Process Technology LUFRAN User manual

LUFRANTM
Fluoropolymer Inline Water Heater
www.processtechnology.com
7010 Lindsay Dr., Mentor, OH 44060 Phone: [phone] Fax: [phone] USA/CN: 800-621-1998

M-43-01 Lufran Single Outlet Manual
Revision - Date: 08 – 04/06/15
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TABLE OF CONTENTS:
INTRODUCTION..........................................................................................4
SYSTEM SPECIFICATIONS.......................................................................8
MODEL NUMBER .....................................................................................10
FACILITY REQUIREMENTS.....................................................................14
SPACE REQUIREMENTS ................................................................................................. 14
WATER PLUMBING REQUIREMENTS ................................................................................ 15
ELECTRICAL REQUIREMENTS ......................................................................................... 15
PURGE GAS REQUIREMENTS ......................................................................................... 15
INSTALLATION.........................................................................................16
INSPECTION AND UNCRATING......................................................................................... 16
POSITIONING THE UNIT.................................................................................................. 19
PLUMBING .................................................................................................................... 21
WIRING ........................................................................................................................ 27
OPERATION..............................................................................................30
TOUCHSCREEN DISPLAY................................................................................................ 32
TOUCHSCREEN MENU OVERVIEW .......................................................35
OPERATIONS MENU ...................................................................................................... 36
SYSTEM SETUP MENU................................................................................................... 37
SYSTEM PARAMETERS MENU ........................................................................................ 38
HEATER CALIBRATION MENU ......................................................................................... 40
REMOTE S. P. CALIBRATION MENU ................................................................................ 41
DATALOG MENU ........................................................................................................... 42
FACTORY DEFAULT MENU ............................................................................................. 43
SYSTEM SERVICE MENU................................................................................................ 44
CONTROL ACCESS MENU .............................................................................................. 45
ALARMS MENU ............................................................................................................. 48
ALARM HISTORY MENU ................................................................................................. 49
STARTUP PROCEDURE..........................................................................50
SHUTDOWN..............................................................................................53
DRAINING THE UNIT ...................................................................................................... 54
ALARM CONDITIONS...............................................................................55
REMOTE INTERFACE..............................................................................58
REMOTE TOUCH-SCREEN INTERFACE (-ROI OPTION).......................61

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OPTIONAL COMMUNICATIONS..............................................................63
ETHERNET COMMUNICATIONS (-C1 OPTION)................................................................... 63
DEVICENET COMMUNICATIONS (-C2 OPTION) ................................................................. 64
INTEGER POINTS........................................................................................................... 65
MAINTENANCE.........................................................................................67
SPARE PARTS..........................................................................................97
CLEANING ................................................................................................99
TROUBLESHOOTING.............................................................................100
WARRANTY............................................................................................103
APPENDIX I.................................................................................................1

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INTRODUCTION:
The LufranTM fluoropolymer inline water heater is an ultrapure heater designed to heat
DI water with very stringent cleanliness requirements. All wetted surfaces in this unit
are fluoropolymer and PVDF material. There are no metallic wetted surfaces. The
cleanliness of these units has been confirmed by independent third party testing. The
cleanliness report is available upon request.
The Lufran fluoropolymer inline water heaters are available in wattages from 24kW to
288kW. These units consist of one or more heating columns combined with a control
system and all necessary power distribution circuitry in a freestanding enclosure. The
table on page 10 shows the various wattages with the corresponding number of heating
columns. The photo on the cover shows a typical unit with two heating columns.
These units are CE, ETL and Semi S2/S3 compliant.
This system features the patented DACTM control system operating from a PLC with a
touch-screen operator interface. The DAC control system provides superior temperature
control and faster response to changes in conditions versus a typical PID temperature
control system.
Figure 1: DAC Performance Graph

