DriSteem ULTRA-SORB XV Installation, Operation And Maintenance Manual
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ULTRA-SORB® MODEL XV
Steam Dispersion Panel
Installation, Operation,
and Maintenance Manual
For pressurized steam applications
Table of contents
MECHANICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Field assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Selecting the location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation in a cold air stream . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Placement upstream from an elbow or duct split . . . . . . . . . . . . . . . . 8
Installation above valuable equipment . . . . . . . . . . . . . . . . . . . . . . . 8
Panel support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mounting in a duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Mounting in an air handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation drawings: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting in a duct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting in an air handler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Recommendations and steam inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Confirming steam dispersion panel configuration . . . . . . . . . . . . . . 13
Optional header overflow P-trap water seal . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ultra-sorb XV operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Sequence of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Start-up checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Strainer, traps, and valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
WARNING
Hot surface hazard
Steam humidifi cation systems have
extremely hot surfaces.
To avoid burns, allow humidifi er, steam
pipes, and dispersion assemblies to
cool before touching any part of the
system.
mc_071411_0753
ATTENTION INSTALLER
Read this manual before installing.
Leave manual with product owner.
DriSteem technical support
800-328-4447
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dispersion tubes and heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . 30
Humidifier de-scaling solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
ii
MECHANICAL SPECIFICATIONS
Mechanical specifi cations
FIGURE 1-1: ULTRA-SORB MODEL XV DIMENSIONS
Top view
A
D
B’
E
F
Blank
side view
G
K
H J
Connections
side view
OM-7483
mc_101410_0755
B
Header
A’
L
Elevation view
Table 1-2:
Ultra-sorb Model XV tube steam capacity*
Diameter lbs/hr kg/h
1.5" 43 19.5
2.0" 80 36.3
* Consult DriSteem if face height is less than 17" (432 mm) for 1.5"
tubes or less than 24" (610 mm) for 2.0" tubes.
Table 1-1:
Ultra-sorb Model XV dimensions
Dimension Inches (mm)
15" (380 mm) min,
C
A Unit width
A' Face width
B Unit height*
B' Face height
C Frame depth 7.2" (183 mm)
D Frame enclosure 3.9" (99 mm)
E Header enclosure 5.85" (149 mm)
F Mounting fl ange 1.5" (38 mm)
G Humidifi cation steam inlet
(internal thread)
H Pressurized steam inlet
(internal thread)
J Float switch or
optional header overfl ow/
access port (internal thread)
K Pressurized condensate
outlet (internal thread)
L Overall width
Control cabinet See Page 17.
* Panels with unit height more than 120" (3048 mm) have two-piece
side fl anges and are shipped with brackets for easy fi eld assembly.
Panels with unit height more than 98" (2490 mm) are shipped
unassembled.
147" (3735 mm) max,
in 1" (25 mm) increments
12" (305 mm) min,
144" (3660 mm) max,
in 1" (25 mm) increments
21.75" (550 mm) min,
153.75" (3905 mm) max,
in 1" (25 mm) increments
12" (305 mm) min,
144" (3660 mm) max,
in 1" (25 mm) increments
• 1" or 2" NPT (DN25 or DN50),
determined by maximum steam
capacity
• 3" (DN80) fl ange, for humidifi cation
steam from STS humidifi er only
3/4" NPT (DN20)
1/2" NPT (DN15)
3/4" NPT (DN20)
• 1" (DN25) connection, same as
dimension A;
• 2" (DN50) connection, dimension A
+ 1" (dimension A + 25 mm)
• 3" (DN80) fl ange, dimension A +
6.5" (dimension A + 165 mm)
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
1
INSTALLATION
Field assembly
UNPACK THE DISPERSION ASSEMBLY
• Remove shipping materials from the dispersion assembly, being careful not
to bump or scrape the white PVDF dispersion tube insulation.
• Do not lay dispersion tubes (if shipped loose by request or by shipping
necessity) across or under anything that could compress or damage the
insulation. Compressing insulating material may reduce its R-value.
VERIFY THAT THE ORDER IS COMPLETE
Verify that all panel and piping components are included in the delivery. Check
the packing list, and see the tables on Page 32.
• Orders may include control valve(s), humidity transmitters or humidistats,
airfl ow switches, and a control cabinet.
Note the dispersion assembly serial number:
• The serial number will be required to ensure proper identifi cation of
replacement parts.
CAUTION
Remove clear poly fi lm; do not remove white PVDF insulation.
High-Effi ciency Tubes are sleeved in clear poly fi lm for protection during processing, shipping, and
installation. Leave the clear poly fi lm on until installation is complete so the insulation stays clean.
