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INSTALLATION AND OPERATING INSTRUCTIONS
Resistive Humidifiers
1115
661
EN
141
2
Defensor Mk5
2
3
Contents
1 Introduction 41.1 To the very beginning 41.2 Notes on the installation and operating instructions 42 For your safety 53 Product overview 73.1 Unit types 73.2 Identificationoftheunit 83.3 Standarddelivery 83.4 Humidificationsystemoverview 93.5 Steamhumidifierconstruction 93.6 Functional description 104 Basic planning 114.1 Selecting the unit 114.2 Selecting the control system 144.3 Options 164.4 Accessories 174.4.1 Accessoriesoverview 174.4.2 Accessorydetails 184.5 Additional planning instructions 205 Mounting and installation works 215.1 Safetyinstructionsformountingandinstallationworks 215.2 Unitfitting 215.2.1 Humidifierlocation 215.2.2 Mountingthehumidifier 235.2.3 Inspecting the installed unit 235.3 Steam installation 245.3.1 Positioningandmountingofthesteamdistributionpipes 245.3.2 Positioningandmountingofthefanunit 275.3.3 Installingthesteamandcondensatelines 285.3.4 Inspecting the steam installation 305.4 Water installation 315.4.1 Performingthewaterinstallation 315.4.2 Inspectingthewaterinstallation 335.5 Electric installation 345.5.1 Electricinstallationoverview 345.5.2 Wiring diagram 355.5.3 Notes on component installation 375.5.4 Inspecting the electrical installation 406 Operation 416.1 Unitconfiguration 416.2 Putting into operation 436.3 Takingoutofoperation 456.4 Interrogationoftheoperatingstatus 466.5 Setting the operating parameters 506.6 Maintenance 556.6.1 Notes on maintenance 556.6.2 Dismantlingandre-assemblywork 566.6.3 Notesoncleaning 596.6.4 Toresetthemaintenanceindication 596.7 Fault elimination 606.7.1 Fault indication 606.7.2 What,if..? 616.7.3 Replacingunitfuses 636.7.4 Resettingfaultindication“Error” 637 Technical data 64
4
Limitation
ThesubjectoftheseinstallationandoperatinginstructionsarethesteamhumidifierDefensor Mk5 in theversions:“Visual”and“Process”.Thevariousaccessories(humidistats,waterfilter,etc.)areonlydescribedinsofarasthisisnecessaryforproperoperationoftheequipment.Furtherinformationonaccessories can be obtained in the respective instructions.
These installation and operating instructions are restricted to:
– the planningofahumidifyingsystemthatistobeequippedwithasteamhumidifierDefensorMk5
– the installation, commissioning, operation and servicing ofthesteamhumidifierDefensorMk5
Theseinstallationandoperatinginstructionsaresupplementedbyvariousseparateitemsofdocumenta-tion(sparepartslist,installationinstructionsforelectricalinstallation,etc.).Wherenecessary,appropri-atecross-referencesaremadetothesepublicationsintheseinstallationandoperatinginstructions.
Conventions
Thissymboldrawsattentiontosafety instructions and warningsofpotentialdangerwhich,ifunheeded,couldresultininjurytopersonsand/ordamagetoproperty.
Safekeeping
Pleasesafeguardtheseinstallationandoperatinginstructionsinasafeplace,whereitcanbeimmedi-atelyaccessed.Iftheequipmentchangeshands,thedocumentationshouldbepassedontothenewoperator.Ifthedocumentationgetsmislaid,pleasecontactyoursupplier.
Language versions
These installation and operating instructions are available in various languages. Please contact your supplierforinformation.
1 Introduction
1.1 To the very beginning
Wethankyouforhavingpurchasedthesteam humidifier Defensor Mk5.
ThesteamhumidifierDefensorMk5incorporatesthelatesttechnicaladvancesandmeetsallrecognizedsafetystandards.Nevertheless,improperusemayresultindangertotheuserorthirdpartiesand/orimpairmentofmaterialassets.
Toensureasafe,proper,andeconomicaloperationof thesteamhumidifierDefensorMk5,pleaseobserveandcomplywithallinformationandsafetyinstructionscontainedinthepresentinstallationand operating instructions.
Ifyouhavequestions,whicharenotorinsufficientlyansweredinthisdocumentation,pleasecontactyoursupplier.Theywillbegladtoassistyou.
1.2 Notes on the installation and operating instructions
5
2 For your safety
Intended use
SteamhumidifiersDefensorMk5are intendedexclusively fordirect or indirect room humidification or for humidification in laboratory and process applications withinthespecifiedoperatingconditions.Anyothertypeofapplication,withoutthewrittenconsentofyoursupplier,isconsideredasnotconformingwiththeintendedpurpose.Themanu-facturer/suppliercannotbemadeliableforanydamagesresultingfromimproperuse.Theuserbearsfullresponsibility.Operationoftheequipmentintheintendedmannerrequiresthat all the information in these instructions is observed (in particular the safety instructions).
General safety instructions
– ThesteamhumidifierDefensorMk5mustonlybeinstalled,operatedservicedandinall cases repaired only by persons who are adequately qualifiedtoundertakesuchworkandarewellacquaintedwiththeproduct.Ascertainingthequalificationsisthecustomer‘s responsibility.Thisunitmaynotbeusedbypersons(includingchildren)withreducedphysical,sensoryormentalabilitiesorpersonswithlackingexperienceand/orknowledge,unlesstheyaresupervisedbyapersonresponsiblefortheirsafetyortheyreceivedinstructionsonhowtooperatetheunit.Childrenmustbesupervisedtomakesurethattheydonotplaywithunit.
– Caution Hot water vapour - Danger of scalding! The Defensor Mk5 produces hot water vapour. There is danger of scalding when getting in touch with hot water vapour or the hot water inside the steam cylinder and the lime collector tank. Prevention:Donotcarryoutanyworkonthesteamsystemduringoperation(steamlines,steamdistributor,fanunit,etc.).IfthesteamsystemisleakysettheDefensorMk5immediatelyoutofoperationasdescribedinchapter6.3.Correctlysealthesteamsystembeforeputtingtheunitintooperationagain.
– Caution Danger of burning! During operation the components of the steam sys-tem (steam cylinder, steam distributor, etc.) get very hot (up to 100 °C). There is danger of burning when touching the hot components. Prevention: BeforecarryingoutanyworkonthesteamsystemsettheDefensorMk5outofoperationasdescribedinchapter6.3,thenwaituntilthecomponentshavecooleddownsufficientlythuspreventingdangerofburning.
– Caution, danger of electric shock! The Defensor Mk5 is operated with mains voltage. Before commencing workontheDefensorMk5,theunitistoberendered inoperative inaccordancewithsection6.3andprevented from further inadvertentoperation(isolateunitfromtheelectricalpowersupply,isolatewatersupply).
– Observe all local safety regulations.– relatingtotheoperationofmains-operatedelectrical and electronic equipment– and the provision of water, steam and electrical installations
– Poorlymaintainedhumidificationsystemscanendangerhealth.The servicing inter-vals should therefore be adhered to without reservation and the servicing work carried out correctly.
– Ifitissuspectedthatsafe operation is no longer possible,thentheDefensorMk5should immediately be shut down and secured against accidental power-up. This canbethecaseunderthefollowingcircumstances:– iftheDefensorMk5isdamaged– iftheDefensorMk5isnolongeroperatingcorrectly– ifconnectionsand/orpipingarenotsealedorcablesareloose
– TheDefensorMk5mustonly be operated under the specified operating conditions (seesection7).
6
– Thecustomer is responsible for theregular inspection,cleaninganddisinfectionoftheductsectioninwhichthesteamdistributorisinstalled.Thismustbeperformedinaccordancewiththehygieneregulationsinforceforoperatingair handling units.
– TheDefensorMk5isprotectedaccordingtoIP21.Makesuretheunitsareinstalledinadrip-prooflocation.
– Caution! IftheDefensorMk5isinstalledinanareawithoutawaterdrain,watersen-sorsmustbefittedinthearea,suchthatintheeventofleakageinthewatersystem,thewaterfeedissafelyshutoff.
– Caution, danger of corrosion! In order to avoid damage, no corrosion-sensitive componentsshouldbelocatedintheareaoftheaerosolstreams.
– No work/repairshouldbecarriedoutontheDefensorMk5otherthanthatdescribedinthese instructions.
– Useexclusivelyoriginal accessories and spare partsavailablefromyoursupplier.
– No modifications must be undertakenon theDefensorMk5without theexpresswrittenconsentofthemanufacturer.
7
3 Product overview
3.1 Unit types
ThesteamhumidifiersDefensor Mk5 are available in 2 different type series:
– Visual Fordirectorindirectroomairhumidificationwithstandard requirements for control precision.
– ProcessFordirectorindirectroomairhumidificationinlaboratory and process appli cationswherethereare increased requirements for control precision.
Basically,thedevicesofbothtypeseriesareofthesameconstructionexceptforthelevelcontrolandelectronics.TheVisualunits>10kg/hareequippedwithacombinedcontactor/electroniccontrolandalevelunitwithasinglefloat.ToachieveahigherlevelofaccuracytheProcessunitsincludeadedicatedelectroniccontrolwithspecialcontrolsoftwareandareequippedwithalevelunitcomprisingtwofloats.
Theyareavailableinversionssuitableforoperationwithuntreated drinking water(with lime collec-tor tank)orwithfully demineralized water(without lime collector tank).Allversionsareequipped,asstandard,withanoperating and display unit,bymeansofwhichthecurrentoperatingparameterscanbereadandtheequipmentconfiguredforoperation,andanintegrated PI controller.Theequip-mentcanbesuppliedwithvariousotheroptions.
Type overview and type designation
Theunitsofbothtypeseriesareavailableinvariousversionswithdifferent steam capacities and layout of the power section(heatingvoltage).Thefollowingtableprovidesanoverviewofthevariousmodels and their capacity ranges.
Defensor Mk5 Visual ..-../Process..-.. Heating voltage
small large double unit large5 8 10 16 20 24 30 40 50 1) 60 1) 80 1)
max. steam capacity in kg/h5.0 8.0 10.0 16.0 20.0 24.0 30.0 40.0 50.0 60.0 80.0 400V/3~/50...60Hz4.6 7.3 9.0 14.6 18.0 21.9 27.0 36.2 45.0 54.0 72.4 220V/3~/50...60Hz5.1 8.4 10.3 16.7 20.6 25.1 30.6 41.5 51.2 61.2 83.0 415V/3~/50...60Hz5.1 8.7 10.3 ––– ––– ––– ––– ––– ––– ––– ––– 240V/1N~/50...60Hz5.1 8.0 10.0 ––– ––– ––– ––– ––– ––– ––– ––– 230V/1N~/50...60Hz3.9 5.8 7.1 11.6 14.3 17.4 21.5 28.8 35.6 43.0 57.6 200V/3~/50...60Hz
1) Mk5 ... 50 ... Mk5 ... 60 ... Mk5 ... 80 ... Unit A: 20 kg/h 30 kg/h 40 kg/h Unit B: 30 kg/h 30 kg/h 40 kg/h
8
Thetypedesignationisstructuredasfollow:
Designation CodeBrand name CondairProduct line Defensor Mk5
Type series –Directorindirectroomhumidification –Humidificationforlaboratoryandprocessapplications
VisualProcess
Operating mode – Operation with untreated drinking water (with lime collector tank) –Operationwithfullydemineralizedwater(withoutlimecollectortank)
–VE
Steam capacity in kg/h – 5, 8, 10, 16, 20, 24, 30, 40, 50, 60 or 80 ..Heating voltage – 400V/3~/50...60Hz – 220V/3~/50...60Hz – 415V/3~/50...60Hz – 240V/1N~/50...60Hz – 230V/1N~/50...60Hz – 200V/3~/50...60Hz
400V/3~220V/3~415V/3~
240V/1N~230V/1N~200V/3~
3.3 Standard delivery
The standard delivery includes:
– SteamhumidifierDefensorMk5compl.(accordingtotypedesignation)equippedwiththedesiredoptions(remoteoperatingandfaultindication,pressurecompensationkit,etc.)accordingtochap-ter 4.3
– Fixingsetincludingdowelsandfixingscrews(forsingleunitsupto40kg/h),mountingprofilewithdowelsandfixingscrews(fordoubleunits50...80kg/h)
– Installation and operating instructions
– Sparepartslist(red)
– Orderedaccessories(steamdistributionpipe,steamhose,etc.)accordingtochapter4.4
CondairAG/CH-8808PfäffikonMk5 Visual 30 XXXXXXX 02.13400V 3~ / 50...60Hz 22.3 kWDampf/Steam/Vapeur=30.0kg/hWasser/Water/Eau=1...10bar
MadeinSwitzerland
3.2 Identification of the unit
Theidentificationoftheunitisfoundonthetypeplate:
Type designation Serialnumber(7digits) Month/Year
Heating voltage
Maximumsteamcapacity
Admissiblewatersupplypressure
Powerconsumption
Fieldwithcertificationsymbols
9
3.4 Humidification system overview
1 Steamhumidifier 2 Electrical connections 3 Water drainage 4 Limecollectortank(onlyonunitsforoperation
with untreated drinking water) 5 Filter valve (accessory “Z261”) 6 Water supply (building side) 7 Fanunit(accessory“FAN3S..”) 8 Condensatehose(accessory“KS10”) 9 Steamhose(accessory“Z10”)10 Steamdistributionpipe(accessory“81–...”)
3.5 Steam humidifier construction 1 Housing (500 or 600) 2 Power board 3 Heating contactor (Visual >10 kg/h only) 4 Mains contactor 5 Supplymodule 6 Control board 7 Cable openings 8 LC-Display 9 Control keys 10 Unit switch 11 Drain switch12 Statusindicator(LED)13 Limecollectortank(onlyonunitsforoperation
with untreated drinking water) 14 Drain 15 Water connection16 Steamcylinder 17 Drain pump 18 Resistance heating element19 Inletvalvewithfilter 20 Water supply 21 Filling pipe22 Overflowpipe23 Steamoutletconnector 24 Water cup 25 Pressure equalizing pipe 26 Level unit 27 Type plate
5
6
4
3
7
1
2
10
8
9
23
1
26
2
3
4
5
6
27
7
8
9
10 11 12 13
15 14
17
16
18
19 20
21 22
24 25
10
3.6 Functional description
TheDefensorMk5steamhumidifierisanunpressurizedsteamgenerator.Itoperatesontheresistanceheatingprincipleandisdesignedfordirect(withfanunit)andindirect(withsteamdistributionpipe)roomair humidification in ventilatingandair-conditioning systems. In conjunctionwitha “Process”steamdistributionpipetheunitmaybeusedforhumidificationinlaboratoryandprocessapplications.
Water supply
Thewateristakenviaafiltervalve(accessory“Z261”)tothesteamhumidifier.Itreachesthesteamcylinderviatheinletvalve(levelcontrolled)andtheopenwatercup.
