Condair 2552940-D SE Series Installation guide
Important: Read and save these instructions. This guide to be left with equipment. Nortec SE-Series Installation and Operation Manual Includes installation, operation, maintenance, and troubleshooting information for your indoor Nortec SETC B+ and Nortec SEP steam exchange humidifier 2552940-D | 23/11/2018 Thank you for choosing Condair. INSTALLATION DATE (MM/DD/YYYY) MODEL # SERIAL # Proprietary Notice This document and the information disclosed herein are proprietary data of Condair LTD. Neither this document nor the information contained herein shall be reproduced used, or disclosed to others without the written authorization of Condair LTD., except to the extent required for installation or maintenance of recipient’s equipment. All references to the Condair name should be taken as referring to Condair LTD. Liability Notice Condair does not accept any liability for installations of humidity equipment installed by unqualified personnel or the use of parts/components/equipment that are not authorized or approved by Condair. Copyright Notice Copyright 2018, Condair LTD. All rights reserved. Contents 1 Introduction 43 Operation 2 Receiving and Unpacking 44 Nortec SETC LED Status Lights 3 Humidifier Components 44 Nortec SEP LED Status Lights 5 Nortec SETC/P Models 45 How the Humidifier Works 6 Options and Accessories 49 Nortec SETC Humidifier Configuration 60 Nortec SEP Humidifier Configuration 9 Installation 63 Maintenance and Servicing 10 Typical Humidifier Installation 11 Location 12 Mounting 64 Required Maintenance 14 Plumbing 65 Maintenance Schedule 15 Boiler Steam and Boiler Condensate Return 69 Maintenance Shutdown and Extended Shutdown 17 Steam Lines and Condensate Returns 70 Maintenance Checklist 71 Troubleshooting 22 Electrical 73 General Troubleshooting 23 External Controls 76 Nortec SETC Warnings and Faults 32 Options and Accessories 82 SEP Faults 83 Wiring Diagrams 33 Start Up 34 Installation Check 35 Nortec SETC User Interface 36 Start Up Procedure 37 Status Screens 39 Digital Controls 41 Start Up Checklists 85 Spare Parts 96 Warranty Introduction CAUTION: Servicing Disconnect main power before any servicing. Shut off pressurized steam supply and ensure steam pressure is safely relieved before any servicing of pressurized steam components. The electrical compartment contains high voltage components and wiring. Access should be limited to authorized personnel only. During and following operation of the humidifier, the steam and components in contact with the steam such as the tank, blower pack, steam lines, steam distributors, and condensate lines can become hot and can burn if touched. Condair does not accept any liability for installations of humidity equipment installed by unqualified personnel or the use of parts/components/equipment that are not authorized or approved by Condair. CAUTION: Electrical All electrical work should be done according to local electrical code. Electrical connection to be performed by a licensed electrician. CAUTION: Plumbing / Steam Lines Plumbing to be performed by a licensed plumber. Pressurized steam line installation to be performed by a qualified installer. Drain water from humidifier can be very hot. Do not drain to public sink. All plumbing and pressurized steam supply line work should be done according to local plumbing code. CAUTION: Installation Do not mount on hot surfaces Do not mount in area where freezing can occur Do not mount on vibrating surface The Nortec SETC/P produces steam at atmospheric pressure no devices which could block steam output should be connected to the steam outlet. Steam output lines must be installed so that no restriction can produce backpressure in the humidifier. Regardless of selecting On/Off or modulating control method, Condair humidifiers must have a closed circuit across its On/Off security loop control terminal to operate. Condair highly recommends the use of a high limit humidistat and an air proving switch in series for this function. Unit damage caused by water quality outside of the specified ranges is not covered under warranty. 1 | Introduction Receiving and Unpacking 1 Check packing slip to ensure ALL material has been delivered. 2 All material shortages are to be reported to Condair within 48 hours from receipt of goods. Condair assumes no responsibility for any material shortages beyond this period. Note: A steam valve, actuator, and wye strainer are shipped along with the SETC/P humidifier but in separate small boxes. 3 Inspect shipment for damage and note damages on shipping waybill accordingly. 4 After unpacking, inspect equipment for damage and if damage is found, notify the shipper promptly. 5 All Condair products are shipped on an FOB factory basis. Any and all damage, breakage or loss claims are to be made directly to the shipping company. Before Installation 1 Ensure that available voltage and phase corresponds with humidifier voltage and phase as indicated on humidifier’s specification label. 2 If steam supply is from a Medium or High Pressure boiler ensure supply steam line includes a relief valve to prevent supply pressure from exceeding 15 psig. 3 Ensure means for returning boiler steam condensate to boiler at atmospheric pressure are available. 4 Ensure sufficient clearances will be available as described in Location on page 11. 5 Ensure steam lines can be routed to distributor SAM-e manifold or blower pack as described in Steam Lines and Condensate Returns on page 17. 6 Report any discrepancy immediately to the site engineer. Figure 1: Specification Label Location Introduction | 2 Humidifier Components Float Chamber Display and Keypad Control Terminal Strip Tank On/Off Switch Clean Out Port Remote Relay Board Heat Exchanger Gasket Driver Board High Voltage Terminal Block Base Manual Drain Switch Total Controller Transformer Vacuum Break Steam Outlet Heat Exchangers Fill Box Steam Inlet (Faceplate) (Boiler Steam) Actuator Wye Strainer CV Valve Fill Valve Drain Outlet P Trap Condensate Drain (Boiler Steam) Auxiliary Drain Outlet Drain Pump Steam Trap Mixing Box Figure 2: Nortec SETC Humidifier Components 3 | Introduction Description of Components Table 1: Humidifier Components Component Actuator Auxiliary Drain Outlet Base Clean Out Port Condensate Drain Control Terminal Strip CV Valve Display and Keypad Drain Outlet Drain Pump Driver Board Fill Box Fill Valve Float Chamber Gasket Heat Exchanger(s) High Voltage Terminal Block Manual Drain Switch Mixing Box On/Off Switch P Trap Remote Relay Board Steam Inlet Steam Outlet Steam Trap Tank Total Controller Transformer Vacuum Break Wye Strainer Function of Component Opens and closes the CV valve in proportion to demand for steam. Drains water from tank in case of pump failure. Provides an integrated floor support for the humidifier. Provides access to clean scale from the tank and heat exchanger. Drains condensate formed from boiler steam in the heat exchanger(s) Terminal strip for connecting external controls and blower pack to humidifier. Controls the amount of steam allowed into the heat exchanger which in turn controls the output of the humidifier. User interface for configuring the humidifier. Drain port used for draining water from the humidifier tank. Drains water from humidifier. Provides input and output connections to humidifier components. Provides an air gap for backflow prevention. Controls flow of water into humidifier. Measures water level in the humidifier tank. Seals heat exchanger face plate and clean out port cover to tank. Exchanges energy from boiler steam to the tank water to produce steam for humidification. The faceplate mounts the heat exchanger to the tank. Primary power connection from remote disconnect to humidifier. Manually activates pump to drain water from the tank. Blends hot tank water with cool fill water to provide drain water cooling. Turns power On/Off to humidifier controller. Note: Turn off humidifier disconnect to shut off primary power to the humidifier. Prevents steam from flowing out the drain outlet. Provides a terminal strip to dry contacts which open/close to indicate the humidifier is on, humidifying, needs service, or is in a fault condition. Connection for boiler steam, it is connected to the heat exchangers. Connect to steam line with steam hose. Drains condensate from the heat exchanger without letting boiler steam escape to drain. Holds the water used to generate clean steam for humidification. Controls all functions of the humidifier’s operation and provides user interface for configuration of the humidifier. Steps primary voltage down to 24 VAC for the controller and internal components such as the fill valve and drain valve. Prevents a siphon from occurring when the drain pump is stopped. Protects CV valve and other system components from dirt and rust in the piping system. Introduction | 4 Nortec SETC/P Models The Nortec SETC with its Total Controller and state-of-the-art features and options is the most advanced steam exchange humidifier available. The base model Nortec SEP provides steady and reliable humidification using the same proven heat exchanger technology as the Nortec SETC. The Nortec SETC/P is available in capacities ranging from 50 lb/hr (23 kg/hr) to 1050 lb/hr (475 kg/hr). Nortec SETC/P humidifiers are packaged in five different cabinets depending on their capacity. Figure 3: Nortec SETC/P Models shows the configuration and relative size of the five different cabinets. Table 3 provides specifications for the Nortec SETC/P product line. SETC50 Note: SE 750 has 2 steam outlets SE 525-750 SE 100-175 SE 1050 SE 250-375 Figure 3: Nortec SETC/P Models The Nortec SE 50, 100, 175, 250, and 375 all have a single heat exchanger. The Nortec SE 525 and 750 have two heat exchangers. The Nortec SE 1050 has three heat exchangers. All models have a single pressurized steam inlet and condensate drain with internal manifold connecting separate heat exchangers if they are present. 5 | Introduction Outdoor Model (Nortec SETC Only) The outdoor model of the Nortec SETC provides a weatherproof enclosure that allows the Nortec SETC to be installed on rooftops in moderately cool climates. Refer to the Nortec SETC installation manual that is provided with the outdoor model to insure proper installation. Options and Accessories Condair provides a complete line of options and accessories for every humidification application. The following options and accessories are available and may have been delivered with your Nortec SETC/P humidifier. Refer to the installation instructions that came with the accessories for their proper installation and operation. Table 2: Options and Accessories Option / Accessory Used For Freeze Protection Package (Nortec SETC Only) Emptying the tank in case of fault or power failure to prevent freezing. (Factory installed) Floor Stand Supporting the humidifier 27 inches above the floor (height can be reduced by cutting legs of floor stand). (field assembled) Ceiling Mounting Kit (Nortec SE50 Only) Providing a drain pan and support brackets for mounting an Nortec SE50 unit from the ceiling. Steam Distributors Adding steam into air ducts Remote Blower Pack Adding steam into a space remote from the humidifier. SAM-e Steam Distribution Manifold Adding steam into air ducts where short absorption is required. Digital or Analog Control Humidistats Controlling the output of the humidifier based on sensed RH (can be mounted in the space being humidified or in the duct). Digital RH Transducers Communicating RH in a space or duct to the humidifier Digital or Analog High Limit Humidistats Preventing over humidification in a duct by shutting down or throttling down the humidifier when duct RH gets high. Air Proving Switches Insuring humidification only occurs when air is moving in a duct. Condair LINKS 2 (Nortec SETC Only) Connecting the humidifier to a building management interface. hardware allows control of the humidifier via BACnet, Lonworks, Johnson N2, or Modbus. Condair OnLine (Nortec SETC Only) User and factory monitoring and configuration of the humidifier via the internet. Introduction | 6 Table 3: Nortec SETC/P Specifications Nortec Model SETC Part No SEP Part No. CV Valve CV Valve, Steam Inlet, Wye Port (NPT) Condensate Port (NPT) 50 2552765 2520383 2.8 1/2 3/4 100 175 250 375 525 750 2550073 2550074 2550075 2550076 2550077 2550078 2525132 2525133 2525134 2525135 2553312 2553313 5.5 10 12 20 28 40 3/4 1 1 1 1/4 1 1/2 2 3/4 3/4 3/4 3/4 1 1 1050 2550080 2525139 77 2, 2 1/2, 2 1/2 1 1/4 Net/Full Weight lb (kg) Required fill line flow gal (l) /min 125/180 (57/82) 267/423 (121/192) 355/599 (161/272) 529/992 (240/450) 703/1384 (318/628) Required Drain capacity gal (l) /min 2.6 (10) 5.2 (20) 4.5 (17) 8 (29) Electrical Voltage 110-120 Phase 1 Amps 1.25 A Power 0.15 KW Max Disconnect 15 A Table 4: Nortec SETC/P Capacities and Water Consumption Nortec Model 50 100 175 250 375 525 750 1050 *Supply Steam Pressure (psig) 5 10 15 5 10 15 5 10 15 5 10 15 5 10 15 5 10 15 5 10 15 5 10 15 *Max Output lb/hr (kg/hr) 13 32 50 26 63 100 46 110 175 65 158 250 98 236 375 137 331 525 195 473 750 273 662 1050 (6) (14) (23) (12) (29) (45) (21) (50) (80) (30) (72) (114) (44) (107) (170) (62) (150) (239) (89) (215) (341) (124) (301) (477) Approximate Boiler Steam Consumption lb/hr (kg/hr) 15 (7) 36 58 30 72 115 52 127 201 75 181 288 112 272 431 157 380 604 224 543 863 314 761 1208 (16) (26) (14) (33) (52) (24) (58) (91) (34) (82) (131) (51) (123) (196) (71) (173) (274) (102) (247) (392) (143) (346) (549) **Water Consumption gal (l) /hr 2.3 5.7 9.0 4.7 11.3 18.0 8.2 19.8 31.5 11.7 28.3 44.9 17.5 42.5 67.4 24.5 59.5 94.4 35.1 84.9 134.8 49.1 118.9 188.7 * Supply steam pressure must be present at the CV valve to achieve rated output ** At maximum output , 25% blow down, and with drain water cooling activated 9 | Installation (9) (21) (34) (18) (43) (68) (31) (75) (119) (44) (107) (170) (66) (161) (255) (93) (225) (357) (133) (321) (510) (186) (450) (714) **Drain Volume gal (l) /hr 0.8 1.9 3.0 1.6 3.8 6.0 2.7 6.6 10.5 3.9 9.4 15.0 5.8 14.2 22.5 8.2 19.8 31.5 11.7 28.3 44.9 16.4 39.6 62.9 (3) (7) (11) (6) (14) (23) (10) (25) (40) (15) (36) (57) (22) (54) (85) (31) (75) (119) (44) (107) (170) (62) (150) (238) Nortec Nortec Nortec Installation | 8 Installation 10 11 12 13 14 15 Typical Humidifier Installation Location Mounting on Optional Stand Ceiling Mounting (Nortec SE50 Only) Plumbing Boiler Steam and Boiler Condensate Return 17 Steam Lines and Condensate Returns 22 Electrical 23 External Controls 23 Control Wiring 23 Control Location 24 On/Off Control Wiring 25 Modulating Control Wiring 27 Transducer Control Wiring 28 29 30 31 32 32 9 | Installation Optional Outdoor Temperature Reset CV Valve Actuator Wiring Remote Relay Board Wiring Staged Modulation Wiring (Nortec SETC Only) Options and Accessories Remote Blower Pack Typical Humidifier Installation SAM-e Distribution Manifold 1ft (30 cm) Location Mounting Pg 11 2 in. (5 cm) min. 36 in. (91 cm) Min. Top Clearance (0 in SE 50) Steam Distribution Pg 17 30 in. (76 cm) 30 in. (76 cm) 30 in. (76 cm) Min. SE 1050 Min. Side Clearance Min. Front Clearance Pressurized steam supply 1 ft (30 cm) min. Water supply 30-80 psig Air gap Plumbing Pg 14 Boiler Steam Pg 15 Tank drain 1- 24 VAC 2- On/Off Loop 3- Ctrl Ground 4- Control Signal 5- Limit Signal 6- 5 VDC 7- Ground 8- Tank Blow Down 9- Ground 10- Actuator 11- Actuator 12- 0-10 VDC Out On/Off Controls Controls Pg 23 E X T Dedicated Circuit Breaker or Disconnect L1 N Modulation Controls Ground Condensate return to boiler SETC/P EXT S E T C / P Electrical Pg 22 Figure 5: Typical Humidifier Installation Installation | 10 Location The Nortec SE series humidifiers are designed to be either floor mounted or stand mounted (stand optional). Nortec SE 50 models can also be ceiling mounted with the optional ceiling installation kit, part number 2520345. Install only in areas with ambient temperature 41-104 °F (5 – 40 °C) relative humidity 5 95% (non condensing). Ensure mounting surface is strong enough to support the full weight of the humidifier and accessories (see Table 3: Nortec SETC/P Specifications). Install in location where electrical power, boiler steam, and drain can be connected to