Troubleshooting Lufran Water Heaters

Lufran Water Heater

# Condition What to Check Action Required
1 Ground Fault (All Systems) Ground Fault A ground fault has occurred somewhere in the unit. This may be caused by a failed component. The cause of the ground fault must be identified and corrected before the heater is reset.
. Using an ohmmeter, measure each heater's power leads to earth ground and look for a short circuit. If a short to ground is identified within a column, it must be replaced. Consult the factory for the appropriate replacement.
2. Check the flashing sequence of the LED light on the GFCI module. The flashing sequence will indicate whether there is an actual Ground Fault problem. The LED sequence can be verified against a label on the GFCI component. Replace as needed. Consult the factory for the appropriate replacement.
2 Process o/t (Rockwell Automation Systems Only) Process Thermocouple Over-temp The outlet water temperature has risen above the HIGH PROCESS SETPOINT value. This setting is located in the SYSTEM PARAMETERS MENU. This may be caused by two possible problems.
1. A sudden and drastic decrease in flow rate
2. A failed forward SSR.
When the outlet temperature falls below the value of this setting, the unit can be reset.
3 Humidistat (1 thru 4)(Rockwell Automation Systems), Humidity Fault (Automation Direct Systems) Humidistat Alarm (Rockwell Automation , Systems)Humidity Fault (Automation Direct Systems) There is moisture detected in the humidistat connected to the purge gas outlet of this particular heating column indicated by the alarm button located on the Alarm screen of the OIP. This may be caused by a ruptured tube or a leaking seal in the heating column, or a normal heater response following an extended shutdown period. A visual inspection should be done on the column when indicated by the alarm for any external water that may be leaking. In most cases this leak cannot be repaired and the heating column must be replaced. Consult the factory for the appropriate replacement.
If restarting the heater following an extended shutdown period, exhaust the purge gas for 8-hours before attempting to reset the unit.
4 Low Flow (Rockwell Automation Systems) Low Flow Deviation Alarm The flow rate through the unit has dropped below the LOW FLOW SETPOINT. This setting is located in the SYSTEM PARAMETERS menu. This may be caused by shutting off the water supply to the unit. This is not an alarm event that requires a manual reset. Once the flow rate through the heater increases to a level higher than the LOW FLOW SETPOINT, the heater will automatically return to normal operation.
5 Cab Leak (Rockwell Automation Systems), Leak Fault (Automation Direct Systems) Cabinet Leak Alarm (Rockwell Automation Systems), Leak Fault (Automation Direct Systems) The cabinet leak detector has detected a leak inside the cabinet. This may be caused by a leaking plumbing connection or one of the heating columns. Any leaking plumbing fitting should be repaired and the leak pan must be drained before the fault can be reset. A leaking heating column must be replaced. Consult the factory for the appropriate replacement.
6 Inlet t/c (Rockwell Automation Systems) Inlet Thermocouple Alarm (Rockwell Automation Systems) The inlet process temperature sensor has failed (open). The process temperature sensor must be replaced. This may also be caused by a disconnected sensor connection. Verify that the sensor is operating properly by using an ohm meter to verify that the Thermocouple is ion good working condition. If the The thermocouple is working properly it is possible that the PLC input card may be damaged and need replaced. Consult the factory for the appropriate replacement component.
7 Liquid Level(1 thru 4) (Rockwell Automation Systems), Liquid Level Fault (Automation Direct Systems) Liquid Level Alarm Column #(Rockwell Automation Systems), Liquid Level Fault (Automation Direct Systems) Note: For the Rockwell Automation Systems, there is one liquid level sensor at the top of each heating column. On the Automation Direct Systems, there is only one liquid level sensor for every two heating columns. The liquid level sensor at the top of heating column does not detect liquid in the outlet tube of that column. The system is disabled until the liquid level sensor detects liquid in the outlet tube of the heating column. This may be caused by a lack of water to the unit. This safety will prevent catastrophic overheat damage to the heating column. The cause of the liquid level fault must be identified and corrected before the unit can be reset. The sensor can be recalibrated. Please reference the Lufran manual for the proper procedure to calibrate the liquid level sensor. This will be located in the Maintenance section of the manual.
8 N2 Purge (Rockwell Automation Systems), Purge Fault (Automation Direct Systems) N2 Purge Alarm (Rockwell Automation Systems), Purge Fault (Automation Direct Systems) The purge gas flow switch does not detect adequate purge gas flow. The unit has been disabled to prevent heater failure. This may be caused by shutting off the purge gas supply to the unit. When the purge gas pressure is at an acceptable pressure, the unit can be reset.
9 Outlet t/c (Rockwell Automation Systems), Outlet TC Open Circuit (Automation Direct Systems) Outlet Thermocouple Alarm (Rockwell Automation Systems), Process Sensor Disconnected (Automation Direct Systems) The outlet process temperature sensor has failed (open). The process temperature sensor must be replaced. This may also be caused by a disconnected sensor connection. Verify that the sensor is operating properly by using an ohm meter to verify that the Thermocouple is in good working condition. If the The thermocouple is working properly it is possible that the PLC input card may be damaged and need replaced. Consult the factory for the appropriate replacement component.
