Process Technology Tytan User manual

TYTANTM
Inline Water Heater
Instruction Manual
www.process-technology.com
7010 Lindsay Dr., Mentor, OH 44060 Phone: [phone] Fax: [phone] USA/CN: 800-621-1998

TABLE OF CONTENTS:
RELATED DOCUMENTS ...............................................................................................3
INTRODUCTION.............................................................................................................4
SYSTEM SPECIFICATIONS ..........................................................................................6
MODEL NUMBER.........................................................................................................10
MODEL NUMBER EXPLANATION.........................................................................................................11
FACILITY REQUIREMENTS ........................................................................................13
WATER PLUMBING REQUIREMENTS..................................................................................................14
ELECTRICAL REQUIREMENTS............................................................................................................14
INSTALLATION............................................................................................................15
INSPECTION AND UNCRATING ...........................................................................................................15
POSITIONING AND MOUNTING..................................................................................17
PLUMBING..............................................................................................................................................18
WIRING ...................................................................................................................................................20
RC1, RC2 COMMUNICATIONS (OPTIONAL)........................................................................................22
RC3 COMMUNICATIONS (OPTIONAL).................................................................................................23
RI REMOTE INTERFACE (OPTIONAL) .................................................................................................23
OPERATIONS ..............................................................................................................25
CONTROL PANEL..................................................................................................................................25
TEMPERATURE CONTROLLER E5CN.................................................................................................26
PARAMETER SETTINGS E5CN.........................................................................................................29
CHANGING SET POINT E5CN...........................................................................................................30
HIGH ALARM E5CN............................................................................................................................30
PID TUNING E5CN..............................................................................................................................31
TEMPERATURE CONTROLLER E5CK (RC OPTIONS).......................................................................32
PARAMETER SETTINGS E5CK.........................................................................................................35
CHANGING SET POINT E5CK...........................................................................................................36
HIGH ALARM E5CK............................................................................................................................37
PID TUNING E5CK..............................................................................................................................38
OVER TEMPERATURE CONTROLLER: FDC-L91................................................................................39
SYSTEM START UP...............................................................................................................................42
SYSTEM SHUT DOWN...........................................................................................................................42
MAINTENANCE............................................................................................................43
WARRANTY .................................................................................................................44
M-45-02 TYTAN Manual
Revision - Date: 01 – 11/16/07 2

RELATED DOCUMENTS:
The following documents are to be used in conjunction with this manual:
ANSI/NFPA70 – National Electric Code→, latest edition. To be used to determine
appropriate electrical service, wire sizing, routing and protection.
SEMI S2 – Semiconductor Equipment Safety Guidelines, latest edition. To be used in
conjunction with safe operation, access and decommissioning procedures.
OMRON E5CN INSTRUCTION MANUAL – To be used to access features of the E5CN
temperature controller. (Secure appropriate manual for any optional temperature
controller used in place of the E5CN).
OMRON E5CK INSTRUCTION MANUAL (for units with RC1, RC2 or RC3 option) –
To be used to access features of the E5CK temperature controller.
ANY – State or local building codes that would cover the electrical, mechanical, or
physical installation of electrical heating equipment.
National Electric Code→
NFPA 1999 Copyright
National Fire Protection Association
Quincy, Mass. 02269
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INTRODUCTION:
The following symbols and warning labels appear on the unit and in the instruction
manual. The table below provides an explanation of each one.
DESCRIPTION PICTORAL 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.
PROTECTIVE EARTH (GROUND)
Table 1: TYTAN Warning Labels
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INTRODUCTION (Continued):
The TYTAN water heater is designed for inline heating of de-ionized (DI) water, city
water, reverse-osmosis (RO) water, and filtered seawater. It can perform both as a
recirculating heater or a single-pass heater.
TEMPERATURE PERFORMANCE: The TYTAN water heater is designed to provide a
specified temperature increase at a given flow rate. Table 2 shows the maximum
temperature increase (∆T) that can be achieved for continuous flow conditions at the
specific heater power ratings varying from 24 kW to 144 kW (Higher wattage systems
available upon request). The temperature control system provided with the heater will
modulate the power to the heating columns in order to maintain your specific outlet
temperature setting.