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INTRODUCTION (Continued):
While the DAC control system is capable of providing an outlet temperature within 0.3°C
of the desired PROCESS SETPOINT, the maximum possible temperature rise through
the heater is dependant upon the wattage of the unit and the water flow rate through the
unit. The following table illustrates the maximum temperature rise of various models
based upon the water flow rate through the unit.
Heater Power (Kilowatts)
Flow Rate 24 36 52 65 72 105 130 144 210 260 288
L/min Maximum Theoretical Temperature Rise (°C)
5 68.6 - - - - - - - - - -
10 34.3 51.4 74.3 - - - - - - - -
15 22.9 34.3 49.5 61.9 68.6 - - - - - -
20 17.1 25.7 37.1 46.4 51.4 75.0 - - - - -
25 13.7 20.6 29.7 37.1 41.1 60.0 74.3 82.3 - - -
30 11.4 17.1 24.8 31.0 34.3 50.0 61.9 68.6 - - -
35 9.8 14.7 21.2 26.5 29.4 42.9 53.1 58.8 85.7 - -
40 8.6 12.9 18.6 23.2 25.7 37.5 46.4 51.4 75.0 - -
45 7.6 11.4 16.5 20.6 22.9 33.3 41.3 45.7 66.7 82.5 -
50 6.9 10.3 14.9 18.6 20.6 30.0 37.1 41.1 60.0 74.3 82.3
55 6.2 9.4 13.5 16.9 18.7 27.3 33.8 37.4 54.5 67.5 74.8
60 5.7 8.6 12.4 15.5 17.1 25.0 31.0 34.3 50.0 61.9 68.6
65 5.3 7.9 11.4 14.3 15.8 23.1 28.6 31.6 46.2 57.1 63.3
70 4.9 7.3 10.6 13.3 14.7 21.4 26.5 29.4 42.9 53.1 58.8
75 4.6 6.9 9.9 12.4 13.7 20.0 24.8 27.4 40.0 49.5 54.9
80 4.3 6.4 9.3 11.6 12.9 18.8 23.2 25.7 37.5 46.4 51.4
Figure 2: Maximum Temperature Rise Table
The Lufran fluoropolymer inline water heaters include a comprehensive system of safety
controls and devices to insure safe and long-lasting operation. The list of safety devices
includes but is not limited to the following:
EMO pushbutton
Circuit breaker
Ground fault (earth leakage) protection
Pressure relief valve
Liquid level sensors
Leak detector
High process temperature sensors
High element temperature sensors
Purge gas flow switch
Moisture sensors in the purge gas exhaust line
Solid state relay (SSR) fault and overheat detection
Sensor failure (open sensor) detection

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INTRODUCTION (Continued):
The following symbols and warning labels appear on the unit and in the instruction
manual. The table below provides an explanation of each one.
DESCRIPTION PICTORIAL DESCRIPTION
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury. This signal word is to
be limited to the most extreme situations.
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury. It may also be used
to alert against unsafe practices.
DANGER: HAZARDOUS VOLTAGE
ENCLOSED
Voltage or current hazard sufficient to cause
shock, burn or death. Disconnect and lock
out power before servicing.
WARNING: HAZARDOUS VOLTAGE
Contact may cause electric shock or burn.
This unit to be serviced by trained personnel
only.
CAUTION: HOT SURFACE. DO NOT
TOUCH
Heater column may be hot. Allow unit to cool
before servicing.
EIP: Electronic Information Product Pollution
Control Logo.
PROTECTIVE EARTH (GROUND)

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INTRODUCTION (Continued):
24 kW – 144 kW Units 157 kW – 288 kW Units
Figure 3: Warning Label Locations

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SYSTEM SPECIFICATIONS:
Product Lufran fluoropolymer inline water heater
Standards CE, ETL, Semi S2/S3
Available Wattages 24kW – 288kW
Refer to model number label for the wattage of any specific unit
Available Voltages
380V – 600V, 50/60Hz, 3 phase only
(Lower voltages available with special construction, consult factory for
details)
Cabinet dimensions and
unit weight: Width Depth Height Weight
24kW – 72kW 508mm (20-in) 769mm (30.25-in) 2123mm
(83.57-in)
270 kg
(595 lbs)
105kW – 144kW
(Including 72kW, 208V unit) 712mm (28-in) 769mm (30.25-in) 2123mm
(83.57-in)
341 kg
(750 lbs)
157kW – 288kW 1220mm (48-in) 769mm (30.25-in) 2123mm
(83.57-in)
682 kg
(1500 lbs)
Wetted surfaces:
Heating elements PTFE fluoropolymer
Columns and plumbing PVDF
o-rings Chemraz®
Operating temperatures:
Process inlet 50°C maximum
Process outlet Up to 95°C, depending upon operating conditions
Temperature accuracy +/- 0.3°C, depending upon operating conditions
Ambient air temperature 30°C maximum
Water flow rate range 1 l/min (0.25 gpm) to 200 l/min (50 gpm)
Water pressure range Minimum 69 kPa (0.69 bar, 10 psi)
Maximum 690 kPa (6.9 bar, 100 psi)
Purge gas flow rate
required (minimum):
24kW – 72kW 141 l/hr (5 scfh)
105kW – 144kW
(and 72kW, 208V unit) 282 l/hr (10 scfh)
210kW – 288kW 564 l/hr (20 scfh)
Purge gas pressure range Minimum 175 kPa (1.75 bar, 25 psi)
Maximum 690 kPa (6.9 bar, 100 psi)