the humidifier. When possible install below the steam distributor. If mounted above the steam distributor take care to provide proper steam line routing and proper condensate traps. DO NOT locate the humidifier any further then absolutely necessary from the steam distributor location as net output will be reduced as a result of heat loss through the steam line. Condensate drain is located close to the bottom of the humidifier. Locate the unit so that condensate line slopes down to boiler or use pump (by others) to lift to boiler. Use stand if necessary. Avoid mounting humidifier on combustible surfaces including (but not limited to) carpet, tile, or certain insulating materials. Clearance dimensions shown are for reference only and are the minimum required for maintenance of the humidifier. Consult local and national codes before final location and installation. Condair does not accept responsibility for installation code violations. Note:. Condensate drain line must be sloped downward to boiler condensate return. Use pump (by others) or stand (optional) if necessary. As Close as Possible to Steam Distributor 36 in. (91 cm) Min. Top Clearance (0 in. for SE50 only) 5-95% Mount Humidifier Level 30 in. (76 cm) 30 in. (76 cm) 30 in. (76 cm) Min. SE 1050 only Min. Side Clearance Min. Front Clearance Condensate drain line must be sloped down, do not use to lift condensate Figure 6: Installation Location / Clearance 11 | Installation Mounting on Optional Stand The optional Nortec SE floor stand positions the Nortec SE humidifier at a convenient working height and provides additional clearances for sloping drains. The stand must be assembled at site. Assemble the stand according to the instructions that are provided with it. Ensure the stand and humidifier are installed on a level surface Permanently secure the stand to the floor via the holes in the leg support plates following any local codes or regulations. Mount stand on level surface Ensure humidifier is Level Fasten Nortec SE humidifier to stand with bolts, lock washers, and nuts provided. Tighten to 200 in-lb (22.6 Nm). Note: Center support only present on Nortec SE 525 and larger. Secure stand to floor four places. (hardware by others) Figure 7: Mounting on Optional Stand Note: The humidifier must be secured to the stand (hardware provided) and the stand must be secured to the floor (hardware by others). Installation | 12 Ceiling Mounting (Nortec SE50 Only) Note:. The Nortec SE50 requires regular maintenance including removal of scale from the heat exchanger and tank. Make sure it is installed in a location where the maintenance can be performed. 12.8 in. (32.6 cm) Anchor 3/8 in (M10) support rods to ceiling (by others) Sloped drain 1/2 in. pipe (by others) Support rods and hardware (by others) must not extend below support bracket flange. Figure 8: Ceiling Mounting the Nortec SE50 Condair offers an optional ceiling mounting kit (part number 2520345) which allows the Nortec SE50 to be ceiling mounted with zero clearance to the ceiling. Follow the following guidelines for installation. Follow the instructions provided with the ceiling mounting kit. Install in a location where regular maintenance can be performed. Provide clearance as shown in Figure 6: Installation Location / Clearance. The Nortec SE50 weighs 180 lb (82 kg) when filled with water and without any accessories or piping. It is the installer’s responsibility to calculate the total weight which must be supported, to ensure the ceiling structure is adequate, and to install support rods and to connect drain pan per local codes and regulations. The humidifier cannot be used as a structural member. All piping connected to the unit must be supported independently. A drain line emptying into an open drain must be connected to the ceiling kit drain pan. Condair recommends a 1/2 in. pipe with sufficient slope to ensure any water collected in the pan will drain from it. 13 | Installation Plumbing 0.75 in. (19 mm). OD un-threaded drain outlet Connect with hose cuff and hose clamps. 1/2 in. NPT Use union to connect supply pipe to unit. Always install a water shut-off valve. Air gap required. 2 1/2 in. to 1 1/4 in. copper reducer is ideal. Hose/line must not touch the bottom of the funnel. Min. 1 1/4 in. OD drain line. Slope down. Increase size if combining multiple drains. Axillary drain, 1/2 in. female NPT For draining tank without pump. Leave valve closed except if freeze protection is installed. *Pipe, unions, and water shut-off valve not supplied by Condair. Figure 9: Water Supply and Drain Connection Note: Drain Water is very hot, do not use plastic pipe for drain or condensate lines, do not drain to public sink. Route to floor drain or equivalent. Supply cold potable water, deionized water or reverse osmosis water at 30 - 80 PSIG. Hardness 5-7 grain or 90 – 120 mg/l (as Ca+2 as CaCO3) Total Dissolved Solvents (TDS) 0.5-3 mg/l or Conductivity 1 to 70 mho/cm Chlorides 0-25 ppm PH 7.2-8.5 Alkalinity 30-130 mg/l (as CaCO3) All water supply and drain line connections must be installed in accordance with local plumbing codes. See Table 3 and Table 4 on page 7 for supply water flow requirements. Install water shut off valve and union before humidifier to facilitate servicing. Insure drain line is adequately sized to provide free and easy draining and that an air gap is installed as shown. See Table 3 and Table 4 on page 7 for flow requirements. Auxiliary drain connection with manual shut off valve is recommended for all units. Valve to be left closed on units without freeze protection option installed. Valve to be left open on units with freeze protection option installed except during servicing. High hardness or silica content supply water may require increased maintenance. Unit damage caused by water quality outside of the specified ranges is not covered under warranty. Installation | 14 Boiler Steam and Boiler Condensate Return Note:. Pressurized steam line installation to be performed by a qualified installer. Damage to Nortec SE heat exchanger will occur if it is exposed to pressure above 20 psi.. A safety relief valve must be installed to prevent the Nortec SE from being exposed to pressure in excess of 15 psi when the Nortec SE is connected to a medium or high pressure boiler via a pressure reducing valve. The steam supply line must be designed to provide design pressure at the CV valve when there is 100 % demand (CV valve completely open). Pressure losses in the steam supply line will reduce Nortec SE output. Condensate must be drained to a non-pressurized boiler condensate return line. Boiler steam supply line. Max 15 psi, Min 5 psi measured at CV Valve 6 in. (15 cm) Max Actuator Boiler steam inlet port location on Nortec SE 1050 CV Valve (see table 3) Pressure gauge (optional) F&T Trap Wye Strainer Isolation Valve Boiler steam inlet port (see table 3) Condensate Drain Port (see table 3) Condensate drain line. Gravity feed to boiler. Use pump if condensate must be lifted. Note: Condair supplies CV valve, actuator and wye strainer. All other components and fittings by others. Not pressurized condensate header (slope down) Pressurized condensate header Figure 10: Nortec SE Boiler Steam and Condensate Connection 15 | Installation Condair supplies a CV valve, actuator and wye strainer with each Nortec SE humidifier. The port sizes of the CV valve, boiler steam inlet port, and condensate drain port are given in Table 3: Nortec SETC/P Specifications on page 7. Follow the following guidelines for installation. All steam line connections must be installed in accordance with local codes. Install the CV valve actuator following the procedure in Figure 11: CV Valve Actuator Installation after the CV valve is installed on the steam line. Wire the actuator as described in CV Valve Actuator Wiring on page 29. Boiler steam supply line design is the responsibility of the installer. The boiler steam supply line must be designed so that that design pressure is present at the CV valve when the CV valve is completely open (100% demand). The diameter of the supply line up to the wye strainer may have to be oversized to insure proper steam pressure. The Nortec SE will operate on supply steam pressures between 5 and 15 psi measured at the CV valve. Lower steam supply pressures will result in lower output. See Table 4: Nortec SETC/P Capacities and Water Consumption on page 7 for capacities at different supply pressures. If condensate cannot be gravity fed to the boiler then a pump must be used to lift the condensate. See Spirax Sarco (www.spiraxsarco.com) and others for pumps and additional information on condensate management. Caution: Condensate leaves the steam traps inside the Nortec SE under slight pressure. Steam flash could occur in the condensate drain line. The boiler steam and condensate connections are independent. Boiler steam condensate should be returned to the boiler and should not be mixed with water from the tank drain. The steam supply pressure can be entered into the Nortec SETC control software to provide display of unit output. See Pressure Based on page 56. Actuator 2 turns then push in and 1/8 turn to lock Install stem extension Install jam nut and lock washer Raise valve stem to full up 1/2 in. (1.2 cm) min. Install and tighten mounting nut CV Valve Turn stem extension until holes line up Insert connecting pin Tighten jam nut against stem extension Figure 11: CV Valve Actuator Installation Installation | 16 Steam Lines and Condensate Returns MAIN RULES FOR ATMOSPHERIC STEAM LINES Slope the steam lines. Trap condensate (Use full size ‘T’ for Traps). Steam lines must not have any restrictions which could cause back pressure. Insulate with 1.0 in. (2.5 cm) pipe insulation. Follow recommended materials, size and length see tables. Use Appropriate Slope Insulate Pipe 10 Degrees 2 in. (5 cm) 1 ft (30 cm) 2 Degrees Steam Direction 0.5 in. (12 mm) 1 in. (2.5 cm) pipe insulation 1ft (30 cm) Figure 12: Main Steam Line Requirements Table 5: Recommended Steam Line Material Steam Line Material Copper Tube *Stainless Steel Tube Condair Hose Note: Lb/hr (kg/hr) Steam Line Length ft m Steam Line Description 0-100 (0-45) 0-90 0-27 1 1/2 in. MED-L Tubing (1.625 in. OD) 101-250 (46-113) 0-180 0-54 3 in. MED-L Tubing (3.125 in. OD) 251-650 (114-295) 0-260 0-79 **4 in. MED-L Tubing (4.125 in. OD) 0-100 (0-45) 0-90 0-27 1.75 inch Tube x 0.065 inch thick wall 101-250 (46-113) 0-180 0-54 3 inch Tube x 0.065 inch thick wall 251-650 (114-295) 0-260 0-79 **4 inch Tube x 0.065 inch thick wall 31-100 (14-45)** <15 <4.5 ***Part Number 1328820 (1 3/4”) * Use only stainless steel tube for reverse osmosis and deionized water applications. ** Use 2 x 4 in. steam lines for steam capacities higher than 750 lb/hr (307 kg/hr) *** Use one steam hose per 100 lb/hr (45 kg/hr) of output. Steam Hose Odour: Condair hose may generate a slight odour during initial use. This odour is temporary and will disappear after a short period of time. 17 | Installation Table 6: Maximum Recommended Length of Steam Line Unit Size Steam Output 50 100 175 250 375 525 750 1050 NOTE: Steam Outlet and Line Size Maximum Length lb/hr (kg/hr) copper (SST) ft (m) 50 100 175 250 375 525 750 1050 (23) (45) (80) (114) (170) (239) (341) (477) 1 1/2 (1 3/4) 1 1/2 (1 3/4) 3 (3) 3 (3) 4 (4) 4 (4) 2X 4 (4) 2X 4 (4) 37 90 90 180 180 220 260 260 (11) (27) (27) (55) (55) (67) (79) (79) Possible Loss lb/hr/ft 0.11 0.11 0.16 0.16 0.22 0.22 0.44 0.44 Possible Loss atLoss at Possible Max. Length Max. length lb/hr (kg/hr) (kg/hr/m) lb/hr (kg/hr) (0.16) (0.16) (0.24) (0.24) (0.33) (0.33) (0.66) (0.66) 4 10 14 28 39 48 114 114 (2) (4.5) (6.5) (13) (18) (22) (52) (52) See Table 7 for equivalent length of common fittings. Tube Diameter in. 1 1/2 or 1 3/4 3 4 4 Table 7: Equivalent Length of Some Common Fittings 90 Degree 45 Degree Elbow Side Outlet Tee Gate Valve Elbow ft (m) ft (m) ft (m) ft (m) GlobeValve Valve Control (m) ft ft (m) 3.5 5 8 8 34 54 80 Tee is same size as steam line (1) (1.5) (2.4) (2.4) 1.75 2.5 4 4 (0.5) 7 (2.1) (0.75) 11 (3.3) (1.2) 15 (4.5) (1.2) 15 (4.5) 0.8 (2.4) 1.1 (3.1) 1.6 1.6 (0.5) (10) (16) (24) Use a full size tee, not a 90 degree elbow for vertical to horizontal transitions. 12 in. (30 cm) min drop to top of ‘P’ Trap P Trap min 8 in. (20 cm) plus duct static pressure ‘P’ Traps Use: - Condair 0.375 in condensate hose - 1/4 in Med-L copper tubing, or - 0.375 in stainless steel tubing . Condensate drains must be sloped down. Route to humidifier fill cup if possible. Figure 13: Condensate Traps Note: Condensate should not be routed to a sink used frequently by personnel. Route to a floor drain or equivalent. Condensate normally cools in traps but is still hot. A SAM-e or larger steam line generates more condensate and water may not cool in the trap. A drain water cooler option may be installed if required by code. Installation | 18 Calculated absorption distance to any obstruction or 8-10 ft (2.4 - 3 m) if unknown 2 x duct height min. 2/3 Duct height 12 in. (30 cm) min. Mount distributor to side of duct Figure 14: Distributor Location in Duct Note: Refer to distributor or SAM-e installation manuals for detailed installation instructions. Hose cuff with clamps Insulated copper steam line. Support so weight is not on steam outlet. 1 ft (30 cm) 2 in. (5 cm) min. Condensate line 1 ft (30 cm) min. before anybend ‘P’ Trap To drain Use steam hose between steam outlet and steam line. Figure 15: SAM-e/Steam Distributor Above Humidifier (Copper Steam Line Shown) 19 | Installation Hose will soften over time proper support Is necessary Min 12 in. (30 cm) radius Support Brackets Install Condensate Tee Before Distributor 1 ft (30 cm) min. Before any bend 1 ft (30 cm) min. ‘P’ Trap ‘P’ Trap To drain To drain Figure 16: Steam Distributor/SAM-e Below Humidifier (Hose Shown) 1 ft (30 cm) 0.5 in. (1.2 cm) min. 1ft (30 cm) min. before any bend Obstruction Use full size condensate tee at low point. Slope lines up to “T” and immediately after it. 1 ft (30 cm) min. ‘P’ Trap To drain To drain ‘P’ Trap Figure 17: Steam Under Obstruction (Copper Steam Line Shown) Installation | 20 Method for Longer Runs With Limited Vertical Space 1 ft (30 cm) min before turn Condensate tee every 15-20 ft (4.5 - 6 m) Install condensate tee before distributor 1 ft (30 cm) min. Condensate tee at low points Individually trap multiple condensate returns before joining on common line. Figure 18: Long Steam Run 21 | Installation To Drain Electrical Caution: Wiring to be performed by a licensed Electrician. All SE humidifiers operate on 120 VAC, single phase, 60 HZ power. Refer to specification label for power requirements. Knockouts provided in top and bottom panels. Install strain relief (by others) High voltage terminal block Note: 1 Dedicated external fused disconnect must be installed. Fusing must not exceed max circuit protection as indicated on the specification label. 2 Ensure that adequate power is available to carry full humidifier amp draw as indicated on the specification label. 3 All wiring to be in accordance with national and local electrical codes. Nortec SETC / P Primary Power Single Phase Supply Ground Ground L1 Neutral L1 Neutral Dedicated circuit breaker or fused disconect. E X T I N T Figure 19: Primary Power Connection Installation | 22 External Controls Control Wiring Controls are available from Condair as accessories. If controls were not ordered with humidifier they must be supplied by others. The following information is relevant to all controls, factory supplied or otherwise. For wiring use minimum of 18 AWG and keep as short as possible. The Nortec SETC humidifier can be operated with two modulating inputs. The Nortec SEP has one modulating input which can be used for a duct high limit or humidity control. Both the Nortec SETC and Nortec SEP can be operated as On/Off. See Control Setting on page 53 for Nortec SETC configuration and On/Off or Modulating Control (J10) on page 61 for Nortec SEP configuration. Caution: Failure to wire the humidifier in accordance with the wiring instructions could cause permanent damage. Such errors will void the warranty. Control Location 10 ft min. 1 Air Proving Switch 2 Duct High Limit 3 Humidity Control (return air duct or in room) Figure 20: Control Location 1 2 Air Proving Switch Locate so that it can sense air flow or lack of it. Duct High Limit Nortec SETC can be modulating, On/Off, or a humidity sensor. Nortec SEP can be modulating or On/Off. Locate at least 10 feet from steam distributor or far enough that under normal conditions steam is fully absorbed. 