Heater Power (Kilowatts)
Flow Rate 12 18 24 36 48 72 96 120 144
GPM Maximum Theoretical Temperature Rise (°F)
1 80.8 121.2 - - - - - - -
2 40.4 60.6 80.8 121.2 - - - - -
4 20.2 30.3 40.4 60.6 80.8 121.1 - - -
6 13.5 20.2 26.9 40.4 53.8 80.8 107.7 134.6 -
8 10.1 15.1 20.2 30.3 40.4 60.6 80.8 101.0 121.2
10 8.0 12.1 16.1 24.2 32.3 48.4 64.6 80.8 96.9
12 6.7 10.1 13.4 20.2 26.9 40.4 53.8 67.3 80.8
14 5.7 8.6 11.5 17.3 23.0 34.6 46.1 57.7 69.2
16 5.0 7.5 10.1 15.1 20.2 30.3 40.4 50.5 60.6
18 4.5 6.7 8.9 13.4 17.9 26.9 35.9 44.8 53.8
20 4.0 6.0 8.0 12.1 16.1 24.2 32.3 40.4 48.4
22 3.6 5.5 7.3 11.0 14.6 22.0 29.3 36.7 44.0
24 3.3 5.0 6.7 10.1 13.4 20.2 26.9 33.6 40.4
Table 2: Maximum Temperature Rise
SAFETY DEVICES: The TYTAN water heaters include a comprehensive system of
safety controls and devices to insure safe and long-lasting operation. The list of
safeties is included in Table 3: system specifications provided on the following page.
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SYSTEM SPECIFICATIONS:
Product TYTAN inline titanium water heater
Standards UL, cUL standard
CE, SEMI S3 optional (-SC)
Available Wattage Range 12kW – 144kW
Refer to model number label for the wattage of any specific unit
Available Voltages 208V – 600V, 50/60Hz, 3 phase standard (Some voltages available in single phase or with special construction,
consult factory for details)
Cabinet dimensions: Width Depth Height Weight
12kW – 48kW 28.5-in (75 cm) 13.5-in (34 cm) 36-in (91 cm) 145 lbs. (66 kg)
72kW 37.5-in (95 cm) 13.5-in (34 cm) 36-in (91 cm) 230 lbs. (104 kg)
96kW – 144kW 28-in (71 cm) 17-in (43 cm) 63-in (160 cm) 300 lbs. (136 kg)
Wetted surfaces:
Heating elements CP2 titanium standard, (316SS optional [-S option])
Columns and plumbing CP2 titanium standard, (316SS optional [-S option])
PRV Valve PVDF
Operating temperatures:
Process inlet
Process outlet Up to 194°F (90°C), depending upon operating conditions
Temperature accuracy +/- 1°F, depending upon operating conditions
Ambient air temperature 86°F (30°C) maximum
Water pressure range Minimum 10 psi (69 kPa, 0.69 bar)
Maximum 100 psi (690 kPa, 6.9 bar)
Minimum water flow rate:
12kW - 24kW 0.5 gpm (2 lpm)
36kW – 48kW 1.0 gpm (4 lpm)
72 kW 1.5 gpm (6 lpm)
96kW 2.0 gpm (8 lpm)
120kW 2.5 gpm (10 lpm)
144kW 3.0 gpm (12 lpm)
Standard Safety Devices: EMO Pushbutton
Pressure Relief Valve (PRV), connected to inlet manifold
Electrically grounded heating chamber construction
Ground Fault Protection (GFP)
Safety Limit Control (SLC)
Bimetallic heater over temperature sensor(s)
Heater outlet overtemperature alarm
Solid state relay (SSR) overheat bimetallic sensor
Sensor failure detection
Control circuit fuse protection
Table 3: TYTAN Specifications
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SYSTEM SPECIFICATIONS (Continued):
Figure 1: Dimensional Drawing, 12kW – 48kW Units
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SYSTEM SPECIFICATIONS (Continued):
Figure 2: Dimensional Drawing, 72kW Unit
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SYSTEM SPECIFICATIONS (Continued):
Figure 3: Dimensional Drawing, 96kW – 144kW Units
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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 on the front of the unit, near the bottom (see
figures 1-3).
Figure 4: Model/Serial Number Label
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Model Number (Continued):
Model Number Explanation:
Provided below is an example of a typical model number along with an explanation of
each part. This key will help you understand your model number.
Model number example:
TY-072-480-3-SC-RI
cdefg
cHeater Series. The beginning of each model number will designate the product
line. In this case, the TYTAN inline titanium water heater.
dHeater Wattage. The numerical portion of the model number will always begin
with the wattage of your heater. The table provided below identifies the standard
available wattage ratings and the number of heater columns needed to provide
that amount of Wattage.