Level regulation
Thewaterlevelinthesteamcylinderiscontinuouslymonitoredwiththelevelunit.Ifthewaterlevelreachesapresetlevel(owingtotheevaporationprocess)thelevelunitsuppliesasignaltothecon-troller.Thisopenstheinletvalveandthesteamcylinderisfilledup.Whenthepresetoperatinglevelisreached, the level unit supplies another signal to the controller to close the inlet valve.Thepressureequalizingpipebetweenthesteamconnectionandthelevelunitensuresthatthewaterlevels are the same in the steam cylinder and the level unit.
Steam generation regulation
Thesteamisproducedinthesteamcylinderbyseveralresistanceheatingelements.Anexternalortheinternalregulatorforconnectionasrequiredcontrolthesteamproductionfullyvariablyfrom0to100%.
Flushing
Theevaporationprocessincreasestheconcentrationofmineralsinthewaterofthesteamcylinder.Asuitablevolumeofwatermustbeflushedthroughthesteamcylinderfromtimetotimeandreplacedbyfreshwatertoensurethatthisconcentrationdoesnotexceedaspecificvalueunsuitableforoperation.TheMk5steamhumidifierperformsanauto-adaptiveflushing.Thisconsistsofthefollowingtwoformsofflushing:
– Automatic flushing takesplaceassoonasthewater inthesteamcylinderexceedstheupperoperatinglevel(e.g.byfoamingofthewater).
– Flushing dependent on time performstheflushingprocessatpreselectedtimeintervals(seesec-tion6.1“Adjustments”).
Automaticortime-dependentflushingtakesplacedependingonthewaterqualityandtheoperatingdata.Ifthelowestoperatinglevelisreachedduringtheflushingprocess,theinletvalveremainsopenuntilthewaterlevelinthesteamcylinderhasreachedthenormalworkinglevelagain.Ifthelowestoperating level is not reached, the inlet valve is closed.
Lime collector tank
Themineralsprecipitatedbytheevaporationprocessaccumulateatthebottomofthesteamcylinder.Unitsdesignedforoperationwithuntreateddrinkingwaterareequippedwithanadditionallimecol-lectortanklocateddirectlyunderneaththesteamcylinder.Thiswaythemineralsdonotaccumulateinthesteamcylinderbutmainlyinthecollectortankthusextendingtheserviceintervalsandreducingthe maintenance costs.
Unitsdesignedforoperationwithfullydemineralizedwaterdonothavealimecollectortankasfullydemineralizedwatercontainsonlysmallamountsofminerals.
11
4 Basic planning
AllthedatanecessaryfortheselectionandlayoutofaDefensorMk5humidifiersystemareprovidedinthefollowingchapters.
4.1 Selecting the unit
Theselectionoftheunitisreflectedinthetypedescription:
1. Application
2. Supplywaterquality
3. Requiredmaximumsteamcapacity
4. Requiredheatingvoltage
1. Application
Thetypeseriescanbeselectedonthebasisofthefollowingtable:
Scopeofuse Type series
For direct or indirect room air humidification with standard requirements for control precision.
Visual
For direct or indirect room air humidification in labora-tory and process applications where there are increased requirements for control precision.
Process
Achievable control precisionNote:Thecontrolprecisionmaydependonthelocationofthehumiditysensor.– Visual: ±5 %rh(PI-controlanduseofuntreateddrinkingwater)
±2 %rh(PI-controlanduseoffully demineralized water) Note:Duringthedraincycle(operationwithdrinkingwater)orduringtherefillcycle(operationwithfullydemineralizedwater)thecontrolprecisioncandeviatefromtheabovestatedvalues.
– Process: ±2 %rh(PI-controlanduseofuntreateddrinkingwater) ±1 %rh(PI-controlanduseoffully demineralized water)
Note:WhenoperatingtheMk5Processwithdrinkingwaterthecontrolprecisioncandeviatefromtheabovestatedvaluesduringthedraincycle.ForprocessairhumidificationwithconstantcontrolprecisiontheMk5ProcessmustbeoperatedwithfullydemineralizedwaterandthedraincyclemustbesettoPos.0(seechapter6.1).
2. Supply water quality Description Version
Unit withalimecollectortankforoperationwithuntreated drinking water and partially softened water (see also notes on water quality in chapter 5.4.1).
–
Unit withoutalimecollectortankforoperationwithfullydemineralizedwaterwithaconductivityvalue<15µS.Caution! Unit without lime collector tanks should not be operated with untreated drinking water or partially softened water.
VE
Defensor Mk5 Visual VE 24-400V/3~
Defensor Mk5 Visual VE 24-400V/3~
Defensor Mk5 Visual VE 24-400V/3~
12
3. Calculating the maximum required steam capacity
Themaximumrequiredsteamcapacityiscalculatedfromthefollowingformulas:
V • ρmD = • (x2 - x1) 1000
V mD = • (x2 - x1) 1000 • ε
mD: maximumsteamdemandinkg/hV: volumeofsupplyairportionperhourinm3/h(forindirectroomhumidification)orroomvolumeto
behumidifiedperhourinm3/h(fordirectroomhumidification)ρ: specificgravityofairinkg/m3
ε: specificvolumeofairinm3/kgx2: desired absolute room air humidity in g/kgx1: minimum absolute supply air humidity in g/kg
Thevaluesforρ, ε, x2 and x1canbegatheredfromtheh,x-diagram or the Carrier-Diagramformoistair respectively.
Foraroughestimateofthecalculatedsteamcapacity,thefollowingtablecanbeused.Thevalueslistedinthetablearebasedonadesiredroomairtemperatureof20°Candadesiredrelativeroomairhumidityof45%rh.
Max.portionofsupplyairinm3/hr or roomvolumetobehumidifiedperhourinm3/hr
max. steamcapacity in kg/hTemperature/rel.humidityofsupplyair
-15 °C/90 %rh -5 °C/80 %rh 5 °C/60 %rh6501000200025003000375050006250750010000
8501350265033004000500066008250990013200
1000160032004000480060008000100001200016000
5816202430
40
50
60
80
Example: Max.portionofsupplyair3000m3/h, temperature/rel. humidityofsupplyair-15°C/90%rh
or
Important notes:
– Therequiredmaximumsteamcapacitydependson thespecificapplicationand the installation.Thecalculatedsteamcapacitybasedontheaboveformulas,theh,xdiagramandtheconditionoftheairtobehumidifieddoesnotconsideranysteamloss(e.g.duetocondensationinthesteamhosesandthesteamdistributors),anyheatlossoftheunitaswellasanyabsorptionorreleaseofhumidityofmaterialslocatedintheroombeinghumidified.In addition, the calculated steam capacity does not consider any losses caused by the draining rate dependingonthewaterquality.
Thetotalamountoflossesdependsontheentiresystemandmustbetakenintoconsiderationwhencalculatingtherequiredsteamcapacity.Ifyouhaveanyquestionsregardingthecalculationofthesteam capacity please contact your supplier.
– Forsystemswherethemax.requiredsteamcapacityvariesextensively(e.g.fortestfacilitiesorforsystemswithvariableairvolumeflow,etc.),pleasecontactyoursupplier.
Defensor Mk5 Visual VE 24-400V/3~
13
4. Heating voltage/control voltage Heating voltage
TheDefensorMk5steamhumidifiersareavailablewithvariousheatingvoltages.Themaximumachievable steamcapacity and the power consumption are directly dependent on the selectedheatingvoltage(seetable).
400 V/3~ 220 V/3~ 415 V/3~ 240 V/1N~ 230 V/1N~ 200 V/3~
50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz 50...60 Hz
DefensorMk5Visual.../Process...
kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A kg/h kW A
...5-.. 5.0 3.8 5.5 4.6 3.4 9.0 5.1 4.0 6.0 5.1 4.0 17.0 5.1 4.0 16.5 3.9 3.0 8.2
...8-.. 8.0 6.0 8.7 7.3 5.5 14.4 8.4 6.5 9.0 8.7 6.5 27.2 8.0 6.0 26.0 5.8 4.5 13.1
...10-.. 10.0 7.5 11.0 9.0 6.7 17.7 10.3 8.0 11.5 10.3 8.0 33.0 10.0 7.4 32.0 7.1 5.5 16.1
...16-.. 16.0 12.0 17.4 14.6 10.9 28.7 16.7 13.0 18.1 –– –– –– –– –– –– 11.6 9.0 26.1
...20-.. 20.0 14.9 21.5 18.0 13.5 35.4 20.6 16.0 22.3 –– –– –– –– –– –– 14.3 11.1 32.2
...24-.. 24.0 18.1 26.2 21.9 16.4 43.1 25.1 19.5 27.2 –– –– –– –– –– –– 17.4 13.5 39.2
...30-.. 30.0 22.3 32.3 27.0 20.2 53.1 30.6 24.0 33.5 –– –– –– –– –– –– 21.5 16.7 48.3
...40-.. 40.0 30.0 43.3 36.2 27.2 71.4 41.5 32.3 45.0 –– –– –– –– –– –– 28.8 22.4 64.9
...50-..A 20.0
+30.0
14.9+
22.3
21.5+
32.3
18.0+
27.0
13.5+
20.2
35.4+
53.1
20.6+
30.6
16.0+
24.0
22.3+
33.5–– –– –– –– –– ––
14.3+
21.5
11.1+
16.7
32.2+
48.3B
...60-..A 30.0
+30.0
22.3+
22.3
32.3+
32.3
27.0+
27.0
20.2+
20.2
53.1+
53.1
30.6+
30.6
24.0+
24.0
33.5+
33.5–– –– –– –– –– ––
21.5+
21.5
16.7+
16.7
48.3+
48.3B
...80-..A 40.0
+40.0
30.0+
30.0
43.3+
43.3
36.2+
36.2
27.2+
27.2
71.4+
71.4
41.5+
41.5
32.3+
32.3
45.0+
45.0–– –– –– –– –– ––
28.8+
28.8
22.4+
22.4
64.9+
64.9B
Shouldyourequireaunitwithadifferentheatingvoltage,pleasecontactyoursupplier.
Control voltage
DefensorMk5steamhumidifiersaredesignedforastandardcontrolvoltageof220...240V/50...60Hz.
Ifusedinsystemswithoutseparatecontrolvoltagesupply,theDefensorMk5maybeequippedwithanoptionaltransformer400-500V/230V(seechapter4.4).
Defensor Mk5 Visual VE 24-400V/3~
14
4.2 Selecting the control system
The various control systems
– System 1: Room humidity control
System1issuitedfordirect room humidification and air conditioning systems with mainly recirculated air.Thehumiditysensororhumidistatrespectivelyispreferablylocatedintheroomitselforintheexhaustairduct.
A1 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatB4 humidistatPII internal continuous controller (PI-controller)PIE external continuous controller (e.g. PI-controller)Y inputsignalfromA1
– System 2: Room humidity control with continuous limitation of the supply air humidity
System2issuitedforairconditioningsystemswithalarge portion of supply air, low supply air temperature, post-humidification, or variable airflow volume.Ifthesupplyairhumidityexceedsthepresetvalue,thecontinuouslimitationiseffectedpriortotheroomhumiditycontrol.Thehumiditysensor(A1)ispreferablylocatedintheexhaustairductorintheroomitself.Thehu-miditysensor(A2)forthelimitationofthesupplyairhumidityislocatedinthesupplyairductafterthesteamdistributionpipe.Thiscontrolsystemrequiresaexternal continuous controllerwiththeoption to connect a second humidity sensor.Attention!Thecontinuouslimitationofthesupplyairhumidityisnosubstituteforthesafetyhumidistat.
A1/2 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatPIE external continuous controller (e.g. PI-controller)Y inputsignalfromA1Z inputsignalfromA2
DefensorMk5
DefensorMk5
15
– System 3: Supply air humidity control
Supply air humidity control (humidity sensor installed in supply air duct) should be used only where room humidity control is impracticable for technical reasons.SuchsystemsalwaysrequireaPI-controller.Thehumiditysensor(A1)islocatedinthesupplyairductafterthesteamdistribution pipe.
A1 humidity sensorB1 ventilation interlockB2 airflowmonitorB3 safetyhumidistatPII internal continuous controller (PI-controller)PIE external continuous controller (e.g. PI-controller) Y inputsignalfromA1
Which humidity control system for which application?
Application Location of the humidity sensor
Room or exhaust air duct supply air ductAir conditioning systems with: supply air portion up to 33% System1 System1 supply air portion up to 66% System1or2 System2or3 supply air portion up to 100% System2 System3 supply air humidity control — System3Directroomhumidification System1 —
Pleasecontactyoursupplier,ifyourapplicationmeetsthefollowingconditions:
– Humidificationofsmallroomsupto200m3
– Airconditioningsystemswithahighnumberofairexchanges
– Systemswithvariableairvolumeflow
– Testfacilitieswithextremecontrolaccuracyrequirements
– Roomswithahighvariationinmax.steamcapacity
– Systemswithtemperaturefluctuations
– Coldroomsandsystemswithdehumidification
DefensorMk5
16
4.3 Options
ThefollowingtablepresentsanoverviewofalloptionswhichareavailableforthesteamhumidifierDefensorMk5.
Defensor Mk5 Visual Process
Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80
Interface RS232/RS485(InterfacePCBRS232/RS485fordataex-changewithabuildingcontrolsystem)
RS
number 1 1 1 1 1 1
Remote operating and fault indication(PCBwithrelaycontactsfortheconnectionofremotedisplaysfor“Operation”,“Steam”,“Fault”and“Service”)
RFS
number 1 1 1 1 1 1
Pressure compensation kit up to 10’000 Pa(Assemblykitfortheinstallationofthefillingbowlontheequipmentcover,fortheopera-tionofthesteamhumidifierininstallationswithductairpressuresupto10’000Pa)
OVP
number 1 1 2 1 1 2
Transformer 400-500V/230V(Transformerforsystemswithoutaseparatecontrolvoltagesupply)
TRAF 1)
number 1 1 1 1
Connection terminal 400-415 V/3~(Separate terminals for systems wheredirectconnectionofheatingvoltagetomaincontactor(standardversion)isnotpermittedbylocalregulations)
KLK KLG KLK KLG
number 1 1 2 1 1 2
Unit housing stainless steel S-Inox L-Inox S-Inox L-Inox
number 1 1 2 1 1 2
1) Whenorderingindicatethetypeofunit
17
4.4 Accessories
4.4.1 Accessories overview
Thefollowingtablepresentsanoverviewofallaccessorieswhichareavailableforthesteamhumidi-fierDefensorMk5.