3 Humidity Control Nortec SETC can be Modulating, On/Off, or a Humidity Sensor. Nortec SEP can be modulating or On/Off. Can be located either in return air duct (preferred) or in room being humidified. Mount in area representative of room humidity (draft, doorways, sunlight, or overhang such as a shelf can affect reading). Avoid placing near discharge diffuser of humidified air. Note: Regardless of selecting on/off or modulating control method, Condair humidifiers must have a closed circuit across their on/off security loop control terminal to operate. Condair highly recommends the use of a high limit humidistat and an air proving switch in series for this function. 23 | Installation On/Off Control Wiring Air Proving Switch Duct High Limit 2548732 - On/Off Duct Humidistat Humidity Control 2548731 - On/Off Wall Humidistat Humidifier Terminal Strip Note: 1 Humidifier will run when circuit between terminal 1 and 2 on humidifier is closed. 2 Terminal 1 is 24VAC Hot, turn unit off to avoid shorting while wiring. 3 Digital Humidistats require 24 VAC power from terminals 1 and 3 of humidifier. 4 Humidity Control can be wall mounted as shown or return air duct mounted. Knockouts provided in top and bottom panels. Install strain relief (by others) Figure 21: On/Off Controls Ground 24 VAC Common Digital Out Fan Relay Fan Relay NTC Sensor NTC Sensor 12345678- Humidity Control 2548731 - On/Off Wall Humidistat or, 2548732 - On/Off Duct Humidistat Ground 24 VAC Common Digital Out Fan Relay Fan Relay NTC Sensor NTC Sensor Duct High Limit 2548732 - On/Off Duct Humidistat Wire to make on drop in humidity 12345678- Com N/O Air Proving Switch Wire to make when sensing air flow OR E S X E T Connect 24 VAC , term inal 1 of hum id ifie r to term inal 2 of controllers. 1- 24 VAC 2 - On/Off Loop 3 - Ground 4 - Control Signal 5 - Limit Signal (SETC only) 6 - 5 VDC 7 - Ground 8 - Full Tank Blow Down 9 - Ground 10 - Actuator power 11 - Actuator power 12 - 0-10 VDC Out Figure 22: Digital On/Off Installation | 24 Modulating Control Wiring Air Proving Switch High Limit Humidistat Control Humidistat Humidifier Terminal Strip Note: 1 Install On/Off controls or jumper between terminal 1 and 2 of humidifier in order to run. 2 Terminal 1 is 24 VAC Hot, turn unit off to avoid shorting while wiring. 3 High Limit Humidistat must be duct mounted. It can be On/Off or modulating. 4 Control Humidistat can be mounted in space or in return air duct and can be On/Off or modulating. 5 The Nortec SEP can only accept one modulating signal. Knockouts provided in top and bottom panels. Install strain relief (by others) Figure 23: Modulating Controls 8 - Temperature 6 - Analog Out 1 - Ground 2 - 24 VAC 1510142 - Digital Wall Humidistat 6 - Analog Out 7 - Analog In 8 - Temperature 1 - Ground 2 - 24 VAC 2520266 - Digital Duct Humidistat Package Insert On/Off controls or jumper between 1 and 2 Analog Out - 3 24 VAC - 2 Ground - 1 1- 24 VAC 2 - On/Off Loop 3 - Ground 4 - Control Signal 5 - Limit Signal (SETC only) 6 - 5 VDC 7 - Ground 8 - Full Tank Blow Down 9 - Ground 10 - Actuator power 11 - Actuator power 12 - 0-10 VDC Out Connect 24 VAC, terminal 1 of Nortec SETC/P to terminal 2 of controllers. Figure 24: Digital Modulating Humidistats 25 | Installation E S X T E Air Proving Switch Duct High Limit 2520261 - Digital Wall W/O Sensor 1509858 - Wall Sensor Humidifier Terminal Strip 2520261 - Digital Wall W/O Sensor + 1509858 - Wall Sensor Wire wall sensor to digital display as shown below, wire digital display to humidifier as shown for 1510142 - Digital Wall Humidistat. Knockouts provided in top and bottom panels. Install strain relief (by others) 6 - Analog Out 1 - Ground 2 - 24 VAC 6 - Analog Out 7 - Analog In 8 - Temperature 2520261 - Digital Wall W/O Sensor 1 - Ground 2 - 24 VAC Figure 25: Digital Wall Humidistat – Remote Wall Sensor Connect 24 VAC, terminal 1 of SETC/P to terminal 2 of controllers. 1509858 - Wall Sensor 1- 24 VAC 2 - On/Off Loop 3 - Ground 4 - Control Signal 5 - Limit Signal (SETC only) 6 - 5 VDC 7 - Ground 8 - Full Tank Blow Down 9 - Ground 10 - Actuator power 11 - Actuator power 12 - 0-10 VDC Out Figure 26: Remote Wall Sensor Wiring Installation | 26 Transducer Control Wiring (Nortec SETC Only) Duct High Limit 1509857 - 2-10V Duct Humidity Transducer Air Proving Switch Humidity Control 1509858 - 2-10V Wall Humidity Transducer Note: 1 Install On/Off controls or jumper between terminal 1 and 2 of humidifier . 2 Terminal 1 is 24 VAC Hot, turn unit off to avoid shorting while wiring. 3 Duct High limit can be duct humidity transducer as shown or duct On/Off humidistat. 4 Humidity Control can be wall humidity transducer as shown, duct humidity transducer, or On/Off humidistat. Humidifier Terminal Strip Knockouts provided in top and bottom panels. Install strain relief (by others) Figure 27: Transducers 6 - Analog Out 1509858 - 2-10V Wall Humidity Transducer 1 - Ground 2 - 24 VAC 1 - Ground 2 - 24 VAC 3 - Analog Out 1509857 - 2-10V Duct Humidity Transducer Insert On/Off controls or jumper between 1 and 2 E S X T E 1- 24 VAC 2 - On/Off Loop 3 - Ground 4 - Control Signal 5 - Limit Signal (SETC only) 6 - 5 VDC 7 - Ground 8 - Full Tank Blow Down 9 - Ground 10 - Actuator power 11 - Actuator power 12 - 0-10 VDC Out Connect 24 VAC , terminal 1 of SETC to terminal 2 of controllers Figure 28: Digital 27 | Installation Optional Outdoor Temperature Reset Figure 29: Outdoor Temperature Reset Each digital controller is equipped with an integrated reset function that can reduce the setpoint during cold weather operation. This will prevent condensation on windows and building structures. The above graph illustrates how the setpoint reset feature operates. On modulating humidistats this feature is enabled by removing the jumper from terminals 8 and 1 on the humidistat and wiring the outdoor temperature sensor to these terminals. On On/Off humidistats this feature must be activated with the humidistat’s keypad. When the outdoor temperature setback feature is in effect, the humidistat will normally display the calculated setpoint limit based on the outdoor air temperature. A snowflake will also be displayed to indicate cold weather operation. When any key on the controller is pressed, the LCD screen will display the customer specified setpoint for a short duration. 2520263 - Outdoor Temperature Sensor 12345678- Ground 24 VAC Common Digital Out Fan Relay Fan Relay NTC Sensor NTC Sensor 2548731 - On/Off Wall Humidistat or, 2548732 - On/Off Duct Humidistat 1 - 24 VAC 2 - Temperature OR Note: 1 The Temperature sensor is intended for duct mounting. 2 Locate the temperature sensor near the fresh air intake. This will ensure accurate representation of the outdoor air temperature. Connect 24 VAC, terminal 1 of humidifier to terminal 2 of controllers. E X T Insert Other On/Off controls in series Figure 30: Outdoor Temperature Sensor (Modulating Control) S E 1- 24 VAC 2 - On/Off Loop 3 - Ground 4 - Control Signal 5 - Limit Signal (SETC only) 6 - 5 VDC 7 - Ground 8 - Full Tank Blow Down 9 - Ground 10 - Actuator power 11 - Actuator power 12 - 0-10 VDC Out Installation | 28 8 - Temperature 6 - Analog Out 1510142 - Digital Wall Humidistat or, 2520266 - Digital Duct Humidistat Package 1 - Ground 2 - 24 VAC 1 - 24 VAC 2 - Temperature 2520263 - Outdoor Temperature Sensor Insert On/Off controls or jumper between 1 and 2 Note: 1 The Temperature sensor is intended for duct mounting. 2 Locate the temperature sensor near the fresh air intake. This will ensure accurate representation of the outdoor air temperature. E X T S E Connect 24 VAC, terminal 1 of SE to terminal 2 of controllers. 1- 24 VAC 2 - On/Off Loop 3 - Ground 4 - Control Signal 5 - Limit Signal (SETC only) 6 - 5 VDC 7 - Ground 8 - Full Tank Blow Down 9 - Ground 10 - Actuator power 11 - Actuator power 12 - 0-10 VDC Out Figure 31: Outdoor Temperature Setback (On/Off Control) CV Valve Actuator Wiring Nortec Nortec SE 1050 Actuator SE 50 - 750 Actuator Note: 1 Wire the CV valve actuator to the humidifier’s low voltage terminal strip. 2 Use minimum of 18 AWG wire and keep as short as possible. 3 After installation and powering humidifier verify that travel of actuator at full demand is to the fully open position. Nortec SE 1050 low voltage terminal strip 9 - Ground Bk R 10 - Actuator 24 VAC Gr 11 - Actuator Ground Y/Bk 12 - 0-10 VDC Out SE 50 - 750 Terminal Strip 9 - Ground R 10 - Actuator 24 VAC 11 - Actuator Ground Bk Y/Bk 12 - 0-10 VDC Out Figure 32: CV Valve Actuator Wiring 29 | Installation Remote Relay Board Wiring The Nortec SETC (not SEP) remote relay board provides the output signal for the CV Valve Actuator and includes 4 relays that can provide remote status indication. The remote relay board is located as shown in Figure 33: Remote Relay Board Wiring. The PCB with the relays includes markings which indicate the function of each terminal on the board. The relays indicate the following status; Error COM Service NO COM NC NO Steam NO COM NO COM NC Unit ON 1 Unit On – The normally open relay is closed when the humidifier has power and the On/Off switch is set to on. 2 Steam – The normally open relay is closed when the control board sends a signal to the CV valve actuator to open the CV valve and steam is being produced. 3 Service – The relay can be wired to open (NC) or close (NO) when a warning is displayed on the humidifier display and the yellow service LED is illuminated. 4 Error – The relay can be wired to open (NC) or close (NO) when a fault is detected by the humidifier controls. Figure 33: Remote Relay Board Wiring Installation | 30 Staged Modulation Wiring (Nortec SETC Only) Connect up to 10 units (equivalent of 10,500 lb/hr (4,770 kg/hr)) using 18-24 AWG multistrand, twisted pair, shielded cable. Connect humidistats/transducers and On/Off safety loop to master unit only. See Multi Mode on page 54 and Multi Unit Op. Range on page 56 for software configuration. Daisy Chain up to 16 Humidifiers Slave 1 Slave X Master Daisy chain pole 2 and 3 of terminal J2a-RS485 of the driver board. Note: Do not reverse polarity. Do not connect to pole 1 or 4. Figure 34: Staged Modulation Wiring 31 | Installation Options and Accessories Note: For installation of options and accessories follow the instructions that are provided with them. Remote Blower Pack Remote blower packs are available for the Nortec SETC/P for applications where steam for humidification must be introduced directly into the space being humidified. For instructions on installing the remote blower pack refer to the installation instructions supplied with it. The steam line and condensate return instructions provided in this manual are also applicable to remote mounted blower packs. The blower packs include a safety relay which should be used to prevent the humidifier from operating if the blower packs do not have power. Wire humidifier security loop in series through all blower packs and other On/Off controls. Drain Water Cooling (External) Pneumatic and electric drain water coolers are available from Condair for installation outside the humidifier or on condensate drains from steam traps, distributors, and SAM-e headers. If condensate cannot be routed back to the humidifier tank via the humidifier’s fill cup then an external drain water cooler may be required to meet regulations restricting the temperature of hot water that can be fed to drain. The external drain water cooler is only available for field installation. Installation | 32 Start Up 34 Installation Check 35 Nortec SETC User Interface 35 36 37 39 40 40 40 41 42 33 | Start Up Manual Drain Switch Start Up Procedure Status Screens Condair Digital Controls Staged Modulation (Nortec SETC Only) LINKS 2 Condair ONLINE Nortec SETC/P Pre-Start Up Checklist Nortec SETC/P Start Up Checklist Installation Check Before turning on power to the Nortec SE, inspect the installation to insure that it was carried out correctly. Refer to Figure 35: Installation Check, to the Nortec SETC/P Pre-Start Up Checklist on page 41, and to the chapter on Installation that starts on page 9. Min 10 ft (3 m) 2 x duct height from fan or transition Calculated absorption distance to any obstruction or 8 - 10 ft (2.4 - 3 m) if unknown. On/Off Controls (Air Proving) in series between terminal 1 and 2 Steam Line - Adequate slope - No restrictions - No kinks (hose) - Condensate traps on long runs Disconnect Correct voltage, amps, phase P Trap(s) with 12 in . (30 cm) min. drop(s) . Boiler Steam - Max 15 psi - Safety valve if from Actuator, med. or high press. - Opens CV Valve boiler. fully at 100% - Design pressure demand at 100% demand. - Closes fully at 0%. 1/2 in line min 30-80 PSI Air gap High Limit - Wired to terminal 5 - On/Off in series between terminal 1 and 2 Control - Wired to terminal 4. - On/Off in series between terminal 1 and 2. - In return duct or location which represents humidified space (no drafts, not by door, not by diffuser). Spec label Not plastic drain, Not to sink. Mounting - Unit level - Service clearance - Properly anchored if on stand Boiler Condensate - Gravity fed to boiler or lift pump Figure 35: Installation Check Start Up | 34 SETC User Interface LCD Display and Input Buttons (Buttons used to navigate . status screens and configure the humidifier, correspond to icons on the display) Status LEDs Software Drain Button (Initiates a software controlled drain) On/Off Switch (Turns humidifier On/Off) Figure 36: Nortec SETC User Interface Manual Drain Switch The Nortec SETC/P has a manual drain switch that can drain the tank even if software is not functioning. To drain the tank put the switch into the drain position. For normal operation the switch should be in the off position. Manual drain switch Figure 37: Manual Drain Switch 35 | Start Up Start Up Procedure 1 Examine the humidifier and installation for damage and or improper installation. Warning: Damaged units or improperly installed units must not be operated. Damaged or improperly installed units may present a danger to persons and property. 2 Open the supply water shut off valve. If the auxiliary drain valve is installed ensure it is closed. 3 Slowly open boiler steam isolation valve to allow boiler steam into the steam supply line up to the CV valve. 4 Turn on the main power using the installed disconnect then turn the On/Off switch on the front of the humidifier to On. Request – xx% Idle 0 lb/hr 04/30/09 14:25:22 Security loop: Closed The LCD display will illuminate and the humidifier will perform a self-diagnostic sequence during which the LED’s and internal components will be momentarily activated. The Nortec SE will then begin filling with water. The fill time is between 10 and 30 minutes depending on the size of the unit. Menu 5 Once the water level is close to the top of the tank the LED lights on the SE’s float chamber will light up and indicate the water level. On start up the Nortec SE will perform a float and drain pump test by first filling until just the green LED is lit and then draining until just the red LED is lit. After the float and drain test the humidifier is in normal operation mode. Note: Pressing the ESC key on the keypad will interrupt the float and drain test and the humidifier will go straight to normal operating mode. If an error is detected during the self-diagnostic sequence a Fault will be displayed. See troubleshooting section for information on diagnosing and correcting faults. Nortec SEP does not have an LCD display. The information on the Nortec SETC’s LCD depends on the Nortec SETC’s configuration and actual operating conditions. It may vary from display shown. 