10 Elem o/t #(1 thru 4) (Rockwell Automation Systems), Element # overtemp (1 thru 4) (Automation Direct Systems) Element Thermocouple Alarm (Rockwell Automation Systems), Element # Overtemp (Automation Direct Systems) The element temperature has risen above the setting of the safety limit control (SLC) module. This may be caused by lack of water flow to the unit, a failed SSR or a failed t/c sensor. This Future Design SLC is redundant to the PLC control system. When the element temperature falls below the setting of the SLC, the unit can be reset.
NOTE: On Rockwell Automation Systems only, this alarm cannot be reset through the PLC. Rather, this alarm must be reset by cycling the main circuit breaker off and then on powering up the unit. Refer to the SHUTDOWN section of this manual for the procedure.
If the element thermocouple is found to be damaged or open then the heater column will need to be replaced. Consult the factory for the appropriate replacement.
11 Element # TC Open Circuit(1-4) (Automation Direct Systems Only) Element # Sensor Disconnected The element over-temperature sensor has failed (open). The sensor must be replaced. This may also be caused by a disconnected sensor connection.
12 PRV (Rockwell Automation Systems), PRV Fault (Automation Direct Systems) Pressure Relief Valve Alarm (Rockwell Automation Systems), Pressure Relief Valve (Automation Direct Systems) The liquid sensor mounted above the pressure relief valve (PRV) discharge tube has detected liquid in the tube. This is caused by high water pressure applied to the unit. This may be caused by inlet water pressure exceeding 6.9 bar (100 psi). When the water pressure drops to an acceptable level and the PRV closes, the unit can be reset.
13 SSR TCO (Rockwell Automation Systems), SSR Fault (Automation Direct Systems) SSR TCO Alarm (Rockwell Automation Systems), SSR Heatsink Fault (Automation Direct Systems) The temperature of the heat sink for one or all of the solid state relays (SSR) has risen above the setting of the thermostat directly located on the heat sink. This may be caused by a malfunctioning fan, high ambient air temperature or inadequate air circulation through the cabinet. The SSR assembly should be replaced. The cause of this over-temp alarm must be identified and corrected before the unit can be reset.
14 Col # MB(1 thru 4) (Rockwell Automation Systems only) Column Monitor Board Alarm One of the SSR monitor boards has detected an open or shorted SSR. This may be caused by a failed SSR or a failed power fuse in the unit. The failed fuse or the failed SSR must be replaced before the unit can be reset. Consult the factory for the appropriate replacement.
15 PLC (Rockwell Automation Systems only) PLC Alarm A problem has occurred with the PLC itself, and the system is unable to operate normally. Inspect the PLC unit itself and correct any open or broken connections. Try cycling main power to clear this fault. If the PLC Fault alarm will not clear, contact PROCESS TECHNOLOGY for assistance.
16 PLC Comm. Fault (Automation Direct Systems Only) Communication Error PLC communications to the ADAM module, TC1 module or SLC modules has been interrupted. Check modules for power or disconnected wiring.
17 PLC Battery Fault (Automation Direct Systems Only) PLC Battery Fault The backup battery for the PLC is measuring low-voltage or has lost it’s charge. The battery must be replaced.
18 Pressure Switch (Rockwell Automation Systems only) Pressure Switch The water supply pressure has dropped below the setting of 10PSI on the pressure switch. The water pressure must increase to a level above 15 PSI in order for the unit to return automatically to normal operation. If proper water is pressure is present it may be a problem with the PLC input card and or the actual pressure switch that is located the inlet plumbing. You will need to verify the proper operation of both. Consult the factory for the appropriate replacement.
19 Col # o/t(1 thru 4) (Rockwell Automation Systems), Col # Overtemp(1-4) (Automation Direct Systems) Column Over-temp The water temperature inside the heating column has risen above the setting of the control system. This may be caused by lack of water flow, a failed SSR or a failed thermocouple sensor. The values of these temperature settings are an internal adjustment that is not accessible by the operator. It may only be adjusted by qualified personnel. When the water temperature falls below the setting of the SLC, the unit can be reset.
NOTE: Rockwell Automation Systems Only: this alarm cannot be reset through the PLC. Rather, this alarm must be reset by shutting down cycling the main circuit breaker off and then on powering up the unit. Refer to the SHUTDOWN of the Lufran manual for the procedure.
20 Column # TC Open Circuit(1-4) Column # Sensor Disconnected One of the column TC sensors has failed (open). The sensor must be replaced. This may also be caused by a disconnected sensor connection.
21 Flow Meter OC Flow Meter Sensor Disconnected The flow meter has suffered a fault and should be replaced.
22 Inlet TC Open Circuit Inlet Sensor Disconnected The inlet temperature sensor has failed (open). The inlet temperature sensor must be replaced. This may also be caused by a disconnected sensor connection.
23 Remote Set-point Open Circuit Remote Input Open Circuit The 4-20mA input signal for the remote set-point is not present. This alarm is disabled when the unit is in LOCAL or MANUAL control modes.