
Pictures of all touch-screen displays are shown in the appendix of this manual.

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__________________________________________________________
3.2.1 Main Menu
The Main Menu consists of six screen switches for the parent screen in each area of the control
system; System Status, Recalibration, Temperature Control, Alarm Menu, and Alarm History,
and External Flow. By touching one of these buttons, you will move to the respective screen.
In addition, the date and time set up buttons are located on this screen (see Section 3.2.6 for
more information).
Please note that an alarm will automatically trigger upon initial start up of the unit. The
“ALARM RESET” button must be pressed prior to the operation of the unit.
__________________________________________________________
3.2.2 System Status
This screen displays the current status of the unit and allows manual overrides of the Auto-
Isolation and Auto-Shutdown valves. It has an audio-alarm defeat (“ENABLE AUDIO” /
“DISABLE AUDIO”) and an alarm reset function (“ALARM RESET”).
Displayed on the screen are the D.I. Temperature Set Point, D.I. Process Temperature,
Shellside (Steam) Temperature, D.I. Flow Rate, D.I. Process Pressure, and Actuator Position.
The current status of the Auto-Shutdown System, Auto-Isolation System, Pressure Relief
Venting Systems, and the Vessel Flooding system are also indicated on this screen.
Two sets of touch keys allow the Auto-Isolation and Auto-Shutdown Valves to be set in the
Auto, Flow or Bypass and Auto, Manual-Open or Manual-Closed position respectively. Upon
initial power up of the equipment, the Auto-Isolation valves are automatically set in the
Manual-Bypass position and the Auto-Shutdown Valve (Steam valve) is set in the Manual-
Closed position. These switches will illuminate denoting which position is currently active.
The “operational password” must be entered in order to activate these switches and be
operated.
The “ALARM RESET” button clears any alarm conditions that are present and will reset the
Auto-Shutdown mode or Auto-Isolation mode back into the “Auto”mode provided that an
alarm condition has occurred triggering those systems. Please note that when the unit is first
powered on the “ALARM RESET” button must be pressed prior to the operation of the unit.
To enable or disable the alarm audio press the “ENABLE AUDIO” or the “DISABLE
AUDIO” buttons respectively.
Three other switches allow for convenient screen changes: “MAIN MENU”,
“RECALIBRATION”, and “ALARM MENU”. The “ALARM MENU” button will illuminate
when any alarm condition is present.

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__________________________________________________________
3.2.3 Recalibration
This screen consists of the D.I. Temperature Set Point, Actuator Control buttons and
parameters, current system status information, the Look-Up Table, and screen-change buttons.
It is on this screen that most of the temperature-control parameters are set. The time interval
and actuator increment for the trimmer function for temperature control can be set on this
screen.
To change the D.I. temperature set point simply press the button located in the box entitled D.I.
TEMP. SET POINT. Please note that an “administrative password” is required to change the
set point.
The Look-Up Table can be configured by pressing the buttons located in the box entitled
LOOK-UP TABLE. Beginning with an empty Look-Up Table, press the box under D.I.
TEMP. SET POINT, enter the “administrative password”if necessary and enter the desired
process set point value. Next, take the maximum flow rate in GPM that will be required for the
unit and divide by ten. This number will become the approximate increment for the FLOW
RATE column in the Look-Up Table. Enter this value for the Look-Up Table under FLOW
RATE by pressing the box in the first row.
Next, open an outlet valve until the flow rate is at the increment entered in the first position.
Then using the “HOT” and “COLD” buttons located in the box entitled ACTUATOR
CONTROL, manually move the actuator until the actual D.I. temperature corresponds with the
set point temperature. Please note that the “operational password” is required to manually
control the actuator. A 100% value for the actuator position corresponds to fully hot (hot valve
is completely open) and 0% to fully cold (cold valve is completely open).
Note: The time for the thermocouple sensor to get an exact reading is approximately 10
to 15 seconds; therefore it is necessary to pause between the movements of the actuator in
order for the temperature to stabilize.
Once the temperature stabilizes, enter the actuator position value required to stabilize the
temperature into the Look-Up Table by pressing the box on the respective row under ACT.
POS. (Actuator Position). Repeat this until the entire Look-Up Table is complete. Finally,
press the “AUTO” button to return the control of the actuator to the PLC.
These recalibration instructions are also available on the touch screen. Press the
“RECALIBRATION INSTRUCTIONS” button to bring up the screen with the instructions for
setting up the Look-Up Table, which is detailed above.