6 If On/Off or a control humidistats have been installed check and adjust the control setpoint on the control and high limit humidistat (see Nortec Digital Controls on page 39). If transducer controls have been installed then adjust the humidity setpoint using the keypad and display (see Transducer Control on page 39) 7 When either the external humidistat or internal controller generate a demand for humidity higher than 15%, the security loop is closed, and the float chamber indicates the tank is full the SE will transmit a signal to the CV valve to open. Steam will flow into the SE’s heat exchanger(s) and the SE will heat the water in its tank. Note: on initial startup with cold water in the Nortec SE’s tank it may take 5 to 15 minutes (depending on unit size) for the Nortec SE to reach a full boil and produce its rated steam. Start Up | 36 8 The green humidifying LED on the front of the humidifier will light up and the display will indicated “Humidifying” and the amount of steam being produced (Nortec SETC only). Request – 100% Idle 04/30/09 Security loop: 750 lb/hr 14:25:22 Closed Menu Status Screens In addition to the main status screen the Nortec SETC includes several status screens which provide additional information about the humidifier. The additional screens can be reached by pressing the buttons corresponding to the left and right arrow key on the LCD display. Request – xx% Idle 04/30/09 Security loop: 0 lb/hr 14:25:22 Closed Main Status Screen This screen reports the current request for humidity, status, output, date and time, and security loop status. If status is not idle or humidifying the left arrow key becomes a “?”. If the button corresponding to the arrow key is pressed the display will give additional information on the status of the humidifier. Menu CONTROL Man Cap. Demand Limit Output : 100% : 55% : 80% : 0 lb/hr CONTROL Man Cap. RH CNT CNT Set-Pt RH Limit LIM Set-Pt Output Menu Menu : 100% : 55% : 50% : 100% : 70% : 0 lb/hr Control Information Screen Output is the lb/hr steam output of the unit. Man Cap is the user configured capacity limitation. Depending on the control configuration the screen also reports the current inputs of channel 1 and 2. If the unit is configured for internal control it also provides the current humidity and setpoints. Caution: Improper control configuration can result in over humidifying which can result in damage to property. See Advanced Control Configuration if the controls displayed in the control information screen do not match those connected to the humidifier. HUMIDIFIER Model Capacity Multimode REG Mode Software Press. In Menu 37 | Start Up : SETC 750 : 750 lb/hr : StandAlone : Demand : XVXX : 15 psi Humidifier Information Screen Model is the humidifier model type. Capacity is maximum output if the unit is supplied 15 psi steam. Multimode indicates if the humidifier is operating as part of a group controlled by a single control signal REG Mode is the configured control method. Software is the installed software version. Press. In is the boiler steam supply pressure. Analog Output Output Signal Capacity Total O/P Tank Monitor Quick Warm Press. Base : X.X VDC : xxx lb/hr : xxx lb/hr : On/Off : On/Off : On/Off Menu TANK STATUS Fill Valve Drain Pump Float Level Run Time Serv. Time Serv Due : ON/OFF : ON/OFF 5 : xxx hr : xxx hr : xxx hr Menu SENSOR INPUTS Sec. Loop : Closed Tank Temp. : Closed Analog Output Information Output Signal is the signal currently being output to the actuator. Capacity is maximum output based on actual boiler steam press. Total O/P is the current output of the humidifier. Tank Monitor indicates if tank monitoring is On/Off. Quick Warm indicates if Quick Warm is On/Off. Press Base indicates if output is based on actual steam pressure. Tank Status Fill Valve indicates if the fill valve is open or closed. Drain pump indicates if the drain is on or off. Float level indicates the current float level. Run Time is total weighted operating hours since last service. Serv Time is the service interval set for the humidifier Serv Due is the time remaining before service is required. Sensor Inputs Sec. Loop indicates if the security loop is open or closed. Tank Temp indicates if the tank is cold (open) or hot (closed).. Menu FEATURES LIST Idle Mode FTBD Time Prop. BD Rate Drain Cool Float Check : Idle Drain : On/Off : On/Off : 25% :On/Off/Smart : On/Off Menu FEATURES LIST Idle Mode FTBD Time Prop. BD Rate Drain Cool Float Check : Idle Drain : On/Off : On/Off : 25% :On/Off/Smart : On/Off Features List Idle Mode indicates what the humidifier is configured to do when there is no demand. FTBD indicates if full tank blow down is enabled. BD Rate indicates water drained for scale control as % of output Drain Cool indicates configuration of drain water cooling feature Float Check indicates if the humidifier will perform float checks. Operational Hours Total indicates the number of hours the humidifier has been producing steam. Weighted indicates the total amount of steam the humidifier has produced expressed as number of hours running at 100% output. Menu 100% 0% -4 hrs 0 hrs Trend Graph This graph provides a history of the humidifiers output for the past 4 hours. It displays a percentage of full output which corresponds to the demand signal. The current demand signal is displayed at the bottom of the screen. Demand: 45% Menu Start Up | 38 Digital Controls Condair provides optional On/Off, Modulating Control, or Transducer digital controls. Figure 38 and Figure 39 show the function and meaning of the Digital Control’s display and buttons. All controls are available either wall mounted or with a remote sensor for duct mounting. Humidity (RH %) Output signal is shown on modulating controller proportional to the demand. Indicates the humidistat is on. A half moon indicates it is off. Snowflake indicates the setpoint is being overridden by outdoor temperature. Power button turns off the humidiistat if pressed for 2 seconds State of On/Off humidistat Setpoint (RH%) Option button accesses sensor calibration. See troubleshooting Increase / Decrease Setpoint Figure 38: Modulating and On/Off Digital Control Operation Modulating Control The modulating controls use a PI control algorithm to transmit a 0-10V control signal to the humidifier. Adjust the setpoint to the desired setting by using the up/down arrow buttons on the controller. On/Off Control The On/Off controls use a PI control algorithm to open and close a relay that opens and closes the humidifier’s On/Off loop. Adjust the setpoint to the desired setting by using the up/down arrow buttons on the controller. Transducer Control The transducer controls transmit a 2-10V control signal proportional to the sensed relative humidity to the humidifier. Humidity setpoint is not set at the transducer. The setpoint is set on the Nortec SETC’s display and keypad. Note: It is possible to field calibrate Condair Digital controls if the displayed humidity is found to be different than a known trusted source. See Digital Humidistat on page 75 of chapter on Troubleshooting. 39 | Start Up Humidity (RH %) Option button accesses sensor calibration. See troubleshooting Adjust calibration while in calibration mode Power button will display “NO” if an attempt is made to turn off the transducer. Figure 39: Transducer Control Operation Staged Modulation (Nortec SETC Only) Start up of each humidifier configured and installed for Staged Modulation is the same as starting up standalone humidifiers with the exception that for the humidifier to fill and produce steam the demand to the master unit must be greater than the Multi Unit Op. Range setting of the unit being started. (Example for a slave unit configured to operate between 20 and 30% the demand to the master must be greater than 22%) Each unit connected in a staged modulation system will display its demand as a percentage of the range for which it is configured. Example, a slave unit configured to operate between 20 and 30% demand will display a demand of 50% when demand to the master is 25%. Note: See Multi Mode on page 54 and Multi Unit Op. Range on page 56for software configuration. See Staged Modulation Wiring on page 31 for control wiring of humidifiers in a Staged Modulation system. LINKS 2 (Nortec SETC Only) LINKS 2 is an option that can be integrated with the Nortec SETC. It allows a Building Management System to monitor and / or control the humidifier. For complete information about LINKS 2 and its operation and configuration, go to www.condair.com and look up the LINKS 2 manual. Condair ONLINE (Nortec SETC Only) Condair ONLINE is an option that can be integrated with the Nortec SETC. It allows a user to monitor their unit from any computer with an internet connection by logging in to www.condaironline.com. It can also be configured to send service reminders and fault warnings when they occur. Start Up | 40 Nortec SETC/P Pre-Start Up Checklist Unit Serial #: Tag: Unit type: Voltage: Customer/Job: Address: V/ ph Steam output: lb/hr Water Quality: Potable (0-12 grains/gal, 0-14 ppm Silica, 0-25 ppm Chlorides) RO DI Humidifier Mounting: (Clearances around the unit Acceptable Obstruction) Level Front/Side Clearance Anchored (if on stand) Steam Line(s): Slope up (min 2 in/ft). Slope down (min 0.500 in/ft) Diameter / Size Material Low point condensate traps No Hose Kinks / Restrictions Insulated Type of Insulation Condensate Line(s): P Trap min 8 in. (20 cm) plus duct static pressure P Trap min 12 in drop Water Line: Can provide required flow Water pressure: 30-80 psig Drain Line: Air gap within 3 ft of the unit Auxiliary drain connected with shut off valve Diameter / Size Boiler Steam Boiler Pressure psi Pressure to humidifier 15 psi relief valve if med/high press boiler Actuator closes and opens CV valve fully Design pressure at CV valve Condensate return Gravity feed or pump Wiring: Wiring connections and connectors secured yes no Controls: Control Location High Limit Location Control to Terminal 4 High Limit to terminal 5 Power: Voltage, amp, fuse per Spec Label: Disconnect switch located close to humidifier Inspected by: Company: 41 | Start Up yes yes Date of inspection: no no / / psi Nortec SETC/P Start Up Checklist Unit Serial #: Tag: Unit type: Voltage: Customer/Job: Address: V/ Preliminary: Pre-start-up checklist completed? ph Steam output: yes lb/hr no If no, perform Pre-Start-up Checklist before starting humidifier. Start-Up Procedure: The prerequisites for the humidifier activating the CV valve actuator to make steam are as follows: Water supply valve opened Boiler steam isolation valve open Mains disconnect switched on Turn On/Off switch on On/Off Security loop (Terminal 1 and 2) closed. Demand greater than 15% Controls: Installed Controls Match Configuration Control Setpoint: Demand (Modulating Humidistat) or Sensed RH < Setpoint (Transducer) yes yes yes yes yes yes no no no no no no yes no High Limit Setpoint: yes no yes no The Humidifier will undergo a self-test when the power is turned on activating the LED’s and other internal components followed by a float test. If the above listed prerequisites are fulfilled the humidifier will fill the tank, open the CV valve and begin normal operation. Note: 1) It can take 10 to 30 minutes for the tank to fill depending on humidifier size. 2) Once filled it can take 5 to 15 minutes (depending on humidifier size) for a cold tank to come to a full boil. Remarks: Started by: Date of Start Up: / / Company: Start Up | 42 Operation 44 Nortec SETC LED Status Lights 44 Nortec SEP LED Status Lights 45 How the Humidifier Works 45 Steam Generation 46 Drains 46 Steam Distribution 47 Selecting an RH Setpoint 49 Nortec SETC Humidifier Configuration 49 Navigating the Nortec SETC Software 49 Main Menu (Nortec SETC Password) 50 Service Level 51 User Defined Settings 53 Control Setting 56 Multi Unit Op. Range 57 RH Settings 59 Diagnostic Menu 60 Nortec SEP Humidifier Configuration 43 | Operation Nortec SETC LED Status Lights The keypad and display panel includes 3 LED’s which provide information about the humidifier’s current status. Fault LED On Indicates the controller has detected a fault condition and stopped humidifier. Check display for fault information Service LED On Indicates that service may be required or that a warning condition exists. Check display for warning information Service LED Blinking Indicates drain button has been pushed and unit is draining. ON LED On Indicates steam is being produced. ON LED Blinking Indicates demand with safety loop open. Figure 40: Nortec SETC LED Status Lights Nortec SEP LED Status Lights DEMAND LED On Indicates steam is being produced. DEMAND LED Blinking Indicates humidifier is in standby waiting for a demand. SERVICE LED Flashing Indicates the controller has detected a fault. The flash sequence of the LED indicates which fault has been detected. FAULT LED On Indicates the controller has detected a fault condition and stopped humidifier. Read Service LED’s flash sequence to determine fault detected. DEMAND ON SERVICE OFF FAULT DRAIN Figure 41: SEP LED Status Lights Operation | 44 Humidifier Schematic Steam Line Steam Distributor CV Valve Actuator ‘P’ Trap Float Chamber Tank Fill Box Cooling to Float Chamber Dual Fill Valve Boiler Steam Vacuum Break CV Valve Drain Outlet Steam Trap ‘P’ Trap / Overflow Heat Exchanger Condensate Return to Boiler Auxiliary Drain Lower Mixing Box Drain Pump Figure 42: Humidifier Schematic How the Humidifier Works The Nortec SETC/P is an atmospheric steam generator that uses energy from pressurized steam flowing through a heat exchanger submerged in water to generate steam. The Nortec SETC/P is designed for air humidification via steam distributor, blower pack, or steam manifold (Nortec SAM-e). Steam Generation After initial start-up and tank filling the humidifier will sit in standby mode, awaiting a call for humidity. When a call is received, the humidifier will send a signal to the electric actuator. The actuator will open as required and the flow of boiler steam will begin. Energy from the boiler steam is transferred to the fresh water tank through a heat exchanger inside of the unit. This causes the water to boil. Full boil from a cold tank can take up to 15 minutes. On Nortec SETC models, the Keepwarm feature can be activated to reduce boil time, see Idle Mode on page 52. 