Defensor Mk5 Visual Process
Steam capacity in kg/h 5...16 20...40 50...80 5...16 20...40 50...80
Steam distribution pipe(seeaccessorydetailsinchapter4.4.2)
81-...
number 1 2 1 2
Steam distribution pipe Process(seeaccessorydetailsinchapter4.4.2)
Z..
number 1 2 1 2
OptiSorp steam distribution system(seeaccessorydetailsinchapter4.4.2)
System 1 System 2 System 1 System 2
number 1 1 1 1
Fan unit(seeaccessorydetailsinchapter4.4.2)
FAN3S Mk M
orFAN3S
Mk M FC
FAN3S Mk L FAN3S Mk M
orFAN3S
Mk M FC
FAN3S Mk L
number 1 1 2 1 1 2
Steam hose / meter Z10 (ø54/42)
number 1 2 1 2
Condensate hose / meter KS10
number 1 2 1 2
Filter valve Z261
number 1(persystem)
Mounting profile BS4 BS5 BS6 1) BS4 BS5 BS6 1)
number 2 2 2 2 2 2
Humidity sensor, room CRC
number 1(persystem)
Humidity sensor, duct CDC
number 1(persystem)
1) FordoubleunitsthemountingprofilesBS6areincludedinthestandarddelivery
18
Steam distribution pipes 81-... for indirect room humidification
Thesteamdistributionpipesareselectedonthebasisoftheduct width(forhorizontalinstallation)orthe duct height(forverticalinstallation)andthecapacityofthesteamhumidifier.Important!Alwaysselectthelongestpossiblesteamdistributionpipe(optimumhumidificationdistance).
4.4.2 Accessory details
Steam distribution pipes 81-... for Defensor Mk5 (CrNi steel)
Duct width (B) Steam output
Type Length in mm (L) 3) in mm max. in kg/h81-200 1) 200 210...400 1081-350 2) 350 400...600 3081-500 2) 500 600...750 3081-650 650 750...900 5081-800 800 900...1100 5081-1000 1000 1100...1300 5081-1200 1200 1300...1600 5081-1500 1500 1600...2000 5081-1800 1800 2000...2400 5081-2000 2000 2200...2600 5081-2300 2300 2500...2900 5081-2500 2500 2700...3100 50
1) Onlyforunitswithamax.steamcapacityof10kg/h2) Onlyforunitswithamax.steamcapacityof30kg/h3) Speciallengthavailableonrequest
Note:Ifthehumidificationdistance(seechapter5.3.1)hastobereducedfortechnicalreasons,theamountofsteamperbasicunitmustbedividedbetweentwosteamdistributionpipesorthe OptiSorp steam distribution system mustbeused.Ifthisisthecase,contactyoursupplier.
Steam distribution pipe “Process” (accessory “Z...”)
Thesteamdistributionpipe“Process”isusedfordirect humidification of materialinmanufacturingprocesses (processhumidification),or inventilationductswithacritical saturation distance (thesteamdistributionpipe“Process”reducesthesaturationdistancebyapproximately30%).Thedesiredlengthmustbespecifiedwhenordering.
Pleasecontactyouryoursupplier,theywillassistyouincustomizingthesteamdistributionhead“Pro-cess”.Pleasehavethefollowinginformationreadilyavailable:
– steamquantityinkg/h
– dimensionsofventilationduct(widthxheight)
Important! Thetableforthedeterminationofthehumidificationdistanceprovidedinchapter5.3.1doesnot apply to the Process steam distribution pipe.
19
OptiSorp steam distribution system
TheOptiSorpsteamdistributionsystemisusedinventilationductswhereonlyashorthumidificationdistance isavailable(seechapter5.3.1forcalculationofhumidificationdistance).Ductdimensionsshouldbegivenwhenordering.Pleasenotethefollowingdataforthis:
OptiSorp Number of steam connections
max. steam capacity in kg/h 1)
Duct dimension
Width in mm Height in mm
System 1 1 45 (30) 450...2700 450...1650
System 2 2 90 (60) 450...2700 450...2200
1) For duct width <600 mm the values in parenthesis are valid
Note:FurtherinformationontheOptiSorpsteamdistributionsystemcanbefoundintheseparatein-stallationandoperatinginstructionssuppliedwiththeproduct.
Fan unit
Thefanunits–incombinationwiththesteamhumidifiersDefensorMk5–areusedforthedirectroomhumidification.Theycanbemountedseparately above the unittothewall.
Thetypeoffanunitandtheamountrequiredisdependentonthesteamcapacityofthebasicunit(s)andcanbegatheredfromthetableinchapter4.4.1.
Note:Furtherinformationonthefanunitcanbefoundintheseparateinstallationandoperatinginstruc-tionssuppliedwiththeproduct.
Thefanunitsaredeliveredwith:
– Installation accessories including steam hose
– Installation and operating instructions Fan unit
20
4.5 Additional planning instructions
Inadditiontotheselectionofthesteamhumidifier,theaccessoriesandtheoptions,otherpointsshouldbeconsideredduringplanning.Pleasenotetheinformationinthefollowingchapters:– Unitfitting(seechapter5.2)– Steaminstallation(seechapter5.3)– Waterinstallation(seechapter5.4)– Electricinstallation(seechapter5.5)
Ifyouhaveotherquestionsrelatingtoplanningthatarenotadequatelycoveredbytheseinstallationandoperatinginstructions,pleasecontactyoursupplier.Hewillbehappytoprovidefurtherassistance.
21
5 Mounting and installation works
5.1 Safety instructions for mounting and installation works
– Allmountingandinstallationworkmustbeperformedonly by adequately qualified personnel.Ascertainingthequalificationsisthecustomer‘sresponsibility.
– Alllocalregulationsrelatingtotheexecutionoftherespectiveinstallationwork(Water,steamandelectricalinstallation)mustbenotedandcompliedwith.
– Alltheinformationcontainedintheseinstallationandoperatinginstructionsrelatingtoequipmentassemblyandtowater,steamandelectricalinstallationmustbeuncondi-tionallyobservedandcompliedwith.
– Caution - Danger from electric shock! The connection of the steam humidifier to the mains electrical supply must not be made until all installation work has been completed.
– Electronic components are very sensitive to electrostatic discharges. In order to protect thesecomponents,duringallinstallationworkwiththeequipmentopened,precautionsmustbetakenagainstdamageduetoelectricaldischarge(ESDprotection).
5.2 Unit fitting
5.2.1 Humidifier location
Theinstallationsiteofthesteamhumidifierdependslargelyonthelocationofthesteamdistributionpipeorfanunit(seechapter5.3.1and5.3.2),respectively.Toensureproperfunctioningofthesteamhumidifierandtoobtainanoptimalefficiency,thefollowingpointsmustbeconsideredandobservedwhenchoosingthelocationforthesteamhumidifier:
– Installthesteamhumidifiersothatthelength of the steam hose is kept as short as possible (max. 4 m) and that the minimum bend radius (R= 300 mm) and up-slope (20 %) or down-slope (5 %)ofthesteamhoseisobserved(seechapter5.3.3).
– ThesteamhumidifiersDefensorMk5aredesignedforwall-mounting.Makesurethattheconstruc-tion(wall,pillar,floor-mountedconsole,etc.)towhichthehumidifiersaretobemounted,offersasufficientlyhighload-bearingcapacity(takenoticeoftheweightinformationfoundinthischapter),andissuitablefortheinstallation.
Warning!Donotmountthesteamhumidifierdirectlytotheventilationduct(insufficientstability).
– ThebackpaneloftheDefensorMk5isretainingheatduringoperation(max.surfacetemperatureofthemetalhousingapprox.60-70°C).Makesure,therefore,thattheconstruction(wall,pillar,etc.)towhichtheunitsaretobemounted,doesnotconsistofheat-sensitivematerial.
– Foroperationinvolvingafanunit,thesteamhumidifiermustalwaysbeinstalledlowerthanthefanunit.
– Installthesteamhumidifierinsuchamannerthatitisfreelyaccessiblewithsufficientspaceavail-ableformaintenancepurposes(refertothefollowingillustrationforminimumdistances).
22
Dimensions and Weights
Minimum distances to observe
437 mm 500 mm
1087
mm
1087
mm
392 mm 594 mm
160 mm257 mm 194 mm212 mm30
0 mm
300 m
m
69 mm 132 mm 103 mm45 mm
min.
400 m
m
min. 600 mm min. 50 mm min. 400 mm
min.
600 m
m
50 mm
min.
600 m
m
Mk5 ...50.. Mk5 ...60.. Mk5 ...80..Unit A: 20 kg/h 30 kg/h 40 kg/hUnit B: 30 kg/h 40 kg/h 40 kg/h
Unit AUnit B
Housing size small large double unit largeSteamcapacity in kg/h 5 8 10 16 20 24 30 40 50 60 80
Netweightin kg 36 36 37 38 41 43 43 44 1x41
1x43 2x43 2x44
Grossweight in kg 51 51 52 53 71 73 73 74 1x71
1x73 2x73 2x74
23
5.2.2 Mounting the humidifier
• Usethedrillingtemplate(printedonthepacking)tomarkattachmentpoint“A”onthewall.Important! Observe location notes.
• Drillholeø10mm,insertthesuppliedplasticplug,andtightenthescrewuntilthedistancebetweenthewallandthescrewheadis5mm.
• Unlockleftfrontpanelandremovebothfrontpanels.Hanguptheunitonthescrew,andusethespiritleveltoadjustithorizontallyandvertically.
• Markattachmentpoints“B”.Whenfinished,removetheunitagain.
• Drillholesø10mmandinsertthesuppliedplasticplugs.
• Hangtheunituponthescrewagainbeforeattachingitwiththeremainingtwoscrews.Beforetight-eningthescrews,readjusttheunitwiththespiritlevel.
• Reattachthefrontpanelsandlockthem.
5.2.3 Inspecting the installed unit
Usethefollowingchecklisttoascertainthattheinstallationwasperformedcorrectly:
Is/aretheunit(s)inthecorrectplace?(seechapter5.2.1)
Is/aretheunit(s)correctlyalignedverticallyandhorizontally?
Issteamhumidifierproperlysecured?(stabilityofthecarryingstructure)
Caution!WhenfixingtheDefensorMk5,useonly the fixing materials supplied with the unit.Iffixingwiththematerialssuppliedisnotpossibleinyourparticularcase,selectamethodoffixingthatisofsimilarstability.Incaseofdoubt,pleasecontactyoursupplier.
Note:Thefollowingexplainshowtofixtheunitwithoutoptionalmountingprofiles.Toinstalltheunitwithmountingprofiles,pleasenotethespecialinstructionsprintedonthepackaging.
View from the front
Measure Housing sizesmall large
a 232,0 mm 237,0 mmb 175,0 mm 181,0 mmc 166,5 mm 166,5 mmd 460,0 mm 460,0 mm
24
5.3 Steam installation
5.3.1 Positioning and mounting of the steam distribution pipes
Thelocationforthesteamdistributionpipesshouldbedeterminedatthetimeofdimensioningtheairconditioningsystem.Pleasenotethefollowinginstructionstoensureproperhumidificationoftheductair.
Calculating the humidification distance
Thewatervapor,emittingfromthesteamdistributionpipes,requiresacertaindistancetobeabsorbedbytheambientairsothatitisnolongervisibleassteam.Thisdistanceisreferredtoashumidifica-tion distance “BN”andservesasabasisforthedeterminationoftheminimumdistancesfromtheupstream components in the system.
Humidificationdistance BN Expansionandmixingzone
φ1: Incoming air humidity beforehumidificationφ2: Air humidity afterhumidification
Thecalculationofthehumidificationdistance“BN”isdependentonseveralfactors.Foraroughestima-tionofthehumidificationdistance“BN”,thefollowingtableisuseful.Recommendedstandardvalueslistedinthistablearebasedonasupply-airtemperaturerangeof15°Cto30°C.Thevaluesgiveninbold type only apply to steam distribution pipes 81-..., the values in brackets apply to the OptiSorp steam distribution system.
Humidity at inlet φ1 in %rh
Humidification distance BN in mHumidity at outlet φ2 in %rh
40 50 60 70 80 905 0,9 (0,22) 1,1 (0,28) 1,4 (0,36) 1,8 (0,48) 2,3 (0,66) 3,5 (1,08)
10 0,8 (0,20) 1,0 (0,26) 1,3 (0,34) 1,7 (0,45) 2,2 (0,64) 3,4 (1,04)20 0,7 (0,16) 0,9 (0,22) 1,2 (0,30) 1,5 (0,41) 2,1 (0,58) 3,2 (0,96)30 0,5 (0,10) 0,8 (0,17) 1,0 (0,25) 1,4 (0,36) 1,9 (0,52) 2,9 (0,88)40 − 0,5 (0,11) 0,8 (0,20) 1,2 (0,30) 1,7 (0,45) 2,7 (0,79)50 − − 0,5 (0,13) 1,0 (0,24) 1,5 (0,38) 2,4 (0,69)60 − − − 0,7 (0,16) 1,2 (0,30) 2,1 (0,58)70 − − − − 0,8 (0,20) 1,7 (0,45)
Forductwidths<600mmthehumidificationdistancefortheOptiSorpsystemincreasesbyapprox.50%
φ1in%rh: Relativesupplyairhumiditypriortohumidificationatthelowestsupplyairtemperatureφ2in%rh: Relativesupplyairhumidityafterthesteamdistributionpipeatmaximumcapacity
Example
given: φ1=30%rh,φ2=70%rh
humidificationdistanceBN: 1,4 m (0.36mforOptiSorpsteamdistributionsystem)
Note:Ifthehumidificationdistancehastobereducedfortechnicalreasons,theamountofsteamperbasicunitmustbedividedbetweentwosteamdistributionpipesortheOptiSorp steam distribution system mustbeused.Ifthisisthecase,contactyoursupplier.
25
Minimum distances to be observed
To prevent thewater vapor, that is emitting from the steam distributionpipe, from condensing ondownstreamsystemcomponents,aminimumdistancetothesteamdistributionpipemustbeobserved(dependsonthehumidificationdistance“BN”).
before/after filter/register before/after fan, zone exit
Caution!Thehumidificationdistanceandderivedfromittheminimumdistancebetweenthesteamdistributorandsystemcomponents locateddownstreamintheductaredeterminedonthebasisoftheexpectedoperatingparameters(e.g.airspeed,supplyairtemperature,etc.)whenplanningthesystem.Analterationoftheseoperatingparametersatalatertimemayinducethatthedeterminedhumidificationdistanceisnotcorrectanylongerandsteamiscondensatingduringoperationonsys-temcomponentslocateddownstreamintheduct.Thismayleadtodamageofthesystemand/oranexcessivegrowingofgerms.
Installation notes and dimensions
Thesteamdistributionpipesaredesignedforeitherhorizontalinstallation(ontheductwall)or,withaccessories,forverticalinstallation(intheductfloor).Theoutlet orifices should always point up-wards and at right angles to the airflow.
Ifpossible,thesteamdistributionpipesshouldbeinstalledonthepressure sideoftheduct(max. duct pressure 1500 Pa).Ifthesteamdistributionpipesareinstalledonthesuctionsideoftheduct,the maximum vacuum must not exceed 1000 Pa.
Selectalocationfortheinstallation,tailoredtosuityourduct(seethefollowingillustrations)andpositionthesteamdistributionpipesintheductsothatauniformdistributionofsteamisachieved.
before/after constriction after expansion before bend
before branch before diffuser before control sensor
2,5xBNbeforesubmicronparticlefilter
0.5 x BN BN0.5 x BN
BN BN 5 x BN
1.5 x BN * 5 cm BN BN
26
Inpositioningthesteamdistributionpipes,thefollowingdimensionsshouldbeobserved.
Note:PleasenotetheinstructionsintheseparatedocumentationforthisproductwhenlocatingtheOptiSorp steam distribution system.