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Chinese RoHS Compliance Table

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MODEL NUMBER:
Process Technology model numbers are designed to offer some description of the
heater construction, including features and options. The model number can be found on
the model/serial number label located directly above the operator interface screen.
Refer to figure 17 (page 31) to see the location of this label.
Figure 4: Model/Serial Number Label

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Model Number Explanation:
Provided below is an example of a typical model number along with an explanation of
each part. This key will help you understand your model number.
Model number example:
130-6UU6-C2-RI

Heater Wattage. The model number will always begin with the wattage of your
heater. The table provided below identifies the standard available wattage
ratings and the number of heater columns needed to provide that amount of
Wattage.
Heater
Model
Number
Heater
Wattage
(W)
Number
of Heater
Columns
Wattage
per
Heater
Column
(W)
Heater
Model
Number
Heater
Wattage
(W)
Number
of Heater
Columns
Wattage
per
Heater
Column
(W)
024 24,000 1 24,000 130 130,000 2 65,000
036 36,000 1 36,000 144 144,000 2 72,000
052 52,500 1 52,500 157 157,500 3 52,500
065 65,000 1 65,000 195 195,000 3 65,000
072 72,000 1 72,000 210 210,000 4 52,500
072
(208V) 72,000 2 36,000
260 260,000 4 65,000
105 105,000 2 52,500 288 288,000 4 72,000

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Model Number Explanation (continued):
130-6UU6-C2-RI

Heater Voltage. The first character following the heater Wattage will describe
the rated Voltage of the heater. Please note that all heaters are rated for Three-
Phase power.
Heater
Model
Number
Rated
Voltage
(V)
Heater
Model
Number
Rated
Voltage
(V)
1 208 6 480
2 240 7 440
3 380 8 575
4 400 9 220
5 415 10 200
Heater Inlet Plumbing Connection.
Heater Outlet Plumbing Connection.
The heater inlet and outlet plumbing connections are usually the same. However, it is
possible to have different plumbing connections for the inlet and outlet. The characters
to describe the plumbing connections have the same designation for both the inlet and
outlet connections. Please refer to the table below to see the specific plumbing
connections provided with the heater:
Heater Model
Number Plumbing Connection Type Plumbing Connection Size: mm (in)
A Flared Tube Fitting 13mm (1/2-inch)
B Flared Tube Fitting 19mm (3/4-inch)
C Flared Tube Fitting 25mm (1-inch)
D Union manifold Connector 32mm (1 ¼-inch)
E Flange 19mm (3/4-inch)
F NPT Pipe Threads, Female 13mm (1/2-inch)
G NPT Pipe Threads, Female 19mm (3/4-inch)
H NPT Pipe Threads, Female 25mm (1-inch)
I NPT Pipe Threads, Male 13mm (1/2-inch)
J NPT Pipe Threads, Male 19mm (3/4-inch)
K
NPT Pipe Threads, Male 25mm (1-inch)
L Butt Fusion Union 25mm (1-inch)
M BCF Union 32mm (1 ¼-inch)
N Socket Fusion Union 32mm (1 ¼-inch)
P Pillar Tube Fitting 13mm (1/2-inch)
Q Pillar Tube Fitting 19mm (3/4-inch)
R Pillar Tube Fitting 25mm (1-inch)
U Socket Fusion Union (Standard) 25mm (1-inch)
X Super 300 Pillar 25mm (1-inch)

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Model Number Explanation (continued):
130-6UU6-C2-RI