45 | Operation Once the humidifier has reached full boil, the humidifier will modulate the actuator, controlling the flow of steam into the unit. This will allow the unit to reduce its output level as the humidity levels in the space being humidifier are reached. During the boiling process minerals are left behind from the water. The unit will occasionally activate the drain pump to flush out some of the minerals in the water and reduce the concentration in the tank. The fill valve will also be activated periodically to replace water that is boiled off during normal operation. When the demand to the unit ceases, the unit will close the steam valve and steam production will stop. The unit will enter standby mode and await a call for humidity. If Keepwarm is activated (Nortec SETC only), the CV valve will be opened periodically to heat the tank. Drains As steam is produced minerals are left behind in the Nortec SE’s tank. The Nortec SE performs periodic drains to reduce the amount of minerals that will precipitate as scale. In general more frequent drains result in less maintenance. The amount of water drained to control mineral concentration in the tank can be configured in the Nortec SETC’s software. To cool drain water the Nortec SE activates the fill valve whenever the drain pump is activated. Cool fill water flows down from the fill box and blends with hot tank water in the lower mixing box before being drawn into the drain pump. The drain cooling feature can be deactivated via software (see Drain Cool on page 51). Steam Distribution Steam generated by the humidifier may be introduced into the air in several different ways. The most common method for adding the steam into the air is to mount a steam distributor tube in a supply air duct as shown in Figure 42: Humidifier Schematic. For larger ducts or larger loads it is also common to use a steam manifold with a single steam line connection and multiple tubes for distributing the steam, see Figure 43: Nortec SAM-e Manifold. For introducing steam directly into a room, remote mounted blower packs are used see Figure 44: Remote Blower Pack. Steam Line The steam line between the tank steam outlet and the distributor may be Condair steam hose, copper pipe, or stainless steel pipe or tube. The Nortec SETC/P is an atmospheric steam generator so it is very important no restrictions are present in the steam line and that the steam line is sized properly to carry the full output capacity of the humidifier. It is also important to minimize the length of steam lines. See Steam Lines and Condensate Returns on page 17 for information on selecting steam lines and maximum recommended lengths. Whenever steam is distributed condensate is formed in the distribution system and steam distributor, manifold, or blower pack. Insulating steam lines is one important way to reduce the amount of condensate formed. Steam lines must be sloped so that condensate does not collect in the lines and create a restriction to steam flow. Condensate Return The condensate must be collected and removed from the system so that it does not build up and leak into the duct (or room if blower pack is used). Condensate must be collected and fed to drain. Operation | 46 Selecting an RH Setpoint The optimum humidity setpoint depends on the reasons that a space is being humidified. The “ASHRAE Handbook – HVAC Applications” recommends specific design relative humidities for specific applications. See also Condair publication “When You Need Humidity” (Form 124A) for more information on humidity settings. Health and Comfort - The benefit of humidity is most pronounced for health and comfort in the 40-60% range. A humidity setting of 40-50 % is recommended for this purpose to prevent over humidifying. Note: The job site design may have specified a setpoint chosen specifically for the site. Refer to site documentation and where possible use setpoints specifically determined for the site. Temperature Setback - In cold climates it is often necessary to reduce the humidity level in a space to prevent build up of condensation on the inside of exterior walls, windows, and trim. It is highly recommended that the temperature setback function of the Condair digital controls be used under these conditions to prevent damage from condensation. The digital control with an outdoor temperature sensor installed will automatically setback the humidity setpoint to correspond with outdoor temperature. Duct High Limit – The duct high limit is intended to prevent saturation and wetting in duct work at high load conditions. Condair recommends a setting of 85% for the duct high limit. It may be necessary to reduce this setting If the duct work is very cold or in contact with exterior cold surfaces. SAMe Manifold Insulated copper steam line. Support so weight is not on steam outlet. Condensate line ‘P’ Trap Figure 43: Nortec SAM-e Manifold 47 | Operation Blower Pack Blower Pack Blower pack condensate drain and ‘P’ Trap Insulate steam lines Balance steam line length to all blower packs Provide 120 V disconnect for blower packs power. Wire blower pack safety loop terminals in series with humidifier safety loop. Condensate to drain Oversize condensate line to combine multiple condensate returns Figure 44: Remote Blower Pack Operation | 48 Nortec SETC Humidifier Configuration Navigating the Nortec SETC Software The four input buttons below the digital display are used to navigate in the Nortec SETC’s software and to enter values. The function of the four buttons changes depending on what is being displayed on the screen. In all cases 4 icons representing the functions of the buttons are shown at the bottom of the screen. Screen Displays Screen Displays Request – 100% Idle 04/30/09 Security loop : Set P 45% 45% 45 % 150 lb/hr 14:25:22 Closed Menu ESC ? Press to go down a menu level Press to go left /right one screen ?=Press for information about current warning or fault message Press to go up a menu level S et Press to increase/ decrease value Press to accept setting and go up a level Figure 45: Navigating the Nortec SETC Software Main Menu (Nortec SETC Password) The menu levels of the Nortec SETC are password protected to prevent configuration changes by unauthorized persons. In order to access the menu level press the button corresponding to the Menu icon and when prompted enter the password 0335. Request – 100% Password 0335 5 Idle 04/30/09 Security loop: 30 lb/hr 14:25:22 Closed Menu ? Main Menu Service Level User Defined Settings Control Settings Diagnostics Menu 49 | Operation Set Enter Code Confirm with Set Menu Set Enter Password Press the Menu button from any status screen. Enter the user level code 0335 using the up arrow to change the value of each digit and the right arrow to move to the next digit. Press the Set button. Main Menu From here you can access all user configurable settings. Select any sub-menu by using the up/down arrow buttons and pressing Set when the desired one is highlighted. Note: Do not make changes unless you are familiar with the software. Service Level The selections in the Service Level allow you to reset service reminders and the fault history. Press Set while highlighting Service Level in the Main Menu. Service Level Service 500 Service Reminder Reminder ::500 Tank Drain Tank PreClean Reset Error History Reset Serv. Reminder Menu Set Service Reminder 500 hr 500 500hr Menu Set Tank Drain If the yes button is pressed the controller activates the drain pump and empties the tank. Interrupt Operation Tank Drain Menu Yes Service Reminder Sets the maintenance time interval for the humidifier based on run time at 100% output. The controller will display a warning when the time expires. (Default = 500 hr) No Set Tank Pre Clean Interrupt Operation? Preparation for regular maintenance to remove loose scale that may be present in the tank. Tank PreClean (This Operation Can Take >1 hr) Menu Yes No Set Reset Error History Reset Error History Menu Yes No Set Reset Error History Deletes the list of errors stored in the error history. The Error History is located in the Diagnostics Menu. Resetting the error history is not normally required, but can be done after repairs to remove faults that are no longer needed. Reset Service Reminder Resets the service reminder after the humidifier has been serviced. Reset Serv. Reminder Reset Serv. Reminder Menu Yes No Set Operation | 50 User Defined Settings The selections in User Defined Settings allow you to configure most user configurable features available with the Nortec SETC. Press Set while highlighting User Defined Settings in the Main Menu. User Defined Settings Drain : On Drain Cool Cool Off BD Rate : 25% FTBD : Off FTBD Time : Off FTBD Hours : 100 Idle Mode : Idle Drain Idle Time : 72 hr Fill Corr : 100% Drain Corr : 100% : 23:30 Float Ck Date : 06/27/09 : 13:22 Time : lb/hr Unit : English Language : 10 Contrast : Off Leak Ck Drain Cool On Off On Smart Menu Set Set Menu Blowdown Rate Sets the amount of water as a Blowdown Rate 25% BD Rate : 25% Menu Set Full Tank Blowdown Off On On FTBD : Off Menu Set Hour Hour 23 23 Set Set FTBD Hours Sets the number of hours between full tank blow downs. Hours are accumulated on a weighted basis (1 hour at 50% demand = 0.5 hrs). (Default = 100 hr) FTBD Hours 100 100 FTBD Hours : 100f Menu 51 | Operation Full Tank Blowdown Sets whether the tank will be periodically flushed to help flush minerals and scale. Blowdown frequency is controlled by the FTBD Hours parameter below. (Default = On) interrupting humidifier operation during critical times. (Default = 23:30) : Off Menu will be drained to control mineral concentration in the tank. (Default – 25%) FTBD Time Sets the time of day when a full tank FTBD Time FTBD Time Drain Cool Selects whether drain water cooling will be performed by adding fill water to drain water. Off = fill valve not activated during drain. On = fill valve activated whenever drain pump is on, Smart = fill valve only activated with drain pump when tank is hot. (Default = Smart) (User Defined Settings Continued) Idle Mode Sets what the humidifier will do Idle Mode Idle Drain Idle Mode : Idle Drain Idle Drain Keep Warm Menu Set Idle Time Sets the time without demand before the Idle Drain function will drain the tank (if activated). (Default = 72 hr) Idle Time 72 hr 72 hr 72 hr Idle Time : 72 hr Menu Set Fill Correction Increases or decreases the length of fill valve pulses to compensate for abnormal site conditions. (Default = 100%) Fill Correction 100 % 100 100 % % Fill Corr : 100% Menu Set Drain Correction Increases or decreases the length of Drain Correction 100% Drain Corr : 100% 100 % site conditions. (Default = 100%) Menu Float Ck Hour Minute Float Ck Set 23 30 : 23:30 Menu Date Day Month Date Set 27 06 : 27/06/09 Menu Only = Do nothing. Idle Drain = Drain the tank if there is no demand (wait time set with idle Time parameter). Keep Warm = periodically open CV valve to keep tank warm. for a demand and drain the tank if no demand (Default = Idle Drain) Set Float Check Sets the time of day when a float check to verify drains and float operation will take place. Can also disable the float check. (Default = 23:30 and On) Date Sets the date. Selecting Day, Month, or year takes the user to a submenu that allows the value to be increased or decreased by pressing up/down arrows. Set accepts the setting. Operation | 52 (User Defined Settings Continued) Time Hour Minute Time 13 22 : 13:22 Menu Unit : lb/hr : English Unit Sets the units of measure to use for display of steam output to either lb/hr or kg/hr. (Default = lb/hr) Unit Steam lb/hr lb/hr kg/hr Menu Language Set Set Language Sets the language to use for the software menu. (Default = English) Language English English French Dutch German Menu Set Contrast Adjusts the contrast of the LCD display to improve visibility under different lighting conditions. (Default = 10) Contrast 10 Contrast 10 10 Menu Leak Ck : Off Set Leak Check Off Off On Menu Time Sets the time of day. Selecting Hour or Minute takes the user to a submenu that allows the value to be increased or decreased by pressing u/down arrows. Set accepts the setting. Set Leak check Sets whether the controller should monitor tank level during periods of no demand. If on a fault will be generated if water level drops with no demand. (Default = Off) Control Setting Control Setting allow you to set the type of external controls the humidifier is connected to. In most cases the Nortec SETC humidifier is factory configured to operate with the external controls that were specified for the site. Press Set while highlighting Control Setting in the Main Menu. CAUTION: Improper control configuration can result in over humidifying which can result in damage to property. 53 | Operation (Control Settings Continued) Control Setting Source : Analog REG Mode : Demand MOD Mode : Dual CH Multi Mode : Standalone CNT Type : 0-10 LIM Type : 0-10 Short CD : On Short CD Tm : 30 s Time Prop. : Off Manual Cap : 100% Mulit Unit Op Range Modbus Settings Press Base : On Supply Press. : 15 psi RH Settings Menu Only present if Mod Mode set to Dual CH Only present if Short CD set to On Only present if Multimode set to Master or Slave Only present if Press Base set to On Only present if REG Mode set to RH (P) or RH (PI) Set Source Configures the humidifier to either accept analog control signals from a humidistat or digital signals from a Building Management System Source Analog Analog Digital Menu REG Mode : Demand Set REG Mode Configures the type of control used Regulation Mode Demand Demand On/Off RH (P) RH (PI) Menu Set MOD Mode Configures the humidifier to either MOD Mode Single CH Single CH MOD Mode : Single CH Menu Set : Standalone Slave Menu (control only) or dual channel (control and high limit). If an On/Off high limit humidistat is used set MOD Mode to Single CH Multi Mode Use Multi Mode to configure the Multi Mode StandAlone Standalone StandAlone Multi Mode proportional only internal control based on a transducer signal. RH (PI) is proportional control with an integral. Set humidifier of a group controlled by a single control signal / transducer signal. See Multi Unit Op. Range later in this section. (Default = Standalone) Operation | 54 (Control Settings Continued) CNT Type : 0-10 CNT Type Configures the Volt or amp range of the control signal connected to the humidifier CNT Type 0-10 V 0-5 V 1-5 V 0-10 V 0-10V 2-10 V 0-16 V 32-16 V 0-20 mA 4-20 mA Menu Set LIM Type Configures the Volt or amp range of the high limit control signal connected to the humidifier. The type of control, VDC or mA, must be the same as that of CNT Type. LIM Type 0-10 V 0-5 V LIM Type : 0-10V 0-10 0-10VV 2-10 V 0-16 V 3.2-16 V Menu Set Short Cycle Delay Sets whether the humidifier must Short Cycle Delay Off Off Short CD : Off Menu Set Short CD Tim Specifies the minimum time the Short Cycle Delay Time 30 s Short CD Tm : 30 s 30 s Menu Set : Off Menu Set Manual Capacity 100% Manual Cap : 100% 100% 100% Menu 55 | Operation whenever demand drops to the off condition. It is only checked if Short CD is set to On. (Default = 30 s) Time Prop Sets whether the humidifier will run Time Proportioning Off Off Time Prop. by the Short CD Tim parameter) whenever demand falls below the On threshold to prevent short cycling. (Defualt = Off). Set demand is less than 15%. On results in the humidifier turning on and off for short periods of time to simulate low output. (Default = Off). Manual Cap Reduces the maximum capacity of the humidifier to a percentage of its full capacity. Use up/down buttons to increase/decrease and press Set to save the setting. (Default = 100%) (Control Settings Continued) Multi Unit Op. Range The Nortec SETC can be configured to network up to sixteen (10) humidifiers (or equivalent of 10,500 lb/hr) using a master slave configuration. To operate the Nortec SETC in a staged modulation system; The humidifiers must be connected in parallel (daisy chained) using the linkup terminal (J2a) on the Nortec SETC driver board (See Staged Modulation Wiring on page 31). One humidifier must be designated the master and all others as slave units (see Multi Mode on page 54 for software configuration). The master unit must be the unit to which external controls / transducers and safety loop are connected. Each humidifier in the system including the master must have the range of demand signal in which it will operate configured (see below). Example, for four humidifiers with equal capacity set the master to operate between 0% and 25%, set the fist slave for 26% to 50%, set the second slave for 51% to 75%, and set the third slave for 76% to 100%. The Multi Unit Op. Range submenu is used to configure the humidifier’s operating range when Multi Mode in the User Defined Settings menu is set to either Master or Slave. The menu is not displayed if the humidifier is set to Standalone operation. Access the Multi Unit Op. Range submenu by pressing the menu button while Multi Unit Op. Range is highlighted in the Control Settings menu. NOTE: The Multi Unit Op. Range submenu is only displayed if the humidifier has been configured as either a Master or Slave. It is not displayed in Standalone mode. Multi Unit Op. Range Full Out sets the system demand at Multi Unit Op. Range Multi Unit Op. Range Full Out Zero Out Menu Modbus Settings : On its full capacity. Zero Out sets the system demand at which the humidifier should shut off. Set Modbus Settings Parity Parity : Even Timeout Rem Disable : 300 s : On Menu Press. Based : 20% : 0% Set Pressure Based On Off On Menu Set Modbus Settings Allows configuration of Selecting an item brings up a screen that allows the value to be changed by using the up/down arrow keys. Rem Disable allows the user to turn the humidifier on if it has been remotely disabled. Pressure Based Configures the humidifier to use steam supply pressure to calculate system output. If set to off the output displayed is based on a supply pressure of 15 psi. Operation | 56 (Control Settings Continued) Supply Pressure 15 psi Supply Press. : 15 psi 15 psi Menu Set Supply Press Sets the steam supply pressure for the humidifier to us in displaying its steam output. It is only displayed if Press Based is set to On. (Default = 15 psi) Note: The RH Settings menu selection will only be displayed in the Control Settings menu if REG Mode is set to RH (P) or RH (PI). RH Settings The RH Settings submenu is used to adjust setpoint, the proportional band, and the integral time if REG Mode is set to RH (P) or