Guidelines for dimensioning the ventilation ducts
– Tofacilitatetheinstallationofthesteamdistributionpipesandforcontrolpurposes,asufficientlysizedcontrolopeningshouldbeplanned.
– Withintherangeofthehumidificationdistance,theventilationductshouldbewater-proofed.
– Airductspassingthroughcoldroomsshouldbeinsulatedtopreventthehumidifiedairfromcon-densingalongtheductwall.
– Poorairflowconditionswithintheairduct(e.g.causedbyobstacles,tightbends,etc.)canleadtocondensationofthehumidifiedair.
– Steam distribution pipes must not be mounted to round ducts.
Ifyouhavequestionsrelatingtothedimensioningofventilationductsincombinationwithsteamhu-midifiers,contactyoursupplier.
Installing the steam pipes/the OptiSorp steam distribution system
Detailedinformationontheinstallationofsteamdistributionpipes/OptiSorpsteamdistributionsystemcanbefoundintheseparate“MountingInstructions”forthisproducts.
gmin= 150mmhmin= 85mm
min.H=250mm H≥400mm min.H=200mm
min.H=400mm min.H=350mm min.H=300mm
min.H=600mm min.H=500mm min.H=400mm
min.H=720mm min.H=600mm min.H=500mm
27
Thefanunitismountedon the wall separately above the unit.Toallowthesteamcomingfromthefanunittospreadoutevenly,withoutcondensingonobstacles(ceilings,joists,pillars,etc.),thefollow-ingminimumdimensionsmustbeobservedwhenselectingthelocationforthefanunit.
FAN3SMkM/FAN3SMkMFC FAN3SMkL
mDmax. 8kg/h 16kg/h 30kg/h 40kg/h
A min. 4.0 m 6.0 m 8.0 m 10.0 m
B min. 1.0 m 1.0 m 1.0 m 1.5 m
C ca. 2.2 m 2.2 m 2.2 m 2.2 m
D ca. 0.5 m 0.7 m 1.0 m 1.5 m
E min. 0.15 m
E max. (max.lengthofsteamhose) 4.0 m (recommended: 2.0 m)
Note:Theminimumspacesinthetableapplyforaroomatmosphereof15°Candmax.60%rh.Forlowertemperaturesand/orhigherhumiditythevaluesmustbeincreasedaccordingly
Note:Inordertoachieveauniformdistributionofthehumiditywithintheroom,additionalfactorssuchastheroomsize,theroomheight,etc.,mustbetakenintoconsiderationbesidesobservingtheminimumdistances.Ifyouhavequestionsconcerningthedirectroomhumidification,pleasecontactyoursupplier.
Furtherinformationisprovidedintheseparateinstallationandoperatinginstructionsforthefanunit.
5.3.2 Positioning and mounting of the fan unit
28
Important! Useoriginalsteamandcondensatehosefromyourunitsupplierexclusively.Othertypesofhosescancauseundesiredoperationalmalfunctions.Important! After installation the protective plastic tube around the steam hose must be removed.
Instructions for the hose layout
Thehoselayoutdependsonthepositionofthesteamdistributionpipe:
– Steam distribution pipe is mounted more than 500 mm above the top edge of the humidifier:
Initially, lead the steam hose at least 300 mm perpendicularly upward above the top edge of the humidifier,thenleadthehosewithaminimum upslope of 20%and/oraminimum downslope of 5% to the steam distribution pipe.
Thecondensatehoseisleddowntothehumidifierwithaminimum slope of 20 %,intheformofa siphon (min. hose bend radius Ø200 mm ),andinsertedabout2cmintothespecifiedopening.Note:Ifyourunitfeedsanumberofsteamdistributionpipes,theindividualcondensatehosesaretobeledintothedischargefunnel.Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.
Note: forsteamcapacities≤20kg/htheseparatereturnofthecondensateviathecondensatehosecanbedispensedwithifthesteamhoseisinstalledinsuchawaythatthecondensatecanflowbackintothesteamcylinderunhinderedwithaconstantdownslope.
5.3.3 Installing the steam and condensate lines
5.3.3.1 Steam line with flexible hose
min.
300 m
m
Rmin.
300 m
m
min. 5 % min. 20 %
max.
4m
min.
300 m
m
Rmin.
300 mm
min. 20 %
max.
4m
min. 20 %
Ømin. 200 mm
min.
300 m
m min. 20 %
Ømin. 200 mm
29
– Steam distribution pipe is mounted less than 500 mm above the top edge of the humidifier:
Initially, lead the steam hose at least 300 mm perpendicularly upward above the top edge of the humidifier,thendowntothesteamdistributionpipewithaminimum slope of 5 %.
Thecondensatehoseisleddownwithaminimum slope of 20 %,intheformofasiphon (min. hose bend diameter Ø200 mm),directlyintoadischargefunnel.Important! Beforeputtingtheunitintooperation,thesiphonofthecondensatehosemustbefilledwithwater.
– Thesteamhoseshouldbekeptasshortaspossible(max. 4 m)whileobservingtheminimum bend radius of 300 mm. Important!Allowancemustbemadeforapressure loss of 10 mm water column (approx. 100 Pa) per meter steam hose.Note:Ifyourparticularinstallationexceedsthemaximumsteamhoselengthof4mcontactyoursupplier. In any case, steam hoses longer than 4 m must be insulated in their entire length.
– Caution! Reducing the cross section or the complete closure of the steam pipe will cause an excessive increase in pressure in the steam cylinder when the unit is operat-ing and could lead to the risk of scalding accidents. Therefore you must comply with the following instructions:
– Wheninstallingmakesurethesteampipeisopenovertheentirelengthandthroughthewholecrosssection.Anysealingplugs,adhesivesealingsheetsetc.mustberemovedbeforeconnectingthesteampipeandreductionsincrosssectionbykinking,forexample,must be avoided.
– Steamhosesmustbepreventedfromsagging(condensatepockets);ifnecessary,sup-portsteamhosewithpipeclamps,trough,orwallbrackets,orinstallacondensatedrainatlowestpointinthesteamhose.
– It is not permitted to install a stop valve(e.g.amanuallycontrolledstopvalve,solenoidvalve,etc.)inthesteampipe.
– Important!Whendecidingonthelengthandlayoutofthehose,itshouldbenotedthatthesteamhosemaybecomesomewhatshorterwithprogressiveageing.
Securing the steam hose
Thesteamhosemustbesecuredtothesteamdistributionpipeandhumidifiersteamoutletbymeansofhose clamps.
max.
4m
min. 5 %
Rmin.
300 m
m
max.
4m
min.
300 m
m
min. 20 %
min.
300 m
m
min. 20 %min. 5 %
Rmin. 300 m
m
min. 20%
min.
300 m
m
min. 20 %
Ømin. 20
0 mm
min.
300 m
m
min. 20 %
Ømin. 20
0 mm
30
Usethefollowingchecklisttoascertainthatthesteaminstallationwasperformedcorrectly:
– Steam distribution pipe
Steamdistributionpipecorrectlypositionedandsecured(screwstightened)?
Aretheoutletorificesatrightanglestotheairflowdirection?
– Steam hose
Maximumlengthof4m?
Minimumbendradiusof300mm(100mmwithfixedpiping)?
Havetheinstructionsforhosepositioningbeenfollowed?
Isthesteampipeopenovertheentirelengthandthroughthewholecrosssection?
Steamhose:nosagging(condensatepocket)?
Rigidsteamlines:properlyinsulated?Correctinstallationmaterialused?Minimalinternaldiametermaintained?
Steamhosesecurelyattachedwithclamps?
Heatexpansionduringoperationandshorteningofthehosewithageingtakenintoconsidera-tion?
Hastheprotectiveplastictubearoundthesteamhosebeenremoved?
– Condensate hose
Downslopeofatleast20%?
Siphonexistingandfilledwithwater?
Condensatehosecorrectlyfixed?
Forsteamlineswithrigidpiping, thesameinstructionsapply to the layingof thepipingasalreadydescribed.Thefollowingadditionalnotesshouldbeobserved:
– The minimum internal diameter of 42 mm mustbeappliedoverthewholelengthofthepiping.
– Useexclusivelycopperpipe(operationwithuntreateddrinkingwater)orstainlesssteel(min.DIN1.4301,operationwithfullydemineralisedwater.
– Tominimizethecondensateformation(=loss),thesteampipesmustbeinsulated.
– The minimum bend radiusforsolidpipesis100 mm.
– Connectionofthesteampipestothesteamdistributionpipeandsteamhumidifieriseffectedbymeansofshortlengthsofsteamhosesecuredwithhoseclamps.Connectiontothesteamhumidi-fierissecuredviaaG11/4”coupling..
– Important! Allowancemustbemadeforapressure loss of approx. 100 Pa per meter length or per90°bend.
5.3.4 Inspecting the steam installation
5.3.3.2 Steam line with rigid piping
31
5.4 Water installation
Allworkconcerningthewaterinstallationmustbeperformedonly by adequately qualified personnel(e.g.plumbers).Ascertainingthequalificationsisthecustomer’sresponsibility.
Please observe all local regulationsconcerningtheinstallationofappliancestothemainsandwastewatersystems.
Warning - danger of electric shock!Forallinstallationwork,thesteamhumidifiermust be disconnected from the mains supply and secured against unintentional re-connection.
5.4.1 Performing the water installation
Overview water installation
1 Waterconnection,unionnutG1/2" 2 Watersupplypipe(min.innerØ:8mm) 3 WaterdrainØ40mm 4 Drainpipe(min.innerØ:40mm,min.30cmdirectedverticallydownwards) 5 Pressurereducingvalve(compulsoryforwaterpressures>10bar,buildingside) 6 Manometer(installationrecommended,buildingside) 7 Filtervalve(accessory“Z261”) 8 Funnel(buildingside) 9 Siphon(min.innerØ:40mm,buildingside)10 Drainline,buildingside(min.innerØ:40mm)
H2O (1...10 bar)
1
3
2
4
5 6 7
8 9 108 9
min
. 30 c
m
32
Water supply
Thewaterfeedpipe(min.internalØ:8mm)istobeconnectedviathefilter valve that is available as anaccessory,totheconnectionontheunit(seedetailedillustration).Alternatively,ashut-off valve and a water filter maybeinstalled.Theinstallationofthefiltervalveshouldbemadeascloseaspossibletothesteamhumidifier.
Warning - danger of damage! Union nutatthehumidifierconnectionmustbehand-tightened only.
Thefollowingconnectionspecificationsmustbeobserved:
– Connection on unit: G 1/2" (Union nut)
– Min.innerØofsupplyline:8 mm
– Admissible mains pressure 1.0 to 10.0 bar(hammer-freesystem)Formainspressures>10bar,connectionmustbemadeviapressurereducingvalve(adjustedto2.0bar).Formainspressures<1.0barpleasecontactyoursupplier.
– Supply rate: 1 l/min per 15 kg/h steam capacity
– Admissible supply temperature: 1…40 °C
– Notes on water quality:
– ForthewatersupplyoftheDefensorMk5,useexclusivelyuntreated drinking waterorfully demineralized water.Note:Theuseoffullydemineralizedwaterreducesthetimeformaintenanceandcleaningtoaminimum.
– The use of additivessuchascorrosioninhibitors,disinfectants,etc.isnot allowed, since these additivesmayendangerhealthandaffectproperoperation.
– IftheDefensorMk5shallbeoperatedwithsoftenedorpartlysoftenedwater,pleasecontactyoursupplier.
– The connection material must be pressure-proof andcertifiedforuseindrinking water supply systems.
Caution! Fullydemineralizedwaterisaggressive.Whenmakingconnectionstoafullydem-ineralizedwatersystem,useexclusivelyplasticorstainlesssteelinstallationmaterials(min.DIN1.4301).
– Important! Beforeconnectingthewaterlinetotheunit,thelinemustbeflushedthoroughly.
Water drain
Thewaterdrainageiseffectedwithoutpressure.Thus,inordertoavoidanydammingofthewater,thedrain pipe must be led straight down into a drainage funnel, through a piece of hose with a min. length of 30 cm.Subsequently,thedrainpipeisconnectedviasiphontothewastewatersystemofthebuilding.Theminimuminsidediameterof40mmmustbeobservedoverthewholelengthofthedrainpipe.Makecertainthatthedrainpipeiscorrectlyfixedandeasilyaccessibleforinspectionsandcleaning purposes.
Thefollowingconnectionspecificationsmustbeobserved:
– Drainage capacity: approx. 2,5l/min per 15 kg/h steam capacity
– Drainage temperature: 60…90 °C Warning! Use only temperature-resistant installation materials!Warning! Fully demineralized water is aggressive. Theconnectionsforademineralizedwatersystemshouldbemadeexclusivelyfrom stainless steel (min. DIN 1.4301) or chemi-cally resistant plastics (e.g. polypropylene).
– Connection on unit: hose connection Ø40 mm
Warning!Hosemustbesecuredtotheunitconnectionwithahoseclamp.
– Min.innerØofdrainline:40 mm
– Min.downslopeaftersiphon:10 %
33
5.4.2 Inspecting the water installation
Usethefollowingchecklisttoascertainthattheinstallationhasbeenperformedcorrectly:
– Water supply
Hasfiltervalveorshut-offvalveandfilter125µmrespectivelybeeninstalledinsupplyline?
Haveadmissiblewaterpressure(1.0–10bar)andtemperature(1–40°C)beenobserved?
Doessupplycapacitymatchthehumidifier(s)?
Areallpipesproperlysecured(threadedconnectionstightened)?
Isthefeedpipeproperlysealed?
– Water drain
Hasminimuminsidediameterofdrainpipesbeenmaintainedatleast40mmthroughouttheentirelength?
Hasdrainpipebeeninstalledwithadownslopeofatleast10%?
Hastheheatresistanceofthematerialusedbeenverifiedtobeatleast100°C?
Arehosesandlinesproperlysecured(hoseclampsandthreadedconnectionstightened)?
34
5.5 Electric installation
– Allworkconcerning theelectric installationmustbeperformedonlybyadequately qualified personnel (electrician or workman with equivalent training). Ascertaining thequalificationsisthecustomer‘sresponsibility.
– Warning - danger of electric shock!The steamhumidifiermaybe connected toelectricmainsonlyafterallinstallationworkhasbeencompleted.
– Please observe all local regulations concerning the electric installation.
– Warning! Electronic components inside the unit are very susceptible to electrostatic discharges.Fortheprotectionofthesecomponents,measuresmustbetakenduringallinstallationworktopreventdamagecausedbyelectrostaticdischarge(ESD–protec-tion)
5.5.1 Electric installation overview
1 Supply heating voltage Up 2 Supply control voltage Uc 3 InterfaceRS232/RS485 4 Remoteoperatingandfaultindications(option“RFS”) 5 Externalcontinuouscontroller 6 Humiditysensor(supplyair/room/exhaust) 7 Safetyhumidistat 8 Airflowmonitor
9 Ventilationinterlock10 Externalsafetycircuit11 Steamhumidifier 12 Internal continuous controller 13 Control voltage supply to second unit 14 Control line to second unit15 Secondunit(from50kg/h)
DefensorMk5(A)
DefensorMk5(B)
35
Theelectricalinstallationistobecarriedoutinaccordancewiththefollowingwiringdiagram.