HEATER
MODEL
NUMBER
HEATER
WATTAGE
(W)
NUMBER
OF HEATER
COLUMNS
WATTAGE
PER
HEATING
COLUMN
(W)
HEATER
MODEL
NUMBER
HEATER
WATTAGE
(W)
NUMBER
OF HEATER
COLUMNS
WATTAGE
PER
HEATING
COLUMN
(W)
012 12,000 1 12,000 072 72,000 3 24,000
018 18,000 1 18,000 096 96,000 4 24,000
024 24,000 1 24,000 120 120,000 5 24,000
036 36,000 2 18,000 144 144,000 6 24,000
048 48,000 2 24,000
Table 4: Wattage and Column Table
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Model Number Explanation (continued):
TY-072-480-3-SC-RI
cdefg
eHeater Voltage. The first character following the heater Wattage will describe
the rated Voltage of the heater.
fHeater Phase. This character will specify if this unit is designed for single
phase (-1) or three phase (-3) power.
gOptions. The remaining characters will specify any options included in this
system. Many of these options can be combined on a single Tytan water heater.
Only a few options are mutually exclusive.
Model Number Option
-CB Include circuit breaker with disconnect switch.
-SC Built to SEMI S3 standards, CE compliant version
(Includes –CB option)
-PLC PLC temperature controller, in place of the standard PID
controller
-RI Remote interface. This will allow the user to start, stop,
reset the unit and monitor the safety circuit remotely.
-RC1 RS485 communications interface with the Omron PID
temperature controller (requires optional E5CK
controller)
-RC2 RS232 communications interface with the Omron PID
temperature controller (requires optional E5CK
controller)
-RC3 4-20mA process output (requires optional E5CK
controller)
-S Wetted surfaces to be passivated 316 stainless steel.
-X Special option, consult factory
-## Special construction design, consult factory for details
Table 5: TYTAN Options
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FACILITY REQUIREMENTS:
Before installing the TYTAN inline water heater confirm the facility requirements listed
below.
Space Requirements:
The TYTAN inline water heater is constructed in a wall-mounted or freestanding
enclosure. The dimensions of this enclosure are based upon the wattage of the unit.
This enclosure includes the common framework for the heating column(s) as well as the
electrical components.
The enclosure requires adequate ventilation. Locate equipment so that ventilation
provisions on the bottom and sides of the enclosure are not obstructed. The ventilation
fan exhausts air through these openings which prevents overheating of the interior. Be
sure to provide adequate clearance for normal operation and maintenance of this
heater.
The standard dimensions of the various models are shown in Table 3 (see appendix for
custom made units). Allow additional space on all sides of the unit for the control
ventilation and service access. (all dimensions are in inches).
Figure 5: Clearance Dimensions for Wall-Mounted Units (72kW Model Shown)
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Facility Requirements (continued):
Water Plumbing Requirements:
The customer supplied inlet and outlet plumbing must be rated to withstand
temperatures up to 275°F (135°C) at pressures up to 100 psi (6.9 Bar).
The wall-mounted TYTAN units are supplied standard with 1-inch MNPT threaded pipe
connections for the plumbing inlet and outlet. These connections extend from the right
side of the unit, with the inlet near the bottom and the outlet near the top (see figures 1-
2). There is also a ½-inch FNPT threaded pipe connection for the PRV valve on the
right side of the enclosure which must be plumbed to a non-pressurized drain. Special
plumbing connections are available as an option. Refer to your specific unit for any
special connections.
The free-standing TYTAN units are supplied standard with 2-inch MNPT threaded pipe
connections for the plumbing inlet and outlet. These connections extend from the back
of the unit, with the inlet near the bottom and the outlet near the top (see figure 3).
There is also a ½-inch FNPT threaded pipe connection for the PRV valve on the back of
the enclosure, which must be plumbed to a non-pressurized drain. Special plumbing
connections are available as an option. Refer to your specific unit for any special
connections.
Do not reverse the plumbing connections of
this unit. Failure to observe the correct
plumbing orientation will result in high-
temperature conditions and heater failure.
Electrical Requirements:
NOTE: Ensure electrical power fusing and disconnects meet local jurisdictional
requirements. Fuse ratings noted in this document are for reference only.
Ensure external electrical components comply with local requirements before
operating this unit.
Reference the model/ serial number label to identify the electrical power requirements of
this unit (see figure 4). Verify that the incoming electrical service is rated and fused for
the required amperage draw.
Do not exceed the rated voltage. Irreparable
damage to the heating column or control
circuitry may result.
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INSTALLATION:
NOTE: The mounting and installation of this unit should only be performed by
qualified personnel.
Inspection and Uncrating:
The wall-mounted TYTAN units are shipped in a horizontal position. The free-standing
TYTAN units are shipped in a vertical position.