RH (PI) and the humidifier is connected to humidity sensors. Access the RH Settings submenu by pressing the menu key while RH Settings is highlighted in the Control Settings menu. RH Settings CNT CNT Set-P Set-P CNT Band CNT Itime LIM Set-P LIM Band LIM Damp RH Alerts RH High RH Low RH Settings :: 40% 40% RH : 15% RH : 5 min : 80% RH : 15% RH :5s : On : 75% RH : 33% RH Menu : 40% 40% RH Menu Set : 15% RH 15% RH Menu humidifier will modulate between 0 and 100% output. (Default = 15%) Set Int Time should not normally be changed. Int Time adjusts the Control Integral Time 5 min CNT Itime : 5 min 5 min Menu 57 | Operation CNT Set-P Sets the humidity setpoint value. The humidifier will attempt to maintain this humidity level in the space where the control transducer is installed. CNT Band should not normally be changed. The CNT Band setting Control Band 15% RH CNT Band Only present if RH Alerts is set to On Set Control Set Point 40% RH CNT Set-P Only present if MOD Mode is set to Dual CH Set corrects for proportional control error. It is only displayed if REG Mode is set to RH (PI) (Default = 5 min) (RH Settings Continued) LIM Set-P Sets the duct high limit setpoint Limit Set Point 80% RH LIM Set-P : 80% 80% RH Menu Set LIM Band Should not normally be changed. The Limit Band 15% RH LIM Band : 15% RH 15% RH Menu Set : 15% RH 5s Menu band before output is throttled down. (Default = 5 s) Set RH Alerts Sets whether the humidifier will RH Alerts On On RH Alerts above or falls below configured limits. (Default = Off) : On Menu Set RH High Sets the RH level above which the RH High 75% RH RH High : 75% 75% RH Menu is generated. Warning is only generated if RH Alerts is set to on. Set RH Low Sets the RH level below which the RH Low 33% RH RH Low : 33% RH within which the humidifier will throttle down the humidifier output from 100 to 0%. (Default = 15%) Limit Damping Sets the number of seconds the Limit Damping 5s LIM Damp the high limit the output of the humidifier will be throttled back to prevent wetting the duct. (Default = 80%) 33% RH Menu is generated . Warning is only generated if RH Alerts is set to on. Set Operation | 58 Diagnostic Menu The Diagnostic Menu provides a historical list of errors and service recorded by the humidifier’s software as well as providing the ability to manually activate humidifier components for troubleshooting purposes. Press Set while highlighting Diagnostic Menu in the Main Menu. Diagnostic Menu Fault History Service History Output Test Remote Test Menu Fault History 04.14.07 21:48 03.20.09 02:35 Set Menu E19A E19A Set Service History Displays a list of service that has been performed on the humidifier. It displays the date and time of service. Service History 04.21.07 09:10 03.21.09 10:10 Service History Menu Set Output Test Output Test Inlet Valve: Off Menu Set Remote Test Remote Test Steam Relay: Off Menu 59 | Operation Fault History Displays a list of faults which the controller has recorded. It shows the date and time at which the faults occurred. Refer to Table 13: Troubleshooting Warnings and Faults for meaning of codes and suggested actions to correct faults. Set Output Test Provides a means for activating all humidifier components (inlet valve, drain pump, etc.) for diagnostic purposes. Components can be activated one at a time. Scroll to component to be tested using up/down buttons, press Set once to activate, press again to turn off. Remote Test Provides a means for testing of remote fault relays to confirm they are operating correctly. Relays can be activated one at a time. Scroll between relays with up/down arrow buttons and press Set once to turn on relay, press again to turn it off. SEP Humidifier Configuration The Nortec SEP is factory configured to operate under most conditions without the need for any changes to its configuration. If required several settings can be made using jumpers on the Nortec SEP’s control board. The blowdown of the Nortec SEP can also be adjusted by using a potentiometer on the Nortec SEP’s control board. See Figure 46: Nortec SEP Control Board Jumpers for location of jumpers and the blowdown adjustment potentiometer. Note: Condair recommends not making any configuration changes unless they are required and that any changes to the Condair SEP’s settings be performed by a qualified technician. Blowdown Adjustment Potentiometer Jumpers J11 to J18 Jumper J10 Figure 46: Nortec SEP Control Board Jumpers Caution: Never adjust jumpers other than those listed in this section. Other jumpers are factory set and must not be changed. Blowdown Adjustment Sets the amount of water as a percentage of steam produced that will be drained to control mineral concentration in the tank. The blowdown adjustment potentiometer is located on the side of the control board as shown in Figure 46. It can adjust the blowdown between 0% and 50% of steam produced. (Factory setting = 25% blowdown). 25% 0% 50% Note: 0% blowdown should never be used even with Deionized water. Minimum recommended setting is 5%. Operation | 60 On/Off or Modulating Control (J10) The Nortec SEP’s output can be controlled by either an On/Off humidistat or a modulating humidistat. To set the Nortec SEP to operate with a modulating humidistat remove Jumper J10. (Factory setting = jumper removed, modulating operation) J10 Removed– Modulating operation, the controller monitors the demand signal on terminal point 4 of the control terminal strip and adjusts humidifier output to match it. J10 Installed - The Nortec SEP is configured for On/Off operation. The controller will ignore any modulating signals even if they are connected. Nortec SEP Model (J11 to J13) The Nortec SEP model is configured using Jumper 11 to 13. The jumper setting is configured at the factory and should not be adjusted in the field. Table 8: SEP Model Configuration Resulting Control J11 J12 J13 SEP 50/100 SEP 175 SEP 250 SEP 375 SEP 525 SEP 750 SEP 1050 0 1 0 1 0 1 1 0 0 1 1 0 0 1 0 0 0 0 1 1 1 Full Tank Blowdown (J14 and J15) The Nortec SEP can be configured to periodically drain the tank to help flush minerals and scale. Jumpers 14 and 15 control blowdown frequency. Hours are accumulated on a weighted basis (1 hour at 50% demand = 0.5 hrs). (Default = J14 and J15 installed, no full tank blowdown) Table 9: Full Tank Blowdown Jumper Configuration Resulting Control J14 J15 No Full Tank Blowdown 96 hours between FTBD 48 hours between FTBD 24 hours between FTBD 1 0 1 0 1 0 0 1 Modulation Offset (J16) The Nortec SEP controller can be configured to work with a modulating humidistat with 4-20 mA or 2- 10 VDC output. Modulation offset can be configured with jumper 16. (Factory setting = Jumper removed, 0-10 VDC or 0-20 mA control signal) J16 Removed – Controller is configured for a 0-10 VDC or 0-20 mA control signal. J16 Installed – Controller is configured for a 2-10 VDC or 4-20 mA control signal. Note: For mA control a 500resister is required between terminals 3 and 4 on the low voltage control terminal. 61 | Operation Table 10: Control Jumper Configuration Resulting Control J10 J16 On/Off Modulating 0-10 VDC or 0-20 mA Modulating 2-10 VDC or 4-20 mA 1 0 0 No Affect 0 1 Drain Water Cooling (J17) The Nortec SEP can be configured to cool drain water by activating the fill valve whenever the drain pump is activated. To disable drain water cooling remove jumper J17. (Factory setting = jumper installed, drain water cooling active) J17 Removed – The fill valve is not activated together with the drain pump. J17 Installed – The fill valve activated together with the drain pump to cool drain water. Float Check (J18) Whenever the Nortec SEP is first powered it performs a float check to ensure water level detection is working properly. The float check can be deactivated via jumper 18. (Factory setting = jumper removed, float check is performed) J18 Removed – A float check is performed whenever the Nortec SEP is powered on. J18 Installed – A float check is not performed whenever the Nortec SEP is powered on. Operation | 62 Maintenance and Servicing 64 Required Maintenance 64 Service Warning / Fault 65 Maintenance Schedule 66 Cleaning the Tank 67 Cleaning the Heat Exchanger 68 Cleaning the Float Chamber 68 Resetting Service Reminder 69 Maintenance Shutdown and Extended Shutdown 70 Nortec SETC/P Maintenance Checklist 63 | Maintenance and Servicing Required Maintenance Caution: Power to the humidifier should always be turned off using the dedicated external disconnect before removing the door or side panel, or before doing any service work on the humidifier. Service Warning / Fault The Nortec SETC controller includes a timer that monitors the humidifier’s operating hours and generates a warning when service is required. Optimal maintenance time is dependent on water supply conditions and humidifier usage. The default factory service reminder is equivalent to 500 hours of operation at 100% output. Failure to perform maintenance when the service warning is displayed will cause the unit to lock out. Condair is not responsible for any damages resulting from, or attributed to not performing required maintenance. (See Manufacturer’s Warranty). Warning When the software determines that the service timer has elapsed it first Request – 68% Warning HMW - Humidifier Maintenance Service LED On + HMW - Humidifier Maintenance = Service timer has expired and humidifier needs maintenance Humidifying 04/30/09 Security loop: 134 lb/hr 14:25:22 Closed Menu ? displays a warning and turns on the yellow service LED. The humidifier will continue to operate for another 200 hours after the warning is displayed. + 200 Hours Request – 68 % Fault HMF - Humidifier Maintenance Fault LED On + HMF - Humidifier Maintenance = Service timer + 200 hours has passed. Maintenance must be performed. Humidifier has shut down. Fault 04/30/09 Security loop: Menu 34 lb/hr 14:25:22 Closed ? Fault After 200 hours the humidifier will display a fault and shut down. If maintenance is not possible the humidifier can be temporarily put back into service by turning the humidifier off and on. The humidifier will run for another 200 hours. This reset can be repeated 4 times after which the humidifier will not run until the Reset Service Reminder function is entered in the software’s service level. Figure 47: Service Warning / Fault Maintenance and Servicing | 64 Maintenance Schedule Regular maintenance is required to keep the Nortec SE Series humidifier operating at its peak capacity and efficiency. Follow the maintenance schedule shown in Table 11: Nortec SE Humidifier Maintenance Schedule to ensure long humidifier life and peak performance. Table 11: SE Humidifier Maintenance Schedule Item Tank 30 Days After Start-up When Service Light is Lit End of Season What to Do 1. Remove service door and inspect for scale. 2. Remove scale deposits from tank walls using plastic scraper. 3. Collect scale deposits from tank bottom using wet vac or scraper and bucket. Heat Exchanger 1. Remove service door and inspect for scale. 2. Remove scale deposits from tank walls using plastic scraper. 3. Collect scale deposits from tank bottom using wet vac or scraper and bucket. 4. Once per season remove heat exchanger, clean, and inspect. Gaskets 1. Inspect for cracking or damages. 2. Remove any scale deposits before re-installing. 1. Remove float chamber, and float chamber lid. 2. Clean any scale deposits from walls and float magnets. 3. Re-install magnets. 1. Inspect for dust and dirt build-up. 2. Blow clean with compressed air. Float Chamber Heater System Fill System 1. Inspect for leaks at float chamber and fill valve. Drain System 1. Inspect for leaks at drain pump, auxiliary drain, and internal vacuum break. Steam Trap 1. Inspect for deposits and float operation. 2. Replace thermal disk if necessary. 3. Clean all ports and inside of trap body. Wye Strainer 1. Remove service plug and clean out collector screen. Steam Valve 1. Inspect actuator operation. 2. Perform leakage test to ensure that valve is closing properly. Boiler Pressure 1. Inspect Pressure Reducing Valve operation. Pressure must not exceed 15 psig Note: After performing the first maintenance on the Nortec SETC it is possible to increase or decrease the service period to match water conditions. If the tank, heat exchanger, and float chamber are relatively clean and free of scale increase the service period. If there is a lot of scale and it is difficult to remove then reduce the service period and consider increasing the blow down setting. (See Nortec SETC Configuration) 65 | Maintenance and Servicing Cleaning the Tank The tank, heat exchanger, and float chamber should be cleaned at least once per season to remove scale and mineral deposits which can reduce unit efficiency. In areas with high mineral content in the water, cleaning should be more frequent. Warning Disconnect main power at the external disconnect before any servicing. Tank and piping may be hot, take care when handling. Avoid using de-scaler chemicals or caustic chemical which can damage the tank or heat exchanger. 1 Follow Maintenance Shutdown and Extended Shutdown procedure on page 69. Give the unit some time to cool down to avoid injury when servicing. 2 Remove the cabinetry covers on the front (all models) and top (Nortec SE 525 – 1050 models) by removing the Phillips type screws and lifting the covers. 3 Remove the tank maintenance doors on the front (all models) and top (Nortec SE 525 – 1050 models) by applying anti seize compound to nuts and using 1/2 in. socket. Remove excess anti seize compound. 4 Inspect the tank door gaskets. Remove any scale from the gaskets, the tank door gasket surface, and tank gasket surface. 5 Using a plastic scraper, such as those used for car windshields, remove scale adhered to tank walls and visible portions of the heat exchanger. Remove this scale from the unit. A wet vacuum can be used for this purpose. 6 Inspect the heat exchanger. If significant scale build-up has occurred, follow the cleaning Top Cover Gaskets Tank Door Locknuts. Apply anti seize compound to remove. Do not crush gasket. Max 5 ft-lbs torque. Top Maintenance Door (Nortec SE 525 - 1050 Only) Front Cover Front Maintenance Door procedure the next section. Figure 48:inTank Access For Cleaning Maintenance and Servicing | 66 7 Reinstall the tank door gaskets and tank doors. When tightening the tank door nuts, take care not to over tighten. The tank door nuts should only be torqued to 5 ft-lbs to prevent crushing the gasket underneath. Cleaning the Heat Exchanger 1 Follow Maintenance Shutdown and Extended Shutdown procedure on page 69. Give the unit some time to cool down to avoid injury when servicing. 2 Remove the cabinet cover on the right side by removing the Phillips type screws and lifting the covers. 3 Disconnect the union that transports steam into the heat exchanger and remove the F&T trap by disconnecting the two unions that hold it in place. 4 Apply anti seize compound to heat exchanger nuts and remove with 1/2 in. socket. Remove excess anti seize compound. 5 Remove the heat exchanger(s) by pulling on the handle and sliding the heat exchanger out of the unit. 6 Note: Heat exchangers are heavy, use proper lifting technique when removing them. It is helpful to have an assistant help remove the heat exchanger. 7 Inspect the heat exchanger gaskets. Remove any scale from the gaskets, the heat exchanger gasket surface, and tank gasket surface. 8 Using a plastic scraper, such as those used for car windshields, remove scale adhered to the heat exchanger. 9 Reinstall heat exchanger gaskets and heat exchanger. When tightening nuts, take care not to over tighten. Only torque nuts to 5 ft-lbs to prevent crushing the gasket underneath. Steam Connection Union Heat Exchanger Gasket Cabinet Cover F&T Trap Union F&T Trap F&T Trap Union Heat Exchanger Figure 49: Heat Exchanger Removal 67 | Maintenance and Servicing Heat Exchanger Locknuts Apply anti seize compound to remove. Do not crush gasket. Max. 5 in-lb torque Cleaning the Float Chamber 1 Follow Maintenance Shutdown and Extended Shutdown procedure on page 69. Give the unit some time to cool down to avoid injury when servicing. 2 Remove the cabinet covers on the front of the unit by removing the Phillips type screws and lifting the covers. 