Caution! Observetheinstallationnotesinthefollowingsection.
5.5.2 Wiring diagram
1 2
3 4
5 6
7 8
9 10
F2 (1
AF)
F1 (6
.3 AT
)
JP1
JP2
JP1
JP2
J7
X1
K1 Q3
A1
M
K3 B3 B2 B1
A2 A3
F3
X6
L1
N SK
1 P
N P1
SK
2
L1
L2
L3
L1L2
L3PE
Q4
F4
L1N
Q4T1
F4
L1N
PE
F2 (1
AF)
F1 (6
.3 AT
)
X1
K1
Q3
F3
X6
L1
N SK
1P
N P1
SK
2
L1
L2
L3
L1L2
L3PE
+–
P / P
I
V+IN
GND
V+
IN G
ND
V+IN
GND
ON-O
FF
140..
.10kΩ
S1
S2
S3
S4
J3
J6
JP2 F5
(2
00 m
AF)
ON 1
2 3
4
Com
-Por
t
200-240V / 50...60Hz
200-
240V
/ 50..
.60Hz
J K1
St
eam
K2
Erro
r K3
Se
rvice
K4
Un
it On
H1
INPU
T 44
0-50
0VΔ
p
max.ϕ
Q3
F3
L1N
PE
Q3
F3
L1N
PE
Unit
BUn
it ASu
pplymo
dule
Supplymo
dule
Contr
ol bo
ard
(Opti
on)
Switches (
K1...K
4) sh
own i
n idle
posit
ion
SetJP2
to
5V
SetJP2
to
24V
(Opti
on)
Unit B
Unit A
LC di
splay
36
Legend to wiring diagram
A1 Controller(active)orhumiditysensorA2 Controller(passive),setjumperJP2to5VA3 On/Offcontrol,setjumperJP2to24VB1 VentilationinterlockB2 AirflowmonitorB3 SafetyhumidistatF1 Internalfusesupplymodule(6.3A,slowacting)F2 Internalfusesupplymodule(1A,quickacting)F3 Externalfuseheatingvoltagesupply(seetableinthefollowingchapter)F4 Externalfusecontrolvoltage(max.10A,slowacting)F5 Internalfusecontrolmodule(200mA,quickacting)H1 Remoteoperatingandfaultindication(option“RFS”)J Shortcircuited,ifnoexternalmonitoringdevicesareconnectedJ3 ConnectionterminalforremoteoperatingandfaultindicationJ6 ConnectionterminalforcontrollinetounitB(forunitswith50...80kg/hsteamcapacityonly)J7 ConnectionterminalforcontrollinefromunitAJP2 Jumper(controlsignal)oncontrolboardunitAK1 Mainscontactor(heatingvoltage)unitA/unitBK3 Externalsafetycircuit(safetyhumidistat,airflowmonitor,etc.)M Fanunit(accessory“FAN3S..”)Q3 ExternalmainswitchheatingvoltagesupplyQ4 ExternalmainswitchcontrolvoltagesupplyT1 Auto-transformercontrolvoltagesupply(option“TRAF”)S1 Rotaryswitch"draininterval”S2 Rotaryswitch“maintenanceinterval”S3 Rotaryswitch“controlsignal”S4 DIP-switch“unitsettings”X1 ConnectionterminalforcontrolvoltagetosupplymoduleX6 ConnectionterminalforvoltagesupplyfromunitAtounitB
37
5.5.3 Notes on component installation
Important note:
– Allconnectingcablesintheelectricalinstallationaretobefedinviathecableglandsonthebaseoftheunit(theexceptiontothisistheheatingvoltageconnectioncable,forwhichthespecialclampisprovided).
– Thedetailsrelatingtoindividualcomponentsaretobenotedandfollowed.
Heating voltage supply Up
Caution!Beforeconnecting,ensurethatthemainsvoltagecorrespondswiththeheating volt-age for the unit (see mains code on the type label).Note:Onequipmentversionscombiningtwobasicunits,eachunithasatypelabel
Thehumidifier(inthecaseoftwinnedunits,eachseparateunit)istobeconnectedtothemainssupplyinaccordancewiththeconnectionschematic,viaaservice switch “Q3”(anallpoledisconnectingdevicewithaminimumcontactopeningof3mmisanessentialrequirement)andan“F3” fuse group (essentialrequirement:fusesaretobeasdetailedinthefollowingtable).Thesupplywiringistobefedintotheunitviathetension-relievingdevice(cableclamp)andconnectedtotheterminalsofthe“K1” mains contactor.
LC display
400 V/3~50…60 Hz
220 V/3~50…60 Hz
415 V/3P~50…60 Hz
240 V/1N~50…60 Hz
230 V/1N~50…60 Hz
200 V/3~50…60 Hz
P N max
. in kW
I N max
. in A
A L min.
in m
m2
F3 in
A, q
uick a
cting
P N max
. in kW
I N max
. in A
A L min.
in m
m2
F3 in
A, q
uick a
cting
P N max
. in kW
I N max
. in A
A L min.
in m
m2
F3 in
A, q
uick a
cting
P N max
. in kW
I N max
. in A
A L min.
in m
m2
F3 in
A, q
uick a
cting
P N max
. in kW
I N max
. in A
A L min.
in m
m2
F3 in
A, q
uick a
cting
P N max
. in kW
I N max
. in A
A L min.
in m
m2
F3 in
A, q
uick a
cting
Mk5 Visual 5-..Mk5 Process 5-..
3,8 5,5 1,5 10 3,4 9,0 2,5 16 4,0 6,0 1,5 10 4,0 17,0 2,5 20 4,0 16,5 4,0 20 3,0 8,2 1,5 10
Mk5 Visual 8-..Mk5 Process 8-..
6,0 8,7 1,5 10 5,5 14,4 2,5 16 6,5 9,0 1,5 10 6,5 27,2 6,0 32 6,0 26,0 6,0 32 4,5 13,1 1,5 16
Mk5 Visual 10-..Mk5 Process 10-..
7,5 11,0 1,5 16 6,7 17,7 2,5 20 8,0 11,5 1,5 16 8,0 33,0 10,0 40 7,4 32,0 10,0 40 5,5 16,1 2,5 20
Mk5 Visual 16-..Mk5 Process 16-..
12,0 17,4 2,5 20 10,9 28,7 6,0 32 13,0 18,1 2,5 20 ––– ––– ––– ––– ––– ––– ––– ––– 9,0 26,1 6,0 32
Mk5 Visual 20-..Mk5 Process 20-..
14,9 21,5 6,0 25 13,5 35,4 10,0 40 16,0 22,3 4,0 25 ––– ––– ––– ––– ––– ––– ––– ––– 11,1 32,2 10,0 40
Mk5 Visual 24-..Mk5 Process 24-.. 18,1 26,2 6,0 32 16,4 43,1 16,0 63 19,5 27,2 6,0 32 ––– ––– ––– ––– ––– ––– ––– ––– 13,5 39,2 16,0 63
Mk5 Visual 30-..Mk5 Process 30-..
22,3 32,3 10,0 40 20,2 53,1 16,0 63 24,0 33,5 10,0 40 ––– ––– ––– ––– ––– ––– ––– ––– 16,7 48,3 16,0 63
Mk5 Visual 40-..Mk5 Process 40-..
30,0 43,3 16,0 63 27,2 71,4 25,0 80 32,3 45,0 16,0 63 ––– ––– ––– ––– ––– ––– ––– ––– 22,4 64,9 25,0 80
Mk5 Visual 50-..Mk5 Process 50-..
A 14,9+
22,3
21,5+
32,3
6,0+
10,0
25,0+
40,0
13,5+
20,2
35,4+
53,1
10,0+
16,0
40+63
16,0+
24,0
22,3+
33,5
4,0+
10,0
25+40
––– ––– ––– ––– ––– ––– ––– –––11,1
+16,7
32,2+
48,3
10,0+
16,0
40+63B
Mk5 Visual 60-..Mk5 Process 60-..
A 22,3+
22,3
32,3+
32,3
10,0+
10,0
40,0+
40,0
20,2+
20,2
53,1+
53,1
16,0+
16,0
63+63
24,0+
24,0
33,5+
33,5
10,0+
10,0
40+40
––– ––– ––– ––– ––– ––– ––– –––16,7
+16,7
48,3+
48,3
16,0+
16,0
63+63B
Mk5 Visual 80-..Mk5 Process 80-..
A 30,0+
30,0
43,3+
43,3
16,0+
16,0
63,0+
63,0
27,2+
27,2
71,4+
71,4
25,0+
25,0
80+80
32,3+
32,3
45,0+
45,0
16,0+
16,0
63+63
––– ––– ––– ––– ––– ––– ––– –––22,4
+22,4
64,9+
64,9
25,0+
25,0
80+80B
AB
Note:Dependingonthesteamcapacitytheloadofthephasesmaybeasymmetric.
38
Control voltage supply Uc
Caution!Beforeconnecting,makesurethatthemainsvoltagecorrespondswiththecontrol voltage of the unit (200…240 V, 50…60 Hz).
Caution!Thehumidifiermustonlybeconnectedtoamains supply with a protective conductor.
TheconnectiontothecontrolvoltageUcismadeinaccordancewiththeconnectionschematic,totheterminal “X1” on the supply module. The customer is to install a service switch Q4 in the supply line (allpoledisconnectingdevicewithaminimumcontactopeningof3mm)andanF4 fuse (max. 10 A slow acting) (thesearebothessentialrequirements).Note:Onversionsinwhichtwounitsareincorporated,thecontrolvoltageconnectionismadetotheunitfittedwiththedisplayandoperatingfacility(unitA).Theterminal“X1”ofthesecondunit(unitB)remainsunused.TosupplythecontrolvoltagetounitB,theterminals“X6”onthesupplymodulesofboth units must be connected using the supplied cable.
Thecross-sectionofthemainscablemustcomplywiththeapplicablelocalregulations(minimumof1.5 mm2).
External safety circuit
Toensurethesafetyofthehumidifiersystem,itisessentialthataso-calledexternalsafetycircuitbeprovided to monitor the operation.
To this end, the potential-free contacts (max. contact loading 250V/5A) oftheexternalmonitoringdevices(e.g.maximumhumidistat,flowmonitor,ventilationinterlock,etc.)areconnectedin series with the corresponding contacts on the terminal “X1”,inaccordancewiththeconnectionschematic.
Caution, danger of electric shock!Themainsvoltage isconnected to terminal “X1”(up to240V).Thesteamhumidifiermustthereforebeisolatedfromthemainssupply(powerandcontrolcomponents),beforestartingtheconnectionwork.
If,forwhateverreason,noexternalmonitoringdevicesareconnected,aconnectingbridge“J”mustbeinstalledontheappropriatecontactsontheterminalstrip“X1”.
Do not apply any extraneous voltage to the terminals.
Thecross-sectionofthecablemustcomplywiththeapplicablelocalregulations(minimumof1mm2).
Remote operating and fault indication H1 (Option “RFS”)
TheoptionalremoteoperatingandfaultindicationPCBistobeconnectedviatheconnectionsocket“J3”onthecontrolboard.TheremoteoperatingandfaultindicationPCBcontainsthepotential-freerelaycontactsK1…K4fortheconnectionofthefollowingoperatingandfaultindications:
– K1“Steamproduction”: Thisrelayclosesassoonastheunitproducessteam.
– K2“Fault”: Thisrelayisactivatedifthereisafault.
– K3“Maintenance”: Thisrelayisactivatedwhenthesetserviceintervalhasexpired.
– K4“UnitOn”: Thisrelayclosesassoonastheunitisswitchedonviathemainswitch.
The maximum contact loading is 250V/5A.
Appropriatesuppressormodulesaretobeusedfortheswitchingofrelaysandminiaturecontactors.
39
Control signal / Humidity sensor signal
Theconnectionofanexternalactivecontroller“A1”,apassivecontroller“A2”,anOn/OffHumidistat“A3”orahumiditysensor(forcontrolviatheinternalcontroller),isaccomplishedontheappropriatecontactsontheterminalstripinaccordancewiththeconnectionschematic.Notethefollowingcon-nectioninformation:
External controller
Internal controller
Connection active controller “A1”
passive controller “A2”
On/Off controller “A3”
Humidity sensor
Pos. Jumper JP2
– neutral X X
– 5 V 140Ω...10kΩ
– 24 V X
Rotary switch S3
Pos. Signal0 No signal selected1 On/Off24V X2 0...5 V DC (Potentiometer) X3 0...10 V DC X X4 0...1 V DC X X5 1...5 V DC X X6 2...10 V DC X X7 0...20 V Phase intersect X X8 4...20 mA X X9 0...20 mA X X
Note:Thecontrollerhumiditysensoristobemountedatasuitablepositionintheductafterthesteamdistributionpipe,withaminimumseparationof5timesthehumidificationdistanceBN(butnotclosetotheheatingorcoolingunitsoftheventilationsystem).Please refer to theseparate installation instructions for thecontroller/sensorwhenpositioningandconnecting these components.
Control cable for versions with two units
Thesuppliedcontrolcable(flatribboncable)isconnectedtoterminal“J6”onthecontrolboardofunitAandtoterminal“J7”onthesupplymoduleofunitB.
Connecting the fan unit
Seeseparatedocumentation“Fanunit”.
RS232/RS485 connection
Seeseparatedocumentation“InterfaceRS232/485”
5V24VJP2
5V24VJP2
5V24VJP2
40
5.5.4 Inspecting the electrical installation
Inspectforcorrectinstallationinaccordancewiththefollowingchecklist:
Dothemainsvoltagesappliedcorrespondtotherespectivedetailsstatedontheratingplate/sforthepowerandcontrolcomponents?
Arethevoltagesupplies(Powerandcontrolcomponents)correctlyfused?
Istheserviceswitch“Q”installedinthesupplycabletothepowerandcontrolcomponents?
Areallcomponentscorrectlyconnectedinaccordancewiththeconnectionschematic?
Areallconnectioncablesfixed?
Aretheconnectingcablesfreeoftension(fittedthroughcableglands/securedwithcableclamps?)
Istherotaryswitch“S3”settocorrespondwiththecontroller(active,passive,On/Off)orhumiditysensor?
Isjumper“JP2”onthecontrolboardcorrectlysetforthecontrollerused?
41
6 Operation
6.1 Unit configuration
Warning - danger of electric shock! Disconnect the steam humidifier from the mains supply(heatingandcontrolvoltage)beforeopeningtheunit.
Warning! Electronic components inside the unit are very susceptible to electrostatic discharges.Fortheprotectionofthesecomponents,measuresmustbetakenduringallinstallationworktopreventdamagecausedbyelectrostaticdischarge(ESD–protection).
All adjusting elements are situated on the control board:– Rotaryswitch“S1”: draininterval– Rotaryswitch“S2”: maintenanceinterval– Rotaryswitch“S3”: controlsignal(seechapter5.5.3)– Rotaryswitch“S4”: unitsettings
Setting the drain interval (“S1”)
Theevaporationprocessincreasestheconcentrationofmineralsaltsinthesteamcylinder.Periodicflushingfollowedbyrefillingoffreshwatercankeeptheconcentrationofmineralsaltsatalowlevel.