Remove and discard the clear poly fi lm before start-up by tearing it along the
perforations. Do not remove the white PVDF insulation.
• Keep fl ame away from the insulating material to avoid damage.
• Indirect, low-intensity UV-C light from germicidal lamps will not cause the insulating material to degrade.
• Do not tighten mounting clamps or fasteners to any part of the dispersion tube.
mc_071211_1530
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
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Field assembly
INSTALLATION
LAY OUT THE PANEL COMPONENTS
Orient the panel components on a large, fl at working surface.
ATTACH THE FLANGES
Guide the fl anges onto the threaded studs of the header assembly, and start the
locknuts onto the threads fi nger-tight.
ATTACH THE TOP FRAME ASSEMBLY
Span the fl anges with the top frame assembly. Align the locating buttons on the
fl anges and top frame, and insert screws.
TIGHTEN THE FLANGE LOCKNUTS
Torque the eight fl ange locknuts to 16 ft-lb (22 N-m) using a 7/16" deep-well
socket.
INSTALL THE DISPERSION TUBES
Note: Do not remove the poly fi lm from the dispersion tubes until after the
panel is installed.
Ensure that each dispersion tube has the seal and spring in place (see
Figure 3-1). Push the dispersion tube plug end into the top frame hole
to compress the spring. Seat the seal end in the corresponding header hole
on the bottom. Rotate the dispersion tubes so the tubelets discharge steam
perpendicular to the airstream. See Figure 9-1.
Note: These assembly instructions are for
Ultra-sorb Model XV panels shipped
unassembled by request or as required.
Panels with overall height more
than 98" (2490 mm) are shipped
unassembled.
FIGURE 3-1: ULTRA-SORB MODEL XV COMPONENTS
Screw
Top frame
assembly
Spring
Flange
Flange
locknut
Header
assembly
OM-7484
Plug
Ring
Seal
Dispersion tube
assembly
Insulation
Table 3-1:
Ultra-sorb Model XV components
Component Qty.
Header assembly 1
Dispersion tube Varies
Top frame assembly 1
Flanges 2
Screws 8
Flange locknuts 8
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
3
INSTALLATION
Piping
FIGURE 4-1: ULTRA-SORB MODEL XV PIPING COMPONENTS WITH ON/OFF
SHUTOFF VALVE, FLOAT SWITCH, PRESSURIZED STEAM SOURCE
Applications with control
cabinet operating internal
heat exchanger.
From
pressurized
steam source
Install inlet strainer within
3' (1 m) of Ultra-sorb
Model XV. Strainer
should be same pipe size
or larger than modulating
steam valve. 2-position
shutoff valve may be
smaller than strainers and
modulating steam valve.
To condensate return main
Note: Dashed lines indicate provided by installer.
FIGURE 4-2: ULTRA-SORB MODEL XV PIPING COMPONENTS WITH TEMPERATURE
SWITCH, PRESSURIZED STEAM SOURCE
2-position
shutoff valve
Modulating steam
valve
Steam trap
Ultra-sorb Model XV
steam dispersion panel
Float switch
To condensate
return main
Applications with full-time
operation of internal heat
exchanger.
Steam
trap
OM-7656d
From
pressurized
Install inlet strainer
within 3' (1 m) of
Ultra-sorb Model
XV. Strainer should
be same pipe size
or larger than
modulating steam
valve. 2-position
shutoff valve may
be smaller than
strainers and
electric modulating
steam valve.
To condensate return main
Note: Dashed lines indicate provided by installer.
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
4
steam source
Modulating
steam valve
Steam trap
To condensate return main
Ultra-sorb Model XV
steam dispersion panel
Temperature switch
(install as close to heat
exchanger outlet as
possible)
Steam trap
OM-7878
Piping
FIGURE 5-1: ULTRA-SORB MODEL XV PIPING WITH STS HUMIDIFIER
Steam to heat exchanger from pressurized steam source,
humidifi cation steam from STS humidifi er
Insulated steam
supply tubing
Cold fi ll water
Steam trap
STS humidifi er
Modulating
steam valve
Inlet
strainer
Isolation valve (by others)
From pressurized steam source
Connection
end of
header
(see inset
below)
Header
On/off valve
(optional)
Pressurized steam to heat exchanger
Pressurized condensate to return main
Dispersion tube
INSTALLATION
Ultra-sorb XV dispersion panel
OM-7902
Open drain
(temper to local code)
Steam trap
To condensate return main
Drane-kooler™ water
tempering device
Steam trap
Pressurized condensate to return main
Connection end of header
Humidifi cation steam
from STS humidifi er
From pressurized
steam source
On-off
solenoid
valve
Float switch
OM-7654_2016
Note: Tubing union shown at steam connection. For STS humidifi er,
connection may also be 3" (DN80) fl ange.