3 Disconnect the electrical connection to the float board. 4 Remove the hose clamps and the hoses from the top and bottom of the float chamber. 5 Remove the reusable tie-wrap from the float chamber by inserting a small screw driver into the top of the buckle. 6 Squeeze both sides of the mounting bracket to release the float chamber from the slots on the support bracket. 7 Use a screw driver to remove the 3 screws from top of the float chamber and remove the lid. Using a small brush or plastic scraper remove any scale from the inside of the chamber. 8 Re-installation is the reverse of removal. Caution: Do not reverse float chamber hoses To tank To fill valve Squeeze tabs to remove assembly from humidifier Figure 50: Float Chamber Cleaning Resetting Service Reminder After completing maintenance of the Nortec SETC reset the service reminder by following the procedure outlined in Reset Service Reminder on page 50. NOTE: If the “Service Reminder” is not reset the humidifier may fault out on the Humidifier Maintenance Fault despite the fact that the maintenance has been performed. Maintenance and Servicing | 68 Maintenance Shutdown and Extended Shutdown The following procedure should be followed to shut down the humidifier for maintenance or should it be required to disconnect power to the humidifier for a period of extended shut-down. When performing maintenance, the Nortec SETC models include a Tank Pre-Clean feature. Tank Pre- Clean will activate the drain pump to flush out some of minerals in the bottom of the tank, then refill partially with cold water to cool the tank, and finally drain the contents of the tank. This cycle will cool the tank, as well as flush out some deposits. 1 Nortec SETC - Activate Tank Pre-Clean as described in Tank Pre Clean on page 50 or press and release the drain button to simply drain the tank. Nortec SEP - Turn the On/Off/Drain switch to Drain. 2 Nortec SETC - If preclean was activated wait until the LCD display indicates the preclean is complete otherwise wait until no water is coming out from the drain. Nortec SEP wait until there is no water coming out from the drain. 3 When the tank has completed draining, turn the main power switch to “Off”. Also, shut off the electrical power at the disconnect. 4 Close the manual shut-off valve on the steam supply. 5 Close the manual shut-off valve on the water supply line. 6 Briefly open the manual valve on the auxiliary drain line (if applicable) to drain any remaining water. 7 The unit can now be serviced (if maintenance is being performed), or “stored” in this state until the next humidification season. Alternatively, Nortec SETC models can be left in 3 day drain state during an “off-season”. 8 To restart the unit follow Start Up Procedure on page 36. Note: As long as the Nortec SETC is powered, it will automatically drain the tank when there has not been a call for humidity for an extended period of time. This feature will reduce or prevent the possible accumulation of algae and bacteria growing in the tank. The tank will remain empty until there is a call for humidity at which time the fill valve will open and refill the humidifier tank. The unit will go through its normal process for optimum operation. 69 | Maintenance and Servicing Nortec SETC/P Maintenance Checklist Model #: Tag: Serial #: System Check HMW (Maintenance Warning ) HMF (Maintenance Fault) Other warnings or Faults shown in display / LED’s? No Yes (See Troubleshooting Chapter for actions to address warnings and faults if present) Clean Tank / Heat Exchanger / Float Chamber Tank drained. Disconnect open, On/Off switch to Off Water shut off and manual steam valve closed, cabinet covers removed. Anti seize compound applied to tank maintenance door nuts. Maintenance doors removed (front and top of 525+). Tank maintenance door gaskets cleaned and in good condition. Scale removed from tank. Heat Exchanger has scale and needs cleaning No Yes If Yes Steam supply and condensate unions disconnected Anti seize compound applied and heat exchanger nuts removed Heat exchanger removed. Heat exchanger gaskets cleaned and in good condition. Heat exchanger cleaned with plastic scraper. Heat exchanger reinstalled. Nuts torque to 5 ft-lb Steam supply and condensate unions reconnected. Tank maintenance doors reinstalled Nuts torque to 5 ft-lb Float Chamber removed inspected and cleaned General Inspection Electrical wiring not loose and in good condition, Steam hoses and steam lines in good condition / No kinks in hose, No Signs of water leaking around humidifier, steam line, condensate returns, Cabinet covers replaced, water shut off valve opened, manual steam valve opened, On/Off switch to On, Disconnect Closed Nortec SETC only - “Reset Service Reminder” in Software, (Password 0335, Service Level) Inspected by: Date of inspection: / / Company: Maintenance and Servicing | 70 Troubleshooting 72 Organization of Troubleshooting Chapter 72 Troubleshooting Requirements 73 General Troubleshooting 73 Humidifier 74 Steam Distributors 74 Nortec SAM-e 75 Blower Pack 75 Digital Humidistat 76 Nortec SETC Warnings and Faults 76 Warnings 76 Faults 76 Clearing a Fault 82 Nortec SEP Faults 82 Faults 82 Clearing a Fault 83 Nortec SETC Wiring Diagram 84 Nortec SEP Wiring Diagram 71 | Troubleshooting Organization of Troubleshooting Chapter The troubleshooting chapter is broken down into 2 sections. General Troubleshooting Deals with troubleshooting incorrect humidifier operation, steam line and plumbing issues without any control software warnings or faults. Humidifier Warnings and Faults Deals with warning and error messages that are generated by the humidifier’s control software. CAUTION: Be aware, when troubleshooting, that the humidifier is powered by high voltage and pressurized steam. Familiarity with both good practices and wiring of the humidifier is recommended. Any troubleshooting that requires opening the cabinet should be done by qualified personnel. NOTE: Most humidifier faults are not caused by faulty equipment but rather by improper installation. A complete fault diagnosis always involves a thorough examination of the entire system. Often, the steam hose connection has not been properly executed, or the fault lies with the humidity control system. Troubleshooting Requirements Ensure the installation meets the installation requirements outlined in the Installation Chapter of this manual. Familiarize yourself with the operation of the humidifier by reading the Operation Chapter of this manual. Wiring diagram specific for your humidifier is installed on the inside of the humidifier door. A generic copy of the Nortec SETC and Nortec SEP wiring diagram is also included at the end of this chapter for reference purposes. When contacting your local representative or Condair for troubleshooting assistance, please ensure the serial number has been obtained for reference purposes. Troubleshooting | 72 General Troubleshooting The following section provides general guidelines for troubleshooting the Nortec SETC/P humidifier and auxiliary components. For detailed troubleshooting information refer to the manuals that were provided with the auxiliary equipment, to Table 13: Troubleshooting Warnings and Faults, and to Table 14: Troubleshooting Nortec SEP Faults later in this chapter. Humidifier Table 12: General Troubleshooting Symptom Nothing happens when On/Off switch is turned on. Cause Corrective Action(s) 1 Fuse blown 1 Check inline fuse in yellow housing between transformer and driver board. Check and replace fuse on driver board. 2 Incorrect or no Voltage 2a Check voltage against spec label and correct. 2b Check disconnect and insure humidifier is getting power. Humidifier will not humidify or not reaching RH setpoint 3 Step Down Transformer not outputting 24VAC 3 Replace the transformer 1 Safety loop open 1a Check if green led is flashing on the humidifier’s display. 1b Check if there is 24 VAC at terminal 2. 1c Check wiring and operation of On/Off devices connected to terminal 1 and 2. Ensure they are closing when they should be. 2 High limit limiting output 2 Check if the high limit is installed too close to the humidifier and if it is operating correctly. 3 No signal on Channel 1 3 Check voltage between terminal 3 and 4. For demand configuration 15% of full scale signal must be present for humidifier to start. For transducer configuration the signal must be lower than setpoint for the humidifier to start. 4 No signal on Channel 2 4 Check voltage between terminal 5 and 3. For demand configuration 15% of full scale signal must be present for humidifier to operate. For transducer configuration the signal must be lower than setpoint for the humidifier to start.. (For units configured for dual channel operation). Humidifier has faulted or has a warning 73 | Troubleshooting 5 Capacity has been manually limited 5 Check Manual Capacity on status screens. Adjust “Manual Cap” in the “Control Setting” menu if necessary. 1 Software has detected an abnormal condition 1 Refer to Table 13troubleshooting warnings and faults. Steam Distributors Symptom Distributor spitting out water Condensation in duct Cause Corrective Action(s) 1 Distributor not level 1 Use support at end o distributor to ensure it is level. 2 “P” Trap too close to distributor 2 “P” Trap must be a minimum of 12 in (30 cm) below the distributor to ensure flow. Relocate if required. 3 Condensate line not sloped sufficiently 3 Sufficient slope to insure flow is required. Reinstall if required. 4 Trap blocked 4 Check that water flows through trap. Clear out if blocked. 5 Condensate line double trapped 5 Condensate lines must not have two traps in sequence. This can cause an air lock and prevent water draining. 6 Steam line not insulated 6 If steam line is long condensate build up could overload distributor condensate port. Insulate line to improve efficiency and install additional condensate traps as required. 1 Installation clearances not observed 1 Refer to distributor installation manual for required clearances. Relocate distributor if required. 2 Design conditions changed 2 Check supply air temperature and humidity to determine if conditions have changed. 3 High limit not functioning 3 Check setting and operation of high limit. Replace if defective. 4 Air proving not installed or not working 4 Check that the humidifier will only operate when there is air moving in the duct. 5 Improper location of high limit 5 Check that high limit is installed where it can detect high duct humidity. SAM-e Symptom Nortec SAM-e spitting out water Cause Corrective Action(s) 1 “P” Trap too close to SAM-e 1 “P” trap must be at least 12 in (30 cm) below header. Relocate if required. 2 Condensate line not sloped sufficiently 2 Ensure line is sloped sufficiently to carry condensate produced. 3 Steam line not insulated 3 If steam line is long condensate build up could overload the Nortec SAM-e condensate port. Insulate the steam line to improve efficiency and install condensate traps as required. Troubleshooting | 74 Symptom Nortec SAM-e Grommet leaks Cause Corrective Action(s) 1 Distributor tubes not seated properly 1 Push distributor tubes down until support washer is resting on rubber grommet. 2 Grommet Damaged 2 Replace any damaged grommets Blower Pack Symptom Blower not operating Cause 1 No power to blower pack Corrective Action(s) 1a Check power connection. 1b Check blower pack fuses Note: Blower pack does not come on unless the humidifier is producing steam. 2 On/Off Thermostat not closing 2 Check wiring to thermostat replace if it does not close when it is exposed to steam. Digital Humidistat Symptom Humidistat Reading incorrectly 75 | Troubleshooting Cause Corrective Action(s) 1 Sensor out of calibration 1 Check reading against known reliable instrument. If out of calibration it can be field calibrated ±10%. Press buttons together until calH appears on the display. Press to display the current calibration trim. Adjust using buttons. Press button when done. 2 Improper sensor location 2 Check that the humidistat is positioned in a location representative of room humidity. 3 Exposed to draft or heat source 3 Check that heat/cold fluctuations, drafts, sunlight, doors, or vents are affecting the reading. 4 No vapour barrier 4 Insure drafts cannot affect reading by ensuing vapour barrier is in place and working. Nortec SETC Warnings and Faults The self-diagnostic system built into the SETC is continually monitoring the operation of the humidifier. Warnings When problem symptoms are detected, the Nortec SETC will attempt to take self-corrective actions to try to correct the problem. A warning is displayed on the screen for information purposes and the humidifier continues to operate. If the condition which generated the warning is eliminated the warning is cleared from the display. Faults If the humidifier is not able to self correct a problem symptom it will if necessary respond by shutting itself down. When this occurs the humidifier illuminates the red “Fault” LED, shuts off the signal to the CV valve actuator, and activates the “Error” relay of the remote relay board. Clearing a Fault Check the fault message that the humidifier is displaying and take any necessary actions to correct the cause(s) as outlined in Table 13, Troubleshooting Warnings and Faults. Power cycle the humidifier with the On/Off switch waiting 3 seconds between turning it off and on. Table 13: Troubleshooting Warnings and Faults Code CLF DCF Display Message Clock Fault Drain Ck Fault LED Red Red System Detected Controller system clock failure. The drain pump is activated but water level has not decreased Cause Corrective Action(s) 1 Software has detected a hardware problem with main control board 1 Restart humidifier, if error occurs within 1 minute replace main control board. If error does not occur then primary power fluctuation may be the cause. 1 Drain blocked 1 Check water flow at air gap when drain activated. Flow should be > 5 gal (20 l) / min. 2 Pump not working 2a Check wiring to pump. 2b Activate pump with diagnostic output test and verify pump runs and drains water. Troubleshooting | 76 Code Display Message LED System Detected DCF Cause 3 Floats stuck (Cont) Corrective Action(s) 3a Watch float board lights while manual drain is activated. Verify lights activate in sequence 3b Remove float chamber and check for scale FCF Fill Check Fault Red The fill valve has been active for an extended time without increasing a float level. 1 Water supply off or inadequate 1a Ensure water line is open and that adequate water supply and pressure is available. 2 Fill valve strainer blocked 2a Disconnect water supply line and remove strainer. Clear if obstructed. 3 Fill Valve not activating 3a Check wiring to fill valve. 3b Activate fill valve with diagnostic output test. Verify water is flowing when activated. 4 Float board not detecting water 4a Check wiring to float board. 5 Manual drain switch on or auxiliary drain open. 5a Check that manual drain switch is not on. 5b Check that auxiliary drain valve is closed. FIF Float Inconsist. 77 | Troubleshooting Red On startup, the unit registers that the float levels do not increase logically from 1 to 5 1 High water flow from fill valve to float chamber cooling. 1 Check flow from fill valve hose connected to float chamber. Is only a trickle. If not check hose is connected to correct side of fill valve or if orifice is missing in fill valve. 2. Float chamber or board not in place 2 Check that float board is properly installed in plastic support , that tie wrap is in place, and that float reservoir is in place. 3 Float level sensor is malfunctioning. 3 Squeeze bottom hose from float chamber and activate fill valve using diagnostic output test. Watch for proper light sequence. Replace assembly if sequence is incorrect. Code FLF Display Message Float Level LED System Detected Red More than one Float Level is registering at the same time FLF (Cont) Red FTF The fill valve has been active for an extended time without reaching level 1. Fill Fault / Warning FTW Cause Corrective Action(s) 1. Float chamber or board not in place 1 Check that float board is properly installed in plastic support , that tie wrap is in place, and that float reservoir is in place. 2 Float level sensor is malfunctioning. 