Theintervaltimetobeselecteddependsonthequalityofthewaterandthetypeofunit.Itmayhavetobeadaptedtotheactualcircumstancesduringoperation.Thefollowingmaintenanceintervalscanbe selected.
Position “S1” drain interval at 100% steam capacity
Unit type Defensor Mk5 Visual/Process
5-.. 8-.. 10-.. 16-.. 20-.. 24-.. 30-.. 40-.. 50-.. 60-.. 80-..0 ∞
1 720 min.2 360 min. VE VE VE VE VE VE VE VE VE VE VE3 180 min.4 120 min. X5 60 min. X X6 30 min. X7 20 min. X X8 10 min. X X X X X9 5 min.
VE= SettingforfullydemineralizedwaterX= Standardsetting
Notes:
– Thestandardsettings(seeprecedingtable)refertoawaterhardnessof210ppm(12°dHor21°fH,respectively).
– IftheDefensorMk5isoperatedwithfullydemineralizedwater,theswitchcanbesetto“2”.
– IftheDefensorMk5shallbeoperatedwithsoftenedorpartlysoftenedwater,pleasecontactyoursupplier.
– Ifnohumidificationtakesplaceformorethan4hours,theunitwillproceedtoaflushingcycleandafloattestuponthenexthumidificationrequest.
42
Setting the maintenance interval (“S2”)
The maintenance interval for the small and the extended maintenance is set with switch “S2”. When the set time has expired, a maintenance message indicates that the unit should be serviced.
The intervals to be selected depend on the quality of the water and the type of unit. It may have to be adapted to the actual circumstances during operation. The following maintenance intervals can be selected:
Position “S2”
Interval for Unit type Defensor Mk5 Visual/Process
small maintenance extend. maintenance 5-.. 8-.. 10-.. 16-.. 20-.. 24-.. 30-.. 40-.. 50-.. 60-.. 80-..0 200 h 600 h1 300 h 600 h2 300 h 900 h3 450 h 900 h4 400 h 1200 h X X5 600 h 1200 h X X X X X6 500 h 1500 h X X X7 750 h 1500 h X8 3000 h 3000 h VE VE VE VE VE VE VE VE VE VE VE9 6000 h 6000 h
VE= Setting for fully demineralized waterX= Standard setting for water with medium hardness (12°dH, 21°fH, 210 ppm)
Note: The maintenance interval times refer to a steam output of 100 %. If less output is required in operation, the maintenance intervals are correspondingly increased. However, we recommend to carry out an extended maintenance at least once a year.
Setting the control signal (“S3”)
See informations in chapter 5.5.3
Unit settings (“S4”)
Various unit parameters can be set at the DIP switch “S4”. The unit parameters are preset at the factory and must only be changed by the customer in consultation with the supplier.
Switch Standard setting Description1 OFF Automatic temperature stabilization ON/OFF
When the automatic temperature stabilization is switched on, the water in the steam cylinder is maintained at a specific temperature when there is a break in steam produc-tion, so that steam can be immediately generated again on renewed demand.
2 OFF Switch pause control ON/OFFIn the “OFF” position the switching element’s pause (Triac and Contactors) is controlled normally (maintaining “Flicker”-regulations). In the “ON” position the pause is reduced to optimize the precision of control.
3 OFF On/off switch delay heating contactor ON/OFFIn the “OFF” position the on/off switch delay is set for optimal life of the contactors. In the “ON” position the on/off switch delay is reduced to optimize the precision of control (reduced life of heating contactors).
4 OFF Output Alarm 3 “Water Supply” as error via optional remote operating and fault indica-tion ON/OFF.When set to the “OFF” position, Alarm 3 is not output as Error. When set to the “ON” position, Alarm 3 is output as Error via the optional remote operating and fault indication.
43
6.2 Putting into operation
Thefollowingprocedureiscarriedoutinordertooperatethesteamhumidifier:
• Whenputtingthesteamhumidifierintooperationthefirsttimeorwhenput-tingthesteamhumidifierintooperationafterworkhasbeencarriedoutonthesteamsystem,thecommissioningpersonnelmustmandatorycheckwhetherthesteampipeisopenovertheentirelength.Todothisproceedasfollows:• Removethefrontdoor(s)oftheDefensorMk5.• Undotheupperhoseclampofthesteamhoseintheunitwithascrewdriver
andpullthehosedowntoremoveitfromthesteamconnection.• Startuptheventilationsystemandcheckwhetheracleardraughtthatcor-
respondsapproximatelytothepressureintheventilationsystem(positiveornegativepressure)canbedetectedattheopensteamoutletinsidetheunit.
Caution! A steam pipe that is reduced in cross section or com-pletely closed will cause an excessive increase in pressure in the steam cylinder when the unit is operating and could lead to the risk of scalding accidents. Therefore: Ifnodraughtoronlyaslightonecanbedetectedthesteampipemustbecheckedforblockagesandreductionsincrosssectionbeforecontinuingwithcommissioningandyoumustensurethat the steam pipe is open across the entire length and through the wholecrosssection.
• Examine the steam humidifier and installation for possible damage.Caution! Damaged unitsandunitswithdamagedordefectiveinstalla-tionfeaturesmust not be operated.
• Mountfrontdooroftheunitandlockit.
• Openthefilter valve/shut-off valveinthewaterfeedline.
• Switchontheserviceswitchforthemainssupply(Heatingandcontrolvoltage).
• Switchonthesteamhumidifiermainswitch.
Thesteamhumidifiercarriesoutasystem test. The adjacent display appears andthethreeLEDslightforapprox.3seconds.Ifafaultisdetectedduringthesystemtest,acorrespondingfaultmessageistriggered(seechapter6.7).
If the system test is successful,thesteamcylinderfillsupandafloattestiscarriedout(functioncheckonthelevelunit).Theadjacentdisplayappears.Note:Ifafaultisdetectedduringthefloattest,anappropriatefaultmessageistriggered(seechapter6.7).
Ifthefloattestissuccessful,theDefensorMk5willbeinnormal operating mode. The adjacent display appears and the green LED lights.
filling
Mk5 Visual
ready
test
44
• The following procedure should be carried out only on the first occasion that the unit is operated:
• Carryoutthesoftware-dependentequipmentsettings(bytheservicetechnicianofthesupplier).Note:Informationonthesettingsthatcanbemadebythecustomerisprovidedinchapter6.5).
• Checkforcorrectfunctioningofthemonitoringequipment(externalsafetycircuit).
• Checkthefunctionofthesteamhumidifier:Switch on the humidification by raising the set humidity value on the humidity controller/humidistat.Switch off the humidification byloweringthesethumidityvalueonthehumiditycontroller/humidistat.
• Setthedesiredhumidityvalueonthehumiditycontroller/humidistat.
Theheatingcurrentswitchesonassoonasthehumiditycontroller/humidistatdemands humidity. The greenLEDlightsandsteamisproducedafterashortdelay(approx.5minutes).
Operating status display on the unit
TheoperatingstatusisdisplayedintheLEDontheunitasfollows:
– Green LED lit: Unit producing steam
– Yellow LED flashing:Majororminorservicingdue.Therelevantnoticeisshowninthedisplay(seechapter6.6).
– Red LED flashing: There is a problem. The unit is trying to solve the problem. The relevant warn-ing message appearsinthedisplay(seechapter6.7).
– Red LED lit: Insoluble problem. The relevant error message appearsinthedisplay(seechapter6.7).
Remote operating and fault indication
Ifyoursteamhumidifierisequippedwiththeoptionalremoteoperatingandfaultindication(option“RFS”),theoperatingstatuswillbeshownasfollows:
Display on unit Meaning Activated remote display relay
Green LED lit Steamproduction K1 “Steam production”
Red LED lit Insoluble problem K2 “Error”
RedLEDflashing Fault elimination No message
Yellow LED flashing Steamcylinderservicedue K3 “Maintenance”
Unit switched on Unitreadyforoperation K4 “Unit on”
45
6.3 Taking out of operation
The followingprocedure is followedwhen it is required toshutdown thesteamhumidifier,e.g. formaintenancework:
• Closethefiltervalve/shut-offvalveinthewaterfeedline.
• Brieflydepressthedrainswitchformorethan7seconds.Theheatingvoltageisisolatedandthesteam cylinder empties.
• Waituntilthesteamcylinderisempty(approx.5-10minutes),thenoperatetheoff-switchonthesteamhumidifier.
• Emptythelimecollectortankviathedrainvalve.
Caution: Danger of scalding!Thewaterinthelimecollectortankmaybehot.
• Isolatethesteamhumidifierfromthemainssupply:Switchoffallserviceswitchesinthemainssup-plylines(heatingandcontrolvoltage)andsecurethemintheoffposition.
Caution: Danger of burning! Ifsteamwasproducedjustbeforetheunitistakenoutofoperation,waitbeforeopeningtheunitandletthesteamcylindercooldowntopreventdangerofburning.
46
6.4 Interrogation of the operating status
TheDefensorMk5operatinganddisplayunithasaso-called“displaylevel”fromwhichvariousoperat-ing parameters can be interrogated. Note: It is not possible to change the values on the display level.
Overview of the display level and operation
Operation: Call up the display level with <B> or <A> <B> next operating parameter <A> previous operating parameter Exit the display level with <Menu>Note: 1)appearsonlyif“controllerfunct”isactive(“on”) 2)appearsonlyif“softstart”isactive(“on”) 3)appearsonlyif“demineral.mode”isactive(“on”) 4) appears only on Mk5 Process units
Menu
Mk5 Visual
ready
steam-prod[kg/h]
ref.=50/act=25
analog input [%]
25
controller funct
on
ref.value rh[%]
45
P-band [%]
30
integr.time[min]
10
elapsed time
623
time to mainten.
600/1200
drain cycle
4: 120
stand-by heating
on
power limit [%]
100
softstart
on
softstart time
30 Min
softst. power
50 %
demineral. mode
on
demineral. delay
3
inlet valve cor.
100
Modbus address
01
analog signal
0 - 5V (poti)
software version
V 01.20
machine type
20kg/400V
1)
2)
4)
2)
1)
1)
3)
Normal service mode
Display levelor
47
steam-prod[kg/h]
ref.=50/act=25
– Steam production
Currentactualandnominalvalueofsteamproductioninkg/h.– Nominalvalue:max.unitcapacityxinputsignalvalue
Note:ifacapacitylimitationissetthenominalvalueisgiveninbrackets– Actualvalue:max.unitcapacityxinputsignalvaluexcapacitylimitation
Note:iftheinternalcontrollerisactivatedonlytheactualvalueisshown.
Underthefollowingconditionstheactualvaluemaydiffer fromthenominalvalue:uponactivationoftheheatingpower,ifcapacitylimitationisactive,dur-ingthefillingcycleofthesteamcylinder.
– Analog input (humidity demand)
Currentvalueofthesignalappliedtotheanaloginputin%ofitsmax.value.Note:Iftheinternalcontrollerisactivethedisplayedvaluecorrespondstothecurrentairhumidity(%rh).
– Internal controller
Internalcontrolleractivated(“on”)/deactivated(“off”).Note:Theinternalcontrollercanbeactivatedonthesettinglevel(seechapter6.5).
– Nominal value of relative humidity
Selectedvalueofrelativehumidityin%rh.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.
– Proportional range of the internal controller
Selectedproportionalrange(P-Range)oftheinternalcontrollerin%.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.
– Integral time of the internal controller
Selectedintegraltimeoftheinternalcontrollerinminutes.Note:Thisoptionisavailableonlyiftheinternalcontrollerisactive.
– Working hours
Totalofworkinghourselapsedsinceinitialcommissioningofthesteamhumidifier.
– Time remaining to small/extended maintenance
Thetimeremaining(inhours)beforethenextsmall/extendedmaintenance.Note:Thestatedtimesarebasedon100%steamcapacity.Iftheoperationisatalessercapacity,thetimeshouldbeextendedaccordingly.Themaintenanceintervalsaresetusingtherotaryswitch“S2”onthecontrolboard.Pleasepayattention to the notes in chapter 6.1.
Description of the operating parameters on the display level
Thefollowingdescribestheindividualoperatingparametersthatcanbeselectedusingthekeys<B> and <A>,afterthedisplaylevelhasbeencalled-up.
analog input [%]
25
controller funct
on
ref.value rh [%]
45
P-band [%]
30
Integr.time[min]
10
elapsed time
623
time to mainten.
600/1200
48
power limit [%]
100
– Flushing cycle
Thefollowingindicationsareprovidedforthesetflushinginterval:Left: Switchsettingonrotaryswitch“S1”Right: Setflushinginterval
Note:Theflushingintervalissetonswitch“S1”onthecontrolboard.Pleaseobserve the notes in chapter 6.1.
– Stand-by heating
Stand-byheatingactivated(“on”)/deactivated(“off”).Note:Ifstand-byheatingisactivethewatertemperatureinthesteamcylinderisconstantlykeptatapprox.70°C.Stand-byheatingmaybeactivated/deac-tivatedwiththeDIPswitch“S4-1”onthecontrolboard.Pleaseobservetheinformationgiveninchapter6.1.
– Capacity limitation
Thesetcapacitylimitationasapercentageofthemaximumcapacity.
– Soft start
Softstartenabled(“on”)/disabled(“off”).Note:Afterrestartoraftertheunithasbeenidlefor4hours(stand-by)theSoftstartfunctionreducesthehumidificationcapacitytoapresetvalueforaselect-ableperiod(valuesettingsseeparametersbelow).
– Time limit for Soft start
SelectedtimelimitforSoftstartfunctioninminutes.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.
– Capacity limit for Soft start
SelectedcapacitylimitforSoftstartfunctionin%ofmaximumcapacity.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.
– Demineralization mode
Demineralizationmodeenabled(“on”)/disabled(“off”).Note:TheDemineralizationmodeflushesthesteamcylinderwithinanhourafterapresetnumberofscumdetectionshastakenplace(seeDemineraliza-tiondelay).Thispreventstheformationofscum.
– Demineralization delay
Selectedthedelayfordemineralization.Note:ThismenuitemisavailableonlyiftheDemineralizationmodeisenabled.
Note:Thisvaluedeterminesthenumberofscumdetectionsallowed(maxi-mumlevelinsteamcylinderisreached)beforethesteamcylinderisflushedforapresettime.
stand-by heating
on
drain cycle
4: 120
softstart
on
softstart time
30 Min
softst. power
50 %
demineral. mode
on
demineral. delay
3
49
– Inlet valve correction
Setinletvalvecorrection(cycleratio)in%ofstandardsettingvaluetobalanceoutwaterpressurevariations.Note:ThismenupointisavailableonlywithMk5Processunits.
– Modbus address
Actualmodbusaddressoftheunit.Note:Themodbusaddressisneededonlyforunitswithbuilt-intelemonitoringinterfaceorbuilt-inRS232/RS485serialinterface.Detailedinformationaboutthetelemonitoringinterfaceandtheserialinterfacecanbefoundintheseparatemanualsthataresuppliedwiththeseoptions.