Flow Meter Device. The flow meter device is part of the DAC temperature
control system. The flow meter is selected based upon total wattage of the
heater and operating flow rate range. This device does not require routine
maintenance or re-calibration.
Heater Model
Number Flow Monitor Device Device Brand Connection Size Process Technology Part Number
0-4 Not Used
5 Ultrasonic Thornton 13mm (1/2-inch) 8136
6 Ultrasonic Thornton 19mm (3/4-inch) 8137
7 Ultrasonic Honda 13mm (1/2-inch) 9238
8 Ultrasonic Honda 19mm (3/4-inch) 09-6820
9 Ultrasonic Thronton 25mm (1-inch) 9964
Options. There are several options available with the Lufran fluoropolymer inline
water heater. Some of these options are described in greater detail in the
OPERATION section of this manual. More than one option may be included in
an individual Lufran heater. Please refer to the table below for a brief listing of the
available options.
Heater
Model
Number
Refer to Page # for
a more detailed
explanation
Description
C1 Ethernet communications
C2 Device net communications
C3 RS232 communications
C4 RS485 communications
C5 Modbus communications
C# N/A Additional communications option. Contact the Process
Technology technical service department for assistance.
CS N/A Color touch-screen interface
RI Expanded remote interface
ROI N/A Remote touch-screen interface.
R# N/A Additional remote interface option. Contact the Process
Technology technical service department for assistance.
RM Thornton resistivity monitor
S4 N/A Stainless steel cabinet
## N/A Customer specific design/construction (Which may or may
not include some of the above options)

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FACILITY REQUIREMENTS:
Before installing the Lufran fluoropolymer inline water heater confirm the facility
requirements listed below.
Space Requirements:
The Lufran fluoropolymer inline water heater is constructed in a freestanding enclosure.
This cabinet includes the common framework for the heating column(s) as well as the
electrical components. No additional support is required.
The dimensions of the specific model are based upon the unit wattage. The cabinet
assembly requires ventilation. Locate equipment so that ventilation fans on the top and
bottom of the enclosure and louvers on the sides are not obstructed. The ventilation fan
exhausts through these openings, preventing overheating of the unit. Be sure to provide
adequate clearance for normal operation and maintenance of this heater.
Figure 5: Clearance Dimensions (Single Column 24-72kW Model Shown)
Typical Cabinet Dimensions
Heater Wattage
(kW)
Number of Heating
Columns
Width Depth Height
24-72 1 508mm (20-in) 769mm (30.25-in) 2123mm (83.57-in)
105-144
(including 72kW,
208V unit)
2 712mm (28-in) 769mm (30.25-in) 2123mm (83.57-in)
157-288 3-4 1220mm (48-in) 769mm (30.25-in) 2123mm (83.57-in)

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FACILITY REQUIREMENTS (Continued):
Water Plumbing Requirements:
This unit is typically supplied with a single inlet and outlet water connection located just
inside the rear of the cabinet. The connections are arranged vertically and do not offset
from the horizontal center of the unit. The inlet plumbing should also include a means
to drain the unit for service. There are also connections for the PRV valve and the leak
pan drain. Reference the unit’s model number and the model number key to identify the
specific plumbing connections provided with your unit.
Electrical Requirements:
Reference the unit’s model number and model number key or the Electrical
Specifications Table inside the front door to identify the electrical power requirements of
this unit. In addition, the model number tag on the front of the unit includes the unit’s
Wattage, Voltage, Amperage draw and Phase. Verify that the incoming electrical
service is rated and fused for the required amperage draw.
Do not exceed the rated voltage. Irreparable
damage to the heating column or control
circuitry may result.
NOTE: Ensure electrical power fusing and disconnects meet local
jurisdictional requirements. Fuse ratings noted in this document are for
reference only. Ensure external electrical components comply with local
requirements before operating this unit.
Purge Gas Requirements:
A source of purge gas, nitrogen (N2) or clean dry air (CDA) is required for the heater
element purge system. All Lufran fluoropolymer inline water heaters use 6.4-mm (0.25-
inch) compression fittings as the purge gas inlet and outlet connections.
The purge gas supply must be regulated between 1.75 – 6.9 bar (25 – 100 psig) gas
pressure. Each heating column inside the unit will use approximately 141 l/hr (5 SCFH)
of purge gas.
If the gas pressure is supplied lower than 1.75 bar (25 psi), the control’s safety circuitry
will disable the heater and indicate a safety alarm. If the gas pressure exceeds 6.9 bar
(100 psi) equipment damage will result.
Do not exceed pure gas pressure of 6.9 bar (100
PSI). Irreparable damage to the heater column
may result.

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INSTALLATION:
Note: Before installation, carefully read this entire section. The installation of this unit
must be performed by qualified technicians.
Due to the weight of the unit, DO NOT
ATTEMPT to move or lift the unit without the
appropriate material handling equipment.
Inspection and Uncrating:
The Lufran fluoropolymer inline water heater is shipped in a horizontal position. The
unit must be raised to a vertical orientation before it can be removed from the shipping
crate.
1) Inspect the shipping crate for evidence of damage. If any damage is detected,
contact the carrier immediately.
2) Inspect the shock sensors located on the outside of the crate. The shock sensors
will indicate if the unit experienced rough handling. If the sensors indicate that the
unit has experienced rough handling, contact the carrier immediately.
Figure 6: Shockwatch Sensor
3) Secure crate with adequate straps and carefully lift into a vertical position.