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__________________________________________________________
3.2.4 Temperature Trending
This screen consists of a graph to monitor the temperature-control of the unit in real time. The
graph plots the actual temperature, actual flow rate and the actual actuator position verses time
to provide insight as to how the unit is functioning.
By clearing and starting the readings on the graph, one can watch the actual temperature, actual
flow rate and the actual actuator position as the look-up table and trimmer function attempt to
adjust the temperature to ± 1°C.
__________________________________________________________
3.2.5 Alarm Menu and Alarm Screens
If an alarm condition occurs, the “ALARM MENU” button will illuminate and an audio alarm
will sound indicating that an alarm condition is present. There is also a set of dry contacts on
the back of the touch-screen display on the main unit. In addition an optional remote display
can be used to monitor alarm conditions at a central control room, etc.
The Alarm Menu screen consists of ten possible alarm conditions. The condition that is
presently causing the alarm will illuminate. It is possible that two or more alarm conditions
could exist at the same time. Some of the alarm types require a manual reset in order to
resume normal operation. To manually reset the alarm press the “ALARM RESET” button
located on the System Status screen or the Alarm Menu screen. Other alarms automatically
reset (see Section 4.7 Summary of Alarm Conditions and System Responses for more detailed
information).Depression of any of the alarm buttons on the Alarm Menu screen will go to the
respective alarm description screen providing a summary of the alarm condition. The
diagnostic information screen provides information on potential causes and troubleshooting of
the alarm by pressing the “DIAGNOSTIC INFORMATION” button.
Each alarm screen contains the activity status for the alarm, a brief description of the reason for
the alarm, Audio Alarm buttons, and numerous screen-switching buttons. The “ENABLE
AUDIO” or “DISABLE AUDIO” buttons will illuminate indicating whether or not it is active.
To silence the audio alarm press the “DISABLE AUDIO” button on either the System Status
screen or any of the alarm description screens. To activate the audio alarm press the
“ENABLE AUDIO” button.
NOTE: Once the “DISABLE AUDIO” button is pressed the audio alarm does not reset
and will remain inactive until the “ENABLE AUDIO” button is pressed.
There are also four screen-switch options on each alarm screen: Main Menu, System Status,
Alarm Menu, and the Diagnostic Information to provide convenient navigation through the
HMI screens. The Diagnostic Information button can be pressed to display additional
troubleshooting information related to the specific alarm condition in order to assist in
troubleshooting the cause for the alarm or to change alarm parameters if available.

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The specific text displayed on the various alarm and diagnostic screens is shown in the
appendix of this manual.
__________________________________________________________
3.2.6 Date and Time Set Up
The date and time can be adjusted on the Main Menu Screen. To adjust/change the date press
the date box and enter the date in the following format: year, month, day (xxxx.xx.xx). To
adjust the time press the time box and enter the time in the following format: hour, minute, sec
(xx.xx.xx). Please note that the hour is based on a military time format, i.e. for 1:00 P.M. enter
13.
Note: An “administrative password”is required in order to change the date or the time.
__________________________________________________________
3.2.7 Alarm History
The Alarm History screen can be accessed by pressing the “ALARM HISTORY” button
located on the Main Menu or the Alarm Menu screen. The Alarm History keeps a log of all
alarm occurrences and records the date, time, and alarm type in the order that they appear. The
log will „roll out‟ older alarm log entries once the maximum allowed number of entries is
achieved. The box located at the left of each entry designates the status of the alarm. A red
box would indicate that an active alarm condition exists, while a blue box would designate that
the alarm condition is no longer active and has been resolved/reset. To scroll up and down the
log entries press the arrows located on the right of the box. To clear the Alarm History log
entries press the “CLEAR ALARM HISTORY” button.
Note: An “administrative password” is required in order to clear the Alarm History log.
__________________________________________________________
3.3 The Remote Control Panel
The optional remote control panel comprises a second touch-screen display identical to that
found on the main unit. All functions available on the main unit are also available on the
remote panel. The remote panel can be disabled during service on the main unit by unplugging
the RS-232 cable from the Omron PLC inside the main electrical enclosure.
The remote control panel can be used for monitoring only by not apprising users of the remote
panel of the “operational password” or “administrative password” thereby permitting access to
all the screens but preventing any changes from being made.