2 Squeeze bottom hose from float chamber and activate fill valve using diagnostic output test. Watch for proper light sequence. Replace assembly if sequence is incorrect. 1 Water supply off or inadequate 1a Ensure water line is open and that adequate water supply and pressure is available. 2 Fill valve strainer blocked 2a Disconnect water supply line and remove strainer. Clear if obstructed. 3 Fill Valve not activating 3a Check wiring to fill valve. 3b Activate fill valve with diagnostic output test. Verify water is flowing when activated. 4 Float board not detecting water 4a Check wiring to float board. 5 Manual drain switch on or auxiliary drain open. 5a Check that manual drain switch is not on. 5b Check that auxiliary drain valve is closed. Red HMF Maint. Fault / Warning Yel HMW KWF Keep Warm Fault Red The Humidifier Maintenance interval and 72 hour window for cleaning has expired The preset service interval time has expired. 1 Humidifier requires maintenance 1 Perform humidifier maintenance as described Maintenance Schedule on page 65 2 Service reminder not reset after maintenance 2 Reset service reminder as described in Reset Service Reminder on page 50 Keep Warm activated but tank temperature has not increased within time allotted 1 Tank temperature sensor not detecting warm tank. 1a Check tank to see if hot (caution). 1b Check wiring to tank temperature sensor. 1c Check if sensor closed when tank is hot. Troubleshooting | 78 Code Display Message LED System Detected Cause 2 No steam supply to humidifier. KWF (Cont) Corrective Action(s) 2a Check that isolation valve is not closed. 2b Check if boiler steam is available. 2c Check if CV valve opens using diagnostic output test. Float level has dropped multiple times while no steam is being produced. Leak Fault / Warning LKW MEM MTW 3a Check that F&T trap is allowing condensate to drain. 1 Steam leaking through CV valve 1a CV valve actuator not adjusted. Follow Figure 11: CV Valve Actuator Installation on page 16. Red LKF LMI 3 Condensate not draining from heat exchanger. Limit signal Is not stable. Limit Instable Flash R/W Fault ModBus Timeout 79 | Troubleshooting Red Controller Memory failure No Modbus signal 1a CV valve defective. Replace CV valve. 2. Auxiliary drain is leaking. 2a Check that auxiliary drain valve is closed and is not leaking. 3. Tank or fittings are leaking. 3a Check for leaks from tank, tank covers, and fittings. 1 High limit humidistat too close to steam distributor 1 Locate the high limit humidistat a minimum of 10 feet (3 m) from the distributor. 2 High limit humidistat setpoint too low 2 Adjust the high limit setpoint to 85% or more. 3 Improper Proportional and Integral settings in control 3 Adjust proportional and integral settings to reduce swings in demand signal. 4 Defective control 4 Replace defective control 1 Software has detected a hardware problem with main control board 1 Restart humidifier, if error occurs within 1 minute replace main control board. If error does not occur then primary power fluctuation may be the cause. 1 Loose connection 1 Check connections and polarity of wires. 2 Incorrect Modbus address 2 Check that Modbus address of humidifier matches that of master. Code Display Message LED System Detected 3 Configure controls correctly in “Control Setting” level of software (see Operation Chapter). 4 Improper wire used 4 Use 120 Ohm impedance shielded twisted pair cable. 5 Noise preventing humidifier from detecting signal. 5 Eliminate source of noise causing interference. No communication is detected from Master unit. (This unit is set up as slave) 1 Improper wiring 1 Check wiring connections, polarity, and type of wire used. (See Staged Modulation Wiring (SETC Only) on page 31) The unit has been remotely disabled through modbus communication or Nortec Online. The measured RH is above the RH High alarm setting. 1 Network signal received by humidifier to shut down. 1 Normal operation for humidifier on network control Contact network administrator to enable humidifier. 1 Setpoint higher than RH alarm setting 1 If the humidifier is still operating then check and adjust setpoints. 1 Humidifier not running 1 Check why humidifier is not running and put it into operation. 2 Setpoint lower than RH low alarm setting 2 Check and adjust setpoints. 1 Sensor not powered 1 Use multimeter to check that sensor is powered. 2 Sensor not wired correctly 2 Check wiring is secure and wired correctly per instructions in installation chapter. 3 Defective sensor 3 Check if sensor is outputting corresponding to RH. If not replace the sensor. 4 RH less than 5% 4 RH less than 5% are interpreted as a broken sensor. Contact Condair Representative for recommendation. (Cont) No Signal Warning RDW Remote Disabled RHW Rh High Warning RLW RMW Rh Low Warning Rh Limit Warning Corrective Action(s) 3 Humidifier configured for Modbus but not connected to network MTW NSW Cause The measured RH is below the RH Low alarm setting. Operation is interrupted until an input higher than 3% is received. Troubleshooting | 80 Code Display Message LED System Detected Cause 5 Humidifier control configuration incorrect 5 Check that the humidifier control configuration matches the installed sensor output. 1 Tank temperature sensor not detecting warm tank. 1b Check tank to see if hot (caution). Red TCF Corrective Action(s) 1a Check wiring to tank temperature sensor. 1c Check if sensor closed when tank is hot. Tank Cold Fault The tank has not become hot with the steam valve activated. 2 No steam supply to humidifier. 2b Check if boiler steam is available. 2c Check if CV valve opens using diagnostic output test. TCW 3 Condensate not draining from heat exchanger. 81 | Troubleshooting 2a Check that isolation valve is not closed. 3a Check that F&T trap is allowing condensate to drain. Nortec SEP Faults The self-diagnostic system built into the Nortec SEP can display some fault conditions by flashing the yellow “Service” LED in sequence. The Nortec SEP does not display any warnings. Faults If the humidifier is not able to self correct a problem symptom it will if necessary respond by shutting itself down. When this occurs the humidifier illuminates the red “Fault” LED, Flashes the yellow LED in a numerical sequence, shuts off the signal to the CV valve actuator, and activates the “Error” relay of the remote relay board. Clearing a Fault Count the number of flashes of the yellow LED and take any necessary actions to correct the cause(s) as outlined in Table 14: Troubleshooting Nortec SEP Faults. Power cycle the humidifier with the On/Off switch waiting 3 seconds between turning it off and on. Table 14: Troubleshooting SEP Faults Number of Flashes / Fault System Detected Cause 1 Internal drain blocked One Flash Humidifier Drain Fault Two Flashes Humidifier Fill Fault Four Flashes Inconsistent Float Level Floats have indicated water level not changing in sequence. Check if water drains from unit when drain manually activated. If not then; 1a Check restrictor in drain line immediately after pump for blockage. Water level is not dropping when pump is activated. Water level not rising or not detected. Corrective Action(s) 1b Check pump rotor to see if it is blocked. 1c Check if scale has built up in sump at bottom of tank and caused a blockage. 2 External drain blocked 2 Check that water can flow freely through drain lines. 1 Water shut off valve closed 1 Open shut off valve 2 Auxiliary drain leaking 2a Close auxiliary drain valve if unit does not have freeze protection. 2b Check freeze protection valve is closed if freeze protection installed. 3 Fill valve strainer blocked 3 Clean out strainer on fill valve inlet. 1 High cooling flow into float chamber 1a Check that orifice in fill valve is in place. Flow should be very low. 2 Defective float board. 2 Observe LED’s on float chamber as tank fills. If LED’s do not light in sequence replace float chamber and float board. 1b Check if tank fill and float cooling lines are reversed. Flow to float chamber should be very low. Tank hoses to centre of float chamber. Troubleshooting | 82 Nortec SETC Wiring Diagram Figure 51: SETC Wiring Diagram 83 | Troubleshooting Nortec SEP Wiring Diagram Figure 52: SEP Wiring Diagram Troubleshooting | 84 Spare Parts 85 | Spare Parts Distributor Spare Parts Figure 53: Distributor Exploded View and Spare Parts Spare Parts| 86 Nortec SETC/P 100 – 1050 Plumbing Parts 4 5 3 8 9 10 6 2 19 7 18 11 15 1 14 13 16 17 12 Figure 54: SETC 100-1050 Plumbing Parts 87 | Spare Parts Table 9: Nortec SETC/P 100-1050 Plumbing Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Description Part No. 100 175 250 375 525 750 1050 Cover Plate Assy. O-ring, Clean Out Port O-ring, Clean Out Port, Cover Plate, Clean Out Port Fill Box Assy. Lower Mixing Box Drain Pump 24v 60 Hz Vacuum Break Valve 1/2" NPT P-Trap Dual Fill Valve 10.0 l/min & 0.35 l/min Dual Fill Valve, 17.0L/Min & 0.35L/Min Auxiliary Drain Termination Steam Trap, 15psi Float Board Float Chamber Mounting Bracket Float Chamber O-ring, Heat Exchanger, Large O-ring, Heat Exchanger, Mini Heat Exchanger Kit, Single Heat Exchanger Kit, Mini Modulating Actuator 0-10 VDC Modulating Actuator 0-10 VDC, 2.5 Val Valve 3/4 in. CV 5.5 Valve 1 in. CV 10.0 Valve 1 in. CV 12.0 Valve 1.25 in. CV 20.0 Valve 1.5 in. CV 28.0 Valve 2.0 in. CV 40.0 Valve 2.5 in. CV 65.0 2544439 2524361 2524361 2547539 2526152 1506749 1502644 1505959 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 2526521 1505759 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1508581 1506925 1508849 2511137 1113777 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 3 1 1 1115933 2524403 1 1 1 1 1 1 1 2 1 2 1 3 2524405 1 1 2581131 2581132 1507549 1 1 2 2 3 1 1 1 1 1 1 1 1 1508472 1594322 1594324 1594332 1594341 1594350 1594360 1508473 1 1 1 1 1 1 1 1 Spare Parts| 88 Nortec SETC/P 100 – 1050 Cabinet and Electrical Parts 15 14 16 13 12 3 4 5 5 11 9 2 10 6 7 1 8 17 Figure 55: Nortec SETC/P 100-1050 Cabinet and Electrical Parts 89 | Spare Parts Table 10: Nortec SETC B+/P 100 – 1050 Cabinet and Electrical Parts List Item 1 2 3 Not Shown 4 Not Shown 5 6 Not Shown 7 8 9 10 11 12 13 14 15 16 17 Description Part No. 100 175 Service Door, Mini Service Door, Single Service Door, Double Service Door, Triple Recessed Handle, Kit Processor Board SE 2523709 2524402 2524401 2523704 2523444 2553861 1 1 Cable , 40 Pin Ribbon 2537230 1 Panel Processor Display, 2544253 1 Membrane, Nortec 1509735 1 2522489 1 2550184 1 Cable, 10pin Ribbon 2522062 1 PCB Driver Board Transformer,120/240V, 24V,150VA Door, Front, GS-SE Panel, Electrical Cabinet Panel, Elec. Bottom Panel, Rear Elec. Panel, Tank Rear Panel, Elec. Top Panel, Top Tank Panel, Left, Base Assembly 2535504 1 2532672 1 Switch Rocker DPST 10A-250V Remote Fault Indication Board SETC 1 1 2523597 Reference - Contact Factory Reference - Contact Factory Reference - Contact Factory Reference - Contact Factory Reference - Contact Factory Reference - Contact Factory Reference - Contact Factory Reference - Contact Factory 250 375 1 1 1 1 1 525 750 1 1 2 2 1050 1 2 1 Spare Parts| 90 Nortec SETC/P 50 Plumbing Parts 1 10 12 11 13 9 8 14 15 18 17 16 2 7 19 3 5 4 6 Figure 56: Nortec SETC/P 50 Plubming Parts 91 | Spare Parts Table 11: SETC B+/P 50 Plumbing Parts Item Description Part No. Qty 1 Tank Replacement Kit, SE50 2520458 1 2 Heat Exchanger Replacement Kits, SE50 2520460 1 3 Gasket, Tank/H.E. Assembly, SE50 1510179 1 4 F&T Trap Assembly, with Plumbing, SE50 1500181 1 5 Float Chamber Assembly, with Board and Connections, SE50 2520239 1 6 Float Board 2511137 1 7 Bracket, Float Chamber Mount, SE50 2520240 1 8 5 Cover Plate Kit, Clean Out Port, SE50 2520461 1 9 Gasket, Clean Out Port, SE50 1510180 1 10 P Trap Mount Assembly, SE50 2520137 1 11 Dual Fill Valve, 5.5L -.35 L/Min 1704234 1 12 Fill Box Assembly with Connections, SE50 2520235 1 13 Vacuum Break Valve 1/2" NPT 1505959 1 14 Termination Assembly with Connections, SE50 2520236 1 15 P Trap Assembly, Complete, SE50 1510187 1 16 Pump Drain, 24VDC, 60HZ (DPS 25-119) 1502644 1 17 Auxiliary Drain Termination 1506925 1 18 Modulating Actuator 0-10 Vdc 1507549 1 19 Valve 1/2in CV 2.80 / VB7263 1594316 1 Spare Parts| 92 Nortec SETC/P 50 Electrical and Cabinet Parts 8 18 17 16 Nortec SETC Electrical NortecSEP Electrical 1 7 1 2 7 12 3 6 9 9 13 5 6 4 10 11 14 15 Figure 57: Nortec SETC/P 50 Electrical and Cabinet Parts 93 | Spare Parts 10 11 Table 12: Nortec SETC B+/P 50 Electrical and Cabinet Parts Item Description Part No. Qty 1 Panel Assembly, Electrical Front, Cabinet SE50 2520268 1 2 Kit Processor Board SE 2553861 1 Cable, 40 Pin Ribbon 2537230 Panel Assm, Display, Cabinet, SE 50 B+ 2552793 1 4 PCB Driver Board 2535504 1 5 Remote Fault Indication Board SETC 2550184 1 Cable, 10 pin Ribbon 2522062 Switch Rocker DPST 10A-250V 2522489 2 7 Bracket Assm, Keypad Mnt, SE50 2520272 1 8 Enclosure, Transformer, Cabinet, SE50 2549857 1 9 Transformer,120/240Vpri,24Vsec,150VA 2532672 1 10 Terminal Block 2 Pole 1473002 1 11 Ground Clamp 1323020 1 12 Switch DPDT ON/OFF/DRAIN SETC/SEP 2538961 1 13 SEP Display / Keypad Assembly, SE50 2520279 1 14 SEP, Led Board Assembly 1508619 1 15 SEP Control Board 1508577 1 16 Panel Access, Elect Right, Cabinet, SE50 2520283 1 Panel,Access,Electrical Front SE 50 B+ 2552792 1 Panel Access, Elect Front, Cabinet, SE50 2520270 1 Panel, Access, Tank Front, Cabinet, SE50 2520267 1 Not Shown 3 Not Shown 6 17 SETC 17 SEP 18 1 1 Spare Parts| 94 95 | Warranty Warranty Condair Inc. and/or Condair Ltd. (hereinafter collectively referred to as THE COMPANY), warrant for a period of two years after installation or 30 months from manufacturer’s ship date, whichever date is earlier, that THE COMPANY’s manufactured and assembled products, not otherwise expressly warranted are free from defects in material and workmanship. No warranty is made against corrosion, deterioration, or suitability of substituted materials used as a result of compliance with government regulations. THE COMPANY’s obligations and liabilities under this warranty are limited to furnishing replacement parts to the customer, F.O.B. THE COMPANY’s factory, providing the defective part(s) is returned freight prepaid by the customer. Parts used for repairs are warranted for the balance of the term of the warranty on the original humidifier or 90 days, whichever is longer. The warranties set forth herein are in lieu of all other warranties expressed or implied by law. No liability whatsoever shall be attached to THE COMPANY until said products have been paid for in full and then said liability shall be limited to the original purchase price for the product. Any further warranty must be in writing, signed by an officer of THE COMPANY. THE COMPANY’s limited warranty on accessories, not of the companies manufacture, such as controls, humidistats, pumps, etc. is limited to the warranty of the original equipment manufacturer from date of original shipment of humidifier. THE COMPANY makes no warranty and assumes no liability unless the equipment is installed in strict accordance with a copy of the catalog and installation manual in effect at the date of purchase and by a contractor approved by THE COMPANY to install such equipment. THE COMPANY makes no warranty and assumes no liability whatsoever for consequential damage or damage resulting directly from misapplication, incorrect sizing or lack of proper maintenance of the equipment. THE COMPANY makes no warranty and assumes no liability whatsoever for damage resulting from freezing of the humidifier, supply lines, drain lines, or steam distribution systems. THE COMPANY makes no warranty and assumes no liability whatsoever for equipment that has failed due to ambient conditions when installed in locations having climates below 14°F (10°C) during January or above 104°F (40°C) during July. THE COMPANY retains the right to change the design, specification and performance criteria of its products without notice or obligation. Warranty | 96 U.S.A. Condair Inc. 826 Proctor Avenue Ogdensburg, NY 13669 CANADA Condair Ltd. 2740 Fenton Road Ottawa, Ontario K1T 3T7 TEL: 1.866.667.8321 FAX: 613.822.7964 EMAIL: [email protected] WEBSITE: www.condair.com Certificate No. 002419
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