Due to the weight of the unit, DO NOT
ATTEMPT to move or lift the unit without the
appropriate material handling equipment.
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. If the shock
sensor on the outside of the crate is missing, there is also a shock sensor located on
the inside of the crate.
Figure 6: Shockwatch Sensor
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INSTALLATION (Continued):
Uncrating the wall-mounted units:
3) Remove the top of the crate.
4) Remove any protective packaging material and any other materials that may have
been packed in the crate with the enclosure.
5) Remove any braces used to hold the unit in place during shipping.
6) Using a hoist or other suitable lifting device, lift the unit from the mounting holes on
the side flanges and remove from the crate. Do NOT lift the unit by holding the
plumbing connections or (if present) the disconnect handle.
Uncrating the free-standing units:
3) Remove the front of the crate.
4) Remove any protective packaging material and any other materials that may have
been packed in the crate with the enclosure.
5) Remove any braces used to hold the unit in place during shipping.
6) Using a hoist or other suitable lifting device, lift the unit from underneath and remove
from the crate. Do NOT lift the unit by holding the plumbing connections or (if
present) the disconnect handle.
Do not tip the unit beyond 10° from vertical.
Serious personal injury or equipment damage
may result.
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INSTALLATION (Continued):
Positioning and Mounting:
Wall-mounted units:
The wall-mounted TYTAN units must be anchored to a support structure that can
support at least 275-pounds (125 kg). We recommend that the mounting bolts are no
smaller than a 3/8-16 thread.
We recommend that the unit is mounted such that the temperature controller is no more
than 78-inches (2 meters) above the floor level (see figure 5).
Free-standing units:
Move the unit into position by lifting the unit from underneath using a fork truck or other
suitable handling equipment. Position the equipment to avoid damaging the cooling
fans located on the bottom of the unit.
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.
Place the unit on a hard, level surface. Ensure the unit is secured so as not to roll as
the casters are unlocked. Once the unit is in position, lock the four castors.
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.
M-45-02 TYTAN Manual
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INSTALLATION (Continued):
Plumbing:
The plumbing installation of this unit should only be performed by qualified technicians.
Verify that the water supply is shut off, and any
necessary lockout/tagout devices are properly
installed.
The customer supplied inlet and outlet plumbing must be rated for temperatures up to
275°F (135°C) at pressures up to 100 psi (6.9 Bar).
On all TYTAN units, the lower plumbing connection will always be the inlet, and the
upper plumbing connections will always by the outlet. The inlet plumbing to the unit
must include the means to drain the unit, which may be necessary in the case of
replacing the heating column or other parts.
Do not reverse the plumbing connections of
this unit. Failure to observe the correct
plumbing orientation will result in high-
temperature conditions and heater failure.
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INSTALLATION (Continued):
Plumbing (Continued):
When tightening all connections on this unit, be sure to support the TYTAN heater
connection to prevent excessive torque or strain from damaging the internal plumbing of
the unit.
Figure 7: Tytan Heater Connection Support
Failure to properly support the TYTAN
plumbing connections during tightening will
result in equipment damage and internal water
leaks. Such damage is not covered under the
product warranty.
Inlet/Outlet Plumbing Connections:
1) Remove the protective plastic caps from inlet and outlet plumbing.
2) Test fit the piping to insure proper length.
3) Support the TYTAN pipe fittings to avoid any damage during tightening.
4) Tighten the connections as required. Take care not to over-tighten.
5) Establish water flow through the unit. Inspect the plumbing for leaks.
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INSTALLATION (Continued):
Plumbing (Continued):
PRV Plumbing Connection:
1) Test fit the drain pipe to insure proper length. The PRV must be connected to a non-
pressurized drain.
2) Support the TYTAN PRV fitting to avoid any damage during tightening.
3) Tighten the connection as required. Take care not to over-tighten.
Wiring:
The wiring of this unit should only be performed by qualified technicians.
Verify that the electrical power supply is shut
off, and any necessary lockout/tagout devices
are properly installed.
Power Connections:
TYTAN units are designed to operate on 4 wire electrical power supplies (3 power
wires, 1 ground wire). All electrical connections should conform to local electrical codes
and/or NFPA 70/79.
There is no pilot hole for incoming power supply conduit. This hole will have to be cut in
the top of the enclosure during installation.
Figure 8: Recommended location for power supply conduit (72kW unit shown)
1) Check the model/serial number on the front of the unit for power requirements.
Do not exceed the rated voltage. Irreparable
damage to the heating column or control
circuitry may result.
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