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__________________________________________________________
3.4 Input/Output Functions
Standard on all units is a contact strip in the electrical enclosure, labeled “Customer Interface
Signals”, which provides for inputs and outputs. The outputs consist of four, 4-20 mA signals
for D.I. water process temperature, D.I. water flow rate, D.I. water supply pressure, and steam
temperature. The other type of output is a relay is used to signal that an alarm condition exists
in the unit. The two contacts on the terminal strip will be a “make” under normal conditions
and open under alarm conditions.
On the same contact strip there are also three sets of 24 VDC contacts, which must be a
“make” to enable the unit. Two of these act as the remote shutdown and isolation input from
your equipment or control room - if you open the contacts labeled “Remote Auto Shut Down”,
the unit shuts down or closes the steam inlet valve. If you open the contacts labeled “Remote
Auto Isolation”, the unit closes the inlet and outlet D.I. water valves and a cold bypass line
automatically opens so that there is always a flow of water to the tools, hot or cold. The Auto-
Shutdown will also initiate causing the steam inlet valve to also shut down when the Auto-
Isolation is initiated. If you subsequently make these circuits, the equipment must still be
restarted at the main unit. These contacts can be left jumpered as shipped from the factory, if
you do not desire to use them. The other dry contact is reserved for the remote EMO
(Emergency Off). The unit can be completely shutdown from a remote location if the contact
labeled “Remote EMO” is opened.
There is also a set of dry contacts on the contact strip in the main unit. The contacts will open
depending on the alarm condition present from the unit. One dry contact indicates a Vessel
Flooding alarm while the other dry contact indicates a Global Alarm for any of the following
alarm conditions: D.I. Pressure Relief Venting, Hot Valve Over Temperature, Low Flow Rate,
Low Process Pressure, Low Process Temperature, Process Over Temperature, Shellside Over
Temperature, Steam Pressure Relief Venting, Vessel Flooding, and Water Leak. All but the
Process Low Temperature, Vessel Flooding and Water Leak will shut down the unit when the
alarm condition exists. The Process Low Temperature, Vessel Flooding and Water Weak are
considered non-critical alarms and warn of the alarm condition but does not affect the
operation of the unit.

World Leaders in Ultra-Pure Heating Revision 10
www.heateflex.com 01/17/13
405 E. Santa Clara St.
Arcadia, CA 91006-7218
Tel: [phone] Fax: [phone]
4.0 Safety Systems
This equipment is not designed, nor intended, for use by the general public, or by anyone who
is not fully trained in the operation of steam-powered, industrial equipment with automatic
electrical and pneumatic control systems. Before anyone should attempt to operate or service
the equipment, he or she should read, and have a full understanding, of the equipment and its
operation as described in this manual.
_________________________________________________________
4.1 Overview
The Fluidix D.I. Water Heating System is provided with a full complement of automatic safety
devices, which prevent a serious safety hazard irrespective of settings entered into the touch-
screen user interface. The unit itself is also protected against damage under normal and
abnormal operation as the highest temperature the equipment can “see” is that of the incoming
steam from the customer‟s steam supply. Harm to the equipment resulting from a “runaway”
in the steam supply temperature/pressure is prevented by means of a large, pressure-relief
valve fitted on the exchanger vessel.
Normal precautions should be observed to prevent electrical shock and burns from the hot
surfaces on the equipment. Only voltages of 24 volts or less are supplied to components
outside of the electrical enclosure on the unit and the highest voltage within the electrical
enclosure is 120 VAC. All hot surfaces are protected with insulation excepting the PVDF
piping, which is not hot enough to cause serious burn, but should be insulated with
polyethylene foam insulation after the unit is installed, run through temperature cycling, and all
possible leaks are eliminated.
Although the unit itself is protected from harm from any temperature/pressure up to the set
point of the pressure relief valve regardless of the failure of all other safety systems on the unit,
care should be taken to ensure that equipment downstream of the unit is protected.
The two basic abnormal conditions that can exist on the equipment are over-pressure and over-
temperature for both the shellside steam and the tube side D.I. water. The system is equipped
with a complement of manual and automatic devices that are designed to avoid hazardous
conditions in the event of the failure of the various components, systems, and software used on
the equipment.
The control system is protected with a door interlock switch, which will prevent the unit from
powering up when the control box is open. In addition, if the unit is powered up and the door
is opened the door interlock switch will shut off the unit.
Note: All default parameters can be found in Section 8.3.2: Fluidix PC Factory Default
Parameters and in the Appendix Section 8.6 Parameter Log.