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Inspection and Uncrating (Continued):
4) Remove one side of the crate.
5) Remove any protective packaging material and any other materials that may have
been packed in the crate with the enclosure.
6) Remove any braces used to hold the unit in place during shipping.
7) Using a fork truck or other suitable lifting device, lift the unit from underneath and
remove from the crate.
Do not tip the unit beyond 10° from vertical.
Serious personal injury or equipment damage
may result.
8) Visually inspect the unit itself for damage. If there is evidence of damage, notify
Process Technology and the freight carrier immediately.

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Inspecting Heater Accessories:
The Lufran fluoropolymer inline water heater is shipped with the following standard
heater accessories. These items are cleaned, double-bagged and packaged in a
separate box that is inside the heater’s shipping crate.
1) Interface Cable (1 each):
The standard interface cable is a 15.2 m (50-foot) with a connector plug for the
heater on one end and loose lead wires at the other end. Longer cables may be
specified at the time of order or purchased separately. Please refer to the electrical
prints for your heater (provided with this instruction manual) for an explanation of the
wire numbers and functions.
This cable may be used during installation to integrate this unit with a customer-
supplied control system. If no remote control system is to be used with this unit,
then the cable will not be necessary.
2) Seismic Brackets, Bottom-half (4 each):
The top-half of the seismic brackets are already attached to the underside of the
heater cabinet. The bottom half of each bracket is provided here in the event they
are required for heater installation. Depending upon local standards or requirements
they may or may not be necessary for the installation of this unit.
3) Plumbing O-rings (2 each, for 25mm Union connections only):
These two Chemraz O-rings are needed for the plumbing connections for the 25mm
union connections for the inlet and outlet plumbing connections. These o-rings are
double-bagged for cleanliness. Please refer to the plumbing procedure on page 20.
4) DeviceNet Communications Cable ( -C2 option only) (1 each):
With the –C2 communications option, a 6 m (20 ft) DeviceNet cable is included to
connect the Lufran heater to a DeviceNet network. The cable has the connector
plug for the heater on one end and loose lead wires at the other end. Please refer to
the electrical prints for your heater (provided with this instruction manual) for an
explanation of the wire numbers and functions.
This cable may be used during installation to integrate this unit with a customer-
supplied DeviceNet communications network.

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Positioning the Unit:
1) Once the Lufran fluoropolymer inline water heater has been removed from the crate
and the unit passes the damage inspection, it can be moved to the service location.
Move the unit using either the lifting hooks located on top of the enclosure or by
lifting the unit from underneath using a fork truck or other suitable handling
equipment.
The castors should not be used to move the
unit over long distances or on uneven surfaces.
They are intended to facilitate small
adjustments to the position of the unit at its
place of operation. Move the unit slowly, as
there is no means of slowing or stopping the
unit. Ensure that there are sufficient personnel
to move the unit safely. Failure to follow these
instructions can result in serious personal
injury and/or damage to the unit.
2) The unit was shipped with the leveling feet extended. To utilize the castors the
leveling feet must be retracted.
Figure 7: Leveling Foot Located on Castor
3) Place the unit on a hard, level surface.
4) Ensure the unit is secured so as not to roll as the casters are extended.
5) Leveling is accomplished by adjusting the stem and foot that is concentric with the
caster spindle.
Ensure the unit is on a smooth, level surface
and there are sufficient personnel to hold the
unit in place. As the leveling feet are retracted
and the unit rests on the castors unexpected
movement may result. Failure to properly
secure the unit may result in serious personal
injury and/or damage to equipment.

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Installing Seismic Brackets (optional):
This unit includes four seismic brackets in the event such brackets are a requirement for
the installation of this unit. The top-half of these brackets have already been installed
on the unit.
Figure 8: Seismic Brackets (top-half) Attached to Cabinet
If the heater installation requires that the seismic brackets be used, the bottom-half of
these seismic brackets may be secured to the floor and then fastened to the bracket
halves on the cabinet. The customer can decide whether to install the bottom half of the
brackets to face inward or outward, as shown below.
Bottom facing outward Bottom facing inward
Figure 9: Seismic Bracket Assembled, two possible orientations