– Analog signal
RangeoftheactiveanalogsignalinVormA,respectively.Note:Therangeoftheanalogsignalmaybeadjustedusingtherotaryswitch“S3”onthecontrolboard.Pleaseobservetheinformationgiveninchapter6.1.
– Software version
Currentsoftwareversionforthesteamhumidifier.
– Unit type
valueleft: Max.steamcapacityinkg/hvalue right: Heating voltage in VAC
Modbus address
01
analog signal
0 - 5V (poti)
software version
V 1.00
inlet valve cor.
100
machine type
20kg/400V
50
6.5 Setting the operating parameters
YoucanadaptvariousDefensorMk5steam-airhumidifieroperatingparameterstotheoperatingrequire-mentsonthesettinglevelofthecontrolanddisplayunit.Thesettinglevelisprotectedbyanaccesscodetoguardagainstunauthorizedaccess.
Caution!Thesettingsonthesettinglevelhaveadirectinfluenceontheoperatingbehaviorofthesteam-airhumidifier.ThesettingsmustthereforeonlybemadebypersonnelwhoarefamiliarwiththetechniquesofhumidificationandclimaticcontrolandwiththeDefensorMk5system.
Overview of the setting level and operation
Operation: – Forcall-upofthesettinglevelseethefollowing“Call-upofthesettinglevel” – <B> Next menu item – <A> Previous menu item – For change to set values see the section “Changing the set values” – Exit the setting level with <Menu>Note: 1) appears only on Mk5 Process units 2) appearsonlyif“controllerfunct”isactivate(“on”) 3) appearsonlyif“softstart”isactivate(“on”) 4) appearsonlyif“demineral.mode”isactivate(“on”)
Menu
Modbus address
(Enter=Entry)
diagnose pgm
(Enter=Entry)
faulthistory
. /. /6.B/6.A
erase history
(Enter=Entry)
integr.time[min]
(Enter=Entry)
softstart
(Enter=Entry)
softstart time
(Enter=Entry)
softst. power
(Enter=Entry)
demineral. mode
(Enter=Entry)
demineral. delay
(Enter=Entry)
language
(Enter=Entry)
power limit [%]
(Enter=Entry)
inlet valve cor.
(Enter=Entry)
controller funct
(Enter=Entry)
ref.value rh[%]
(Enter=Entry)
P-band [%]
(Enter=Entry)
adjust level
entry code
8808
Mk5 Visual
ready
1)
2)
3)
3)
2)
4)
2)
Normal service mode
and
Settinglevel
51
Mk5 Visual
ready
entry code
9999
entry code
8999
adjust level
language
English
Sprache
Deutsch
new data
entered
unchanged
ref.value rh [%]
045
ref.value rh [%]
045
XXXXXXXX
(Enter=Entry)
new data
not valid
Call-up of the setting level
WiththeDefensorMk5innormaloperation:
• Simultaneouslydepressthekeys<B> and <A>.
Youarenowpromptedtoenterthefourdigitaccesscode“8808”. The digit on thefarleftflashes.
• Entertheaccesscode“8808”asfollows:
Changethefirstdigitwiththekeys<B> and <A>.Acceptyourinputwiththekey<C>.Thenextdigitstartstoflash.Repeatthisstepfortheremainingdigits.
Afteracceptanceofthelastdigit,theadjacentmessageappearsbrieflyonthedisplaytoconfirmthatyouareonthesettinglevel.Thefirstmenuitemthenap-pears on the display.Note:Ifyouhaveenteredanincorrectcodethemessage“Incorrect Code”ap-pearsbrieflyonthedisplay.Theunitthenreturnstothenormalservicemode.
To change the set values
The unit is on the setting level.
• Pressthekey<C>,ifyouwishtochangethecurrentsetting.
– Menu items with selected values
• Pressthekey<B> or <A>,inordertoselectthedesiredsettingfromthelist.
• Acceptyourinputwiththe<C> key.
– Menu item with numerical set value
Thedigitonthefarleftstartstoflash.
• Pressthekey<B>,inordertoreducethevalueoftheselecteddigitorthekey<A>,inordertoincreasethevalueofthedigit.
• Acceptyourentrywiththe<C> key.Note:Ifthevaluetobeenteredisamulti-digitvalue,thenextdigitstartstoflash.Youcanchangethisdigitasdescribedabove.
Afterconfirmingthelastdigit(numericalsetvalue)andtheselectedsetvalue,theadjacentmessageappearsbrieflyonthedisplaytoconfirmthatyouhaveenteredanewvalue.Thentheselectedmenuitemappearsagain.Note:Ifaninvalidvaluehasbeenenteredinanumericalinput,theadjacentmessage appears.
Ifyouhaveexitedtheinputfieldwiththekey<C>,withouthavingchangedthesetvalue,theadjacentmessageappearsbrieflyonthedisplay.Thenthedis-playforalteringthesetvalueappearsagain.
Theprocessofchangingthevaluecanbeinterruptedatanypointbypressingthe <Menu> key.Thelaststoredsetvaluethenremainsunchanged.
52
Description of the menu items on the setting level
The following lists all the menu items that can be selected and changed after activation of the setting level.
– Language
Dialogue language of the display unit.Factory setting: depends on the countryOptions: german, english, french
Note: The display unit switches to the selected language immediately after the suitable language option has been confirmed.
– Capacity limitation
Limitation of the steam capacity (in %) in reference to the maximum steam capacity.Factory setting: 100 %Setting range: 10…100 %
Note: This parameter is used to limit the maximum performance in case the steam capacity exceeds the humidification required by your installation.
– Inlet valve correction
Setting the cycle frequency of the inlet valve in % of the standard setting.Note: This menu point is only given in Mk5 Process unit.Factory setting: 100 %Setting range: 10…200 %
Comment: The water feed quantity can be reduced (value <100) or increased (value >100) with this parameter in order to balance out variations in water pressure.
– Controller setup
Activation (“on”)/Deactivation (“off”) of the internal PI controller.Factory setting: offOptions: on (PI controller activated), off (PI controller deactivated)
Note: The internal controller must not be activated if an external controller is connected to the humidifier because the internal controller would interpret the analog signal of the external controller as the actual humidity value detected by a humidity sensor. This would cause the internal controller to switch the humidifier to 100% steam capacity if the input signal drops to 0% which, in turn, would lead to over-humidification.
– Nominal humidity value
Nominal humidity value in % rh.Note: This menu option is available only if the internal PI controller is active.Factory setting: 45 %rhSetting range: 10…100 %rh
language
English
power limit [%]
100
controller funct
off
ref.value rh [%]
045
inlet valve cor.
100
53
– Proportional range(P-band)oftheinternalPIcontroller
ProportionalrangeoftheinternalPIcontrollerin%.Note:ThismenuoptionisavailableonlyiftheinternalPIcontrollerisactive.
Factory setting: 30 %Setting range: 4…100 %
Note: The P-Range is used to smooth the control characteristic. Increasing the P-Range boosts the smoothing applied to the control characteristic. However,thiscausesapermanentdeviation,proportionaltothebandwidthoftheP-Range.
– Integral timeoftheinternalPIcontroller
IntegraltimeoftheinternalPIcontrollerinminutes.Note:ThismenuoptionisavailableonlyiftheinternalPIcontrollerisactive.Factory setting: 10 MinutesOptions: off(000/integraltimedisabled),2 - 100 Minutes
Note:Theintegraltimesettingdeterminestheperiodallowedtoreachthenominal humidity. Setting the integral time to the optimal value prevents the controlcharacteristicfromovershootingand,atthesametime,balancesthe permanent deviation caused by the P-Range value.
– Soft start
Enabling(on)ordisabling(off)theSoftstartfunction.Note:Enablethesoftstartfunctionifyouareusingsoftenedwaterorwaterwithahighconductivity.Factory setting: offAvailable settings: on(Softstartenabled),off(Softstartdisabled)
Note:Afterrestartoraftertheunithasbeenidlefor4hours(stand-by)theSoftstartfunctionreducesthehumidificationcapacitytoapresetvalueforaselect-ableperiod(valuesettingsseeparametersbelow).
– Time limit for Soft start
SelectthetimelimitfortheSoftstartfunctioninminutes.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.Factory setting: 30 minutesSetting range: 1…255 minutes
– Capacity limit for Soft start
SetthecapacitylimitfortheSoftstartfunctionin%ofmaximumhumidifica-tion capacity.Note:ThismenuitemisavailableonlyiftheSoftstartfunctionisenabled.
Factory setting: 50 %Setting range: 4…100 %
Integr.time[min]
010
P-band [%]
030
softstart
off
softstart time
30 Min
softst. power
50 %
54
Modbus address
01
Diagnose pgm
(ENTER=Entry)
erase history
(ENTER=Entry)
– Demineralization mode
Enabling(“on”)ordisabling(“off”)theDemineralizationmode.Note:Enable thedemineralizationmode ifyouareusingsoftenedwaterorwaterwithahighconductivity.Factory setting: onAvailable settings: on(Demineralizationmodeenabled) off(Demineralizationmodedisabled)
Note:TheDemineralizationmodeflushesthesteamcylinderwithinanhourafterapresetnumberofscumdetectionshastakenplace(seenextparameter“Demineralizationdelay”).Thispreventstheformationofscum.
– Demineralization delay
Setthedemineralizationdelayafterwhichatime-controlledflushingcyclewillbeinitiated.Note:ThismenuitemisavailableonlyiftheDemineralizationmodeisenabled.
Factory setting: 3Setting range: 1…9
Note: The demineralization delay determines the number of times themaximumlevel(scumdetection)maybereachedbeforeatime-controlledflushingcyclewilltakeplace.
– Modbus address
Setthemodbusaddressforunitswithbuilt-intelemonitoringinterfaceorbuilt-inRS232/RS485serialinterface.
Factory setting: 1Setting range: 1...16
Note:Detailedinformationaboutthetelemonitoringinterface(installation,correctaddressingofunitsinacluster)andtheserialinterface(installation,configura-tion)canbefoundintheseparatemanualsthataresuppliedwiththeseoptions.
– Diagnostic program
Thediagnosticprogramsimulatesvariousoperatingconditionsofthesteamhu-midifier.However,thediagnosticprogramrequiresin-depthknowledgeofpar-ticularinternalfunctionsoftheunit.Therefore,thediagnosticprogramshouldbeusedbytheservicetechniciansofyoursupplieronly.
– Error history
Numericalcodesofthelast4errorsencountered(oldestentryfarleft).Note: For detailed information on themeaning of particular error numberspleaserefertochapter6.7.
– Delete fault history
Faulthistoryisdeleted.Anappropriatemessageappearsfollowingthedeletion.
demineral. delay
3
faulthistory
. / . /9.A/9.A
demineral. mode
on
55
6.6 Maintenance
– All maintenance work must be performed only by adequately qualified and trained personnel familiar with the dangers involved.Ascertainingthequalificationsisthecustomer‘s responsibility.
– Instructionsanddetailsconcerningthemaintenanceworkmustbeobservedandad-heredtowithoutfail.
– Onlythetypeofmaintenanceworkoutlinedinthisdocumentationmustbecarriedout.
– Useoriginalsparepartsfromyoursupplierexclusivelytoreplacedefectiveparts.
– Before maintenance is initiated, the steam humidifier must be taken out of op-eration in accordance with instructions in chapter 6.3 and protected against unintentional switching on.
6.6.1 Notes on maintenance
Tosafeguard reliableoperation, themaintenanceof theDefensorMk5shouldbedevised in threestages.Adistinction ismadeherebetweenperiodic inspections,smallmaintenanceandextendedmaintenanceofthesteam-airhumidifier.
Theintervalsrequiredbetweensmallmaintenanceandextendedmaintenancedependonthewaterqualityandthequantityofsteamgeneratedandcanbepre-selectedontherotaryswitch“S2”onthecontrolboard(seechapter6.1).Afterexpiryoftheselectedinterval,theyellowLEDflashes/lightsandanappropriatemessagealternateswiththenormaloperationindication.Note:Werecommendtocarryoutanextendedmaintenanceatleastonceayear,independentlyfromthe maintenance counter.
Thefollowingisanoverviewoftheworkthatshouldbeundertakenforthethreemaintenancestages.
– Periodic inspectionsWhen: 1 per weekWork: • Inspectthewaterandsteaminstallationsforcorrectsealinganddamage. • Inspectthedrainlineforsoiling. • Inspecttheelectricalinstallationforloosecablesanddamagedcomponents. • Inspectthesteam-airhumidifierfordamage.
– Small maintenanceWhen: The yellow LED flashes andthemessage“sm. maintenance due”appears,alternat-
ingwiththenormaloperationindication.
Work: • Carryouttheperiodicinspectionitems • Emptythesteamcylinderandcleanthelimecollectortank.
– Extended maintenanceWhen: The yellow LED lightsandthemessage“lg. maintenance due”appears,alternating
withthenormaloperationindication.
Work: • Carryouttheperiodicinspectionitems • Emptythesteamcylinderandcleanthelimecollectortank. • Dismantleandcleanthesteamcylinder • Cleantheunitinnerchamber • Inspectthecomponentsinsidetheunitfordamage(e.g.heatingcableconnector
onthesteamcylinder,levelunit,etc.)
sm. maintenance
due
lg. maintenance
due
56
6.6.2 Dismantling and re-assembly work
Note:Thelimecollectortankmustbereplacedevery 5000 hours,orafter3 years at the latest.
Removal of the lime collector tankCaution!Beforecommencinganydismantlingwork,thesteam-airhumidifieristobetaken out of operation as described in chapter 6.3 and rendered safe from inadvertent operation.
1. Emptythelimecollectortankviathedrainvalve.
Caution: Danger of scalding!Thewaterinthelimecollectortankmaybehot.
2. Pressthesecuringknobonbothrotationlocks.Thenrotatebothrotationlocksclockwiseandremovethelimecollectortankdownwards,fromthebaseoftheunit.
Installation of the lime collector tank
Installationofthelimecollectortankiscarriedoutinthereversesequencetothatdetailedaboveforremoval.
Important! CheckO-ringsinthetankcouplingsleeveoftheunitandreplaceifdefective.Beforere-mountingthelimecollectortank,greasetheO-ringsinthetankcouplingsleevewithsiliconegrease.
Important! Turntherotationlocksanticlockwiseuptothestop(bothsecuringknobsmustengage).
Important! Closedrainvalveonlimecollectortank.
1 2
57
Removal and dismantling of the steam cylinderCaution!Beforecommencinganydismantlingwork,thesteam-airhumidifieristobetaken out of operation as described in chapter 6.3 and rendered safe from inadvertent operation.
Caution!Ifsteamhasbeenproducedshortlybeforediscontinuingoperation,the steam cylin-der will be hot.Well-insulatedglovesshouldthereforebewornwhencarryingouttheremovaloperation.
1. Releasethefrontdoorlockingdevicesusingascrewdriver(rotate90°left)andremovethefrontdoors.
2. Freetheupperhoseclampofthesteamhoseusingascrewdriverandpullthehosedownwardfromthe steam connection.
3. Removethetwoscrews,thenpresssnap-fasteningstogetherandthenremovetheheatingcableloomplugconnectorfromtheconnectorsocket.
4. Releasetheclampingring(steamcylinderfixation).
5. Liftthesteamcylindercarefullyfromthecouplingbushandremoveittowardsthefrontoftheunit.
Caution!Setthesteamcylinderdowncarefully.
6. Loosenthesteamcylindercoverclampingring.
1 2 3
4 5 6
58
7. Carefullyliftoffthecoverwiththeheatingrods.
Warning!Takecarewiththecoverwhilstitisremoved,soasnottodamagetheheatingrods.
Note:Ifthecovercannotberemovedduetoheavycalcification(maintenanceperiodexceeded),placethesteamcylinderinabasinofformicacid(8%)untilitcanberemoved(Caution! Observe instructionsonthesafeuseofthiscleaningagent).
8. Ifnecessary,loosenthecylinderinsertbylightlyrotatingitineitherdirectionandliftitfromthesteamcylinder.Thenremovethescreeninsertandthefunnelinsert.
9. Ifaheatingelementhastobereplacedduringservicing:firstmakeanoteofhowthecablesareconnectedandthepositionoftheheatingelement.Thendetachthecable,loosentheclampingnutand remove the heating element.
Assembly and installation of the steam cylinder
Assemblyofthesteamcylindertakesplaceinreversesequence.Pleasenotethefollowinginstructions:
– Installationofanyheatingelementswhichhavebeenremovedshouldfollowfigure9.Pleasetakecarethattheheatingelementsarecorrectlypositionedandthecablesarecorrectlyconnected(ac-cordingtoyournotes).
– BeforeinstallationofthesteamcylindercoverplacetheDurosealantaroundtheedgeofthecover.TheDurosealantmustbecleanandundamaged(replaceifnecessary).
– BeforeinstallationofthesteamcylinderintheunitcheckO-ringsinthecouplingboxfordamageandreplaceifnecessary.
– Insertsteamcylinderintheunitcorrectlyandfastenwithclampingring.
– Fastensteamhosewithhoseclamps.Aleakysteamhosecancausedampdamageintheinterioroftheunit.
– Theplugof theheatingcableboommustconnect in theconnectionboxand fastenedwith thescrews.
7 8 9
59
6.6.3 Notes on cleaning
Cleaning the steam cylinder, lime collector tank, steam cylinder insert
• Whereverpossible,chipoffthelimecoatingthathasformed.
• Washpartswithlukewarmsoapsudsandthenrinseoffwell.Note:Ifthecomponentsareheavilyscaled,placethemin8-percentformicaciduntilthescalehasdissolved. Then treat components as previously described.
Cleaning the heating elements
• Immersecoverwithheatingelementsfittedto2cmbelowtherimofthecoverinacontainerwith8-percentformicacid.Allowtheacidtotakeeffectuntilthescalecoatinghasdissolved.Note:Theheatingelementsdonothavetobeentirelyfreefromscale.
• Thenrinseheatingelementsthoroughlywithfreshwater.
Warning! Ensure that the electrical connections remain dry.Warning!Onnoaccountremovescalecoatingontheheatingelementswithtools(screwdriver,scraper,etc.)orbystriking.Thiscoulddamagetheheatingelements.
Cleaning the interior of the unit
Wipedowncomponentsinsidetheunitwithadampcloth(cleanwater).Severelyscaledcomponents,e.g.theinletfunnelandtheblow-offpump,shouldbecleanedusingcommerciallyavailablecleaningand descaling agents. Warning! Ensure that the electrical connections and electronic components remain dry.
Notes on cleaning agents
Diluteformicacidisobtainablefromanychemist’sshopordrugstore.Warning! Formicacidis indeedharmlesstotheskin,but itattacksthemucousmembranes.Protecttheeyesandrespiratorytractsthereforefromcontactwiththeacidanditsvapor(weargogglesandworkinawellventilatedroomoroutside).
Theuseofdisinfectantsisonlypermittediftheyleavenotoxicresidues.Thecomponentsmustberinsedthoroughlywithwateraftercleaninginallcases.
Caution! Do not use any solvents, aromatized or halogenized hydrocarbons, or other ag-gressive substances for cleaning purposes.
Theinformationandinstructionsregardingcleaningagentsaretobeunconditionallyobservedandimplemented.Inparticular:Informationrelatingtotheprotectionofpersonnel,environmentalconservation and restrictions regarding usage.
In all cases, local regulations relating to environmental protection must be implemented.
6.6.4 To reset the maintenance indication
Whenmaintenanceworkhasbeencompleted,themaintenance displaycanberesetasfollows:
• With the unit switched off,depressandholdthedrainswitch.
• Switchonthesteam-airhumidifierwiththeunitswitch.
• Continuetodepresstheblow-offpushbuttonuntilthesystemtesthasfinished(approx.10seconds).
60
Ifthecontrol,afterseveralattempts,failstosolvetheproblem(numberofattemptsdependsonthetypeofmalfunction)oriftheproblemobstructsfurtheroperation,theheatingvoltageisinterruptedviathe main contactor. The red LED stays lit and an error message appears in the display alternating withthenotice“Please turn off unit”.
Example of an “Error” indication
red LED stays lit Message in the display
6.7 Fault elimination
6.7.1 Fault indication
Incaseofmalfunctionduringoperation,thehumidifiercontrolcheckswhetherthereisatemporaryproblem(e.g.watersupplyinterruptedforashorttime)orwhetheritcanresolvetheproblembytakingnecessarymeasures.Suchmalfunctionssettheunitintothe“Alarm”status(faultelimination).Thered LED flashes and an alarm message appearsinthedisplayalternatingwiththenotice“recover-ing - please wait”.Note:Ifthecauseofthemalfunctiondisappearsofitsownaccordorifthecontrolscanrepairthemal-function,thealarmmessagewillautomaticallyswitchoff.
Example of an “Alarm” indication
red LED flashes Message in the display
please turn
off unit
Error code
Unit designation (A or B)
Note:Iftheunitisindisplayorsettinglevelthealarmmessageinthedisplaywillbesuppressed.
Error code
Unit designation (A or B)
Note:Iftheunitisinthedisplayorsettingleveltheerrormes-sageinthedisplaywillbesuppressed.
Error 1A
filling time
Alarm 1A
filling time
recovering
please wait
61
6.7.2 What, if..?
Mostoperationalmalfunctionsarenotcausedbyfaultyequipmentbutratherbyimproperinstallationordisregardingofplanningguidelines.Therefore,acompletefaultdiagnosisalwaysinvolvesathoroughexaminationoftheentiresystem.Often,thesteamhoseconnectionhasnotbeenproperlyexecuted,orthefaultlieswiththehumiditycontrolsystem.Thefollowingtablegivesalistofpossiblemalfunctions,theappropriatealarmorerrormessage,detailsoftheircause,andnotesonhowtodealwitheachproblem.
Malfunction/Indication Cause Remedy
Min. filling time not reachedError code: 1A/1B
Waterfeedtosteamcylinderheavilycalcified.Level in steam cylinder and level unit do not match.
Carry out major servicing.
Internal safety chain interruptedError code: 2A/2B
Connection to over-temperature switch on steam cylinder broken or over-temperature switch faulty.Steamcylinderoverheating,over-temperatureswitch has responded.Flat-band cable between control and power board interrupted or not connected.
Check connections or replace over-temperature switch.
Inspect steam cylinder, clean if necessary.replace over-temperature switch.Inspect connections, connect or replace flat-band cable.
Max. filling time exceeded (alarm message only)Error code: 3A/3B
Waterfeedblocked(mainwatertapclosed,filtervalve closed or blocked).Water pressure too low.Inlet valvedoesnotopen,filtersieve in Inletvalveblockedorinletvalvefaulty.
Feedhosesintosteamhumidifiernotconnectedor kinked.Level unit not connectedFloat in the level unit sticking or level unit faulty.
Checkwaterfeed(openmainwatertap,openorcleanfiltervalve.Raise water pressure (range 1-10 bar).InspectelectricalconnectionsandfuseF2onsupply module. Clean filter sieve or replaceInlet valve.InspecthosesintoUnitandconnectifnecessary.Replace Faulty Hoses.Connect level unit.Clean or replace level unit.
Max. vaporization time exceededError code: 4A/4B
Individualheatingelementsfaulty.Fusesonthepowerboardfaulty.Mainsvoltagetooloworfailureofaphase(L1,L2 or L3).Steamleadtoolongornotinsulated.
This error may also occur upon a cold start.
Replacefaultyheatingelements.Replacefusesonpowerboard.Check mains voltage and connections.
Maintain maximum lead lengths (max. 4 m), Insulate steam lead.EnableSoftstart(seechapter6.5).
Alarm 1A
filling time
Error 1A
filling time
Alarm 2A
safety chain int
Error 2A
safety chain int
Alarm 3A
water supply
Alarm 4A
steam time
Error 4A
steam time
62
Malfunction/Indication Cause Remedy
Max. flushing time exceededError code: 5A/5B
Drainpumpnotconnectedorfaulty.Outletleadfromunitkinkedorblocked.
Water outlet blocked (external outlet lead or siphon blocked.Hoses to level unit blocked.
Connect or replace drain pump.Inspectoutletleadfromunit,replaceifneces-sary.Clean water outlet lead and siphon.
Clean or replace hoses.
Invalid levelError code: 6A/6B
Levelunitfaulty.Magneticfieldinvicinityoflevelunit.
Replace level unit.Eliminatemagneticfield.
Steam pressure supervision (error only)Error code: 7A/7B
Steamhoseblockedorrestricted(watertrap).Pressure balance adapter into steam connection fittingblocked.
Duct pressure too high (>1500 Pa).
Inspect steam hose, clean if necessary andinstall correctly.Remove adapter and clean opening with a needle.Inspect ventilation settings.
Humidity sensor fault (error only)Error code: 8A/8B
Internal controller activated.Humidity sensor signal < 5 %.
Deactivate internal controller.Checkhumidity sensor.Recalibrate if neces-sary.
External safety chain interruptedError code: none
Ventilation interlock open.Automaticflowcontrolhasresponded.Maximum humidistat has responded.No heating voltage available.
Switchonventilator/ventilationsystem.Inspectventilator/filterofventilationsystem.Servicing,inspectsystemifnecessary.Check mains voltage.
Heating voltage dropped at Unit B. Inspect voltage supply to Unit B.
Alarm 6A
level indicat
Error 6A
level indicat
Error 7A
communication
safety chain
external A
mains failure
B
Alarm 5A
drain
Error 5A
drain
Notes on fault elimination
Warning: Danger of death!Inordertoeliminatefaults,thesteamhumidifiermust be switched off and secured against unintentional reconnection asdescribedinchapter6.3.Takecarethattheelectricitysupplytothemaincontactorisdisconnected(checkwithvoltagetester).
Onlyallowtrainedandqualifiedpersonneltorepairfaults.Faultsrelatingtoelectricalinstallation(e.g.changeofunitfuse)mustonlybecarriedoutbyauthorizedpersonneloryoursupplier’sservice technician.
Repairworkandreplacementoffaultycomponentsmustonlybecarriedoutbyyoursupplier’sservice technician!Exception: Replacing faulty components during servicing(seechapter6.6)andreplacing faulty unit fuses(seechapter6.7.3).
Error 8A
sensor fault
63
6.7.3 Replacing unit fuses
Warning Danger of death! Before replacing the unit fuse the steam humidifier must be switched off and secured against unintentional reconnection as described in chapter 6.3. Take care that the electricity supply to the main contactor is disconnected (check with voltage tester).
Warning! Electronic components are very sensitive to electrostatic discharge. To protect these components, measures must be taken against damage from electrostatic discharge when replac-ing the unit fuse (ESD protection).
The unit fuses may only be replaced by trained and qualified personnel.
Important! If the unit fuse blows this is generally due to a faulty unit component. Therefore you should check these components before replacing the fuse (see table below).
Only use the correct type of fuse according to the following table.
Warning! It is not permitted to use repaired fuses.
Power board (F1..F3, F1...F6 or F1...F9)
Supply module (F2)
Supply module (F1)
Control board (F5)
Fuse Specification Before replacing, check
F1 on supply moduleF2 on supply module
6.3 A, slow-acting
1 A, quick-acting
Drain pump (blocked or coil faulty)
Inlet valve (blocked or coil faulty)
F5 on control board 200 mA, quick-acting Control signal
F1…F3 on power board (Mk5 Visual/Process 5-.. and 8-..)
F1…F9 on power board (all other models)
16 A, super quick-acting
20 A, super quick-acting
Heating elements (on short-circuit)
Heating elements (on short-circuit)
6.7.4 Resetting fault indication “Error”
In order to return the steam humidifier to operation after fault elimination, the steam humidifier must be switched off for approx. 5 seconds and then switched on again.
64
7 Technical data
DefensorMk5Visual/Process
5-.. 8-... 10-.. 16-.. 20-.. 24-. 30-. 40-.. 50-.. 60-.. 80-..
Steamoutput 0-100%infinitelyvariable
Numberofunits 1 1 1 1 1 1 1 1 2 2 2
Steamconnection G 1 1/4”
Resolution 1,0 %
Controlofsteamoutput
– active 0…20 V (Phase intersect), 0…10 VDC, 1…5 VDC, 0…5 VDC 0…4.25 VDC (Potentiometer), 0…1 VDC, 2…10 VDC
0…20 mADC, 4…20 mADC
– passive allpotentiometrichumiditysensorsfrom140Ω…10kΩ
–On/Offcontrol <2,5VDC-->Off;≥2,5 VDC…20 VDC --> On
Duct air pressure Overpressure max. 1500 Pa, Underpressure max. 1000 Pa (forductpressuresoutsidethesevaluescontactyoursupplier)
Permissible ambient temperature 1...40 °C
Permissible ambient humidity 1...75 %rh (non-condensing)
Waterfeed
– Connection G 1/2”
– Permissible water pressure 1...10 bar
– Feed temperature 1...40 °C
– Water quality untreateddrinkingwaterorfullydemineralizedwater(foroperationwithsoftenedorpartlysoftenedwaterpleasecontactyoursupplier)
Water outlet
– Connection Internal-ø=40mm
– Outlet temperature 60...90 °C
Weight in kg
– Operation 51 51 52 53 71 73 73 74 1x711x73
2x73 2x74
– Net 36 36 37 38 41 43 43 44 1x411x43
2x43 2x44
Dimensions in mm
– Height 1087 1087
– Width 500 594
– Depth 437 392
Contentoflimecollectortankinl 5 10
Testcertificate SEV,VDE,GS,CE,GOST
Typeofprotection IP21
65
Notes
Notes
© Condair Ltd., Printed in SwitzerlandTechnical modifications reserved
CONSULTING, SALES AND SERVICE:
Manufacturer:Condair Ltd.Talstrasse 35-37, 8808 Pfäffikon, SwitzerlandPh. +41 55 416 61 11, Fax +41 55 416 62 [email protected], www.condair.com
Reg.No. 40002-2