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
5
INSTALLATION
Selecting the location
FIGURE 6-1: PLACING A DISPERSION ASSEMBLY IN AN AIR HANDLING UNIT
Outside air
Exterior
building
wall
Relief air
Economizer
control device
Preheat coil
Motorized
air dampers
Filters
Return airfl ow
Cooling coil
Heating coil
ABD
3' to 5' (1 to 1.5 m)
10' to 15' (3 to 4.5 m)
10' to 15' (3 to 4.5 m)
Duct high limit humidity control
for dispersion locations A, B
Airfl ow proving switch
Fan
C
DC-1081
mc_092507_1530
Supply airfl ow
Airfl ow proving switch
Duct high limit humidity control
for dispersion location C
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
6
Selecting the location
DETERMINE STEAM DISPERSION PANEL PLACEMENT
Dispersed steam must be absorbed into the airfl ow before it comes in
contact with duct elbows, fans, vanes, fi lters, or any object that can cause
condensation and dripping.
• Install the Ultra-sorb panel in a location where discharged water vapor will
be absorbed by the airstream.
• Place the Ultra-sorb panel where the air temperature is capable of
absorbing discharged steam without causing condensation at or after the
unit. This will normally be downstream of the heating coil where the air is
warmest.
• Do not place the Ultra-sorb panel in an outside air intake unless the air is
fi rst tempered with a preheat coil.
• Do not place the Ultra-sorb panel near the entrance of a high-effi ciency
fi lter. The fi lter will remove visible moisture and become waterlogged.
See the Caution “Installing Ultra-sorb upstream from fi lter media” on Page
28.
INSTALLATION
• Do not place the Ultra-sorb panel where discharged visible mist will
impinge directly on a metal surface.
PLACEMENT IN AN AIR HANDLING UNIT (FIGURE 6-1)
• Location A is the best choice. Installing downstream of heating and cooling
coils provides the most even fl ow through the dispersion unit; plus, the
heated air provides an environment for best absorption.
• Location B is the second-best choice. However, in change-over periods, the
cooling coil will eliminate some moisture for humidifi cation.
• Location C is the third-best choice. Air leaving a fan is usually very turbulent
and can cause vapor to not absorb at the expected non-wetting distance.
Allow for more distance if installing downstream of a fan.
• Location D is the poorest choice. The cooler air at this location requires an
increased non-wetting distance.
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
7
INSTALLATION
Mounting and support
INSTALLATION IN A COLD AIR STREAM
When a steam dispersion panel is installed in a duct that will carry cold air,
determine the dew point temperature. If the psychrometric chart reveals that
saturation may occur, protection should be provided. A high-limit humidistat or
thermostat set to cut off the steam dispersion panel at a safe temperature can
be used for this purpose. See Figure 8-1.
PLACEMENT UPSTREAM FROM AN ELBOW OR DUCT SPLIT
Due to Ultra-sorb's rapid steam absorption performance, installation upstream
from elbows or duct splits can be done with confi dence. See Figure 8-2.
INSTALLATION ABOVE VALUABLE EQUIPMENT
Water piping and humidifi ers should not be installed above expensive
equipment. A condensing or leaking water pipe or other accidental water
spillage could cause serious damage to the equipment below. When such
an installation cannot be avoided, install a galvanized drip pan under the
humidifi er piping, valve, etc. to catch and drain away unintended water. See
Figure 8-3.
See also “Optional header overfl ow P-trap water seal” on Page 17.
PANEL SUPPORT
The duct or air handler section and Ultra-sorb panel must be properly
supported to carry the weight of the assembly. The weight of the piping must
be supported by the building structure rather than by the Ultra-sorb unit.
Otherwise, the weight may impose stress on the connections, causing them to
fracture and leak.
mc_071311_1540
FIGURE 8-1:
INSTALLATION IN A COLD AIR STREAM
Extended trails of
Cold
air
fl ow
High limit duct humidistat 10' to 15'
(3 to 4.5 m) downstream from Ultra-sorb
OM-197
mc_052411_0830
FIGURE 8-2: UPSTREAM PLACEMENT
Airfl ow
Airfl ow
FIGURE 8-3:
INSTALLATION ABOVE VALUABLE
EQUIPMENT
Ultra-sorb
Airfl ow
Ultra-sorb
Ultra-sorb
Ultra-sorb
OM-178
fog may develop
Elbow
Non-wetting
distance
Duct split
Vapor absorption
Duct
area
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
8
Drip pan
Pipe to drain size as required
OM-198
* This length of duct should have sealed seams
and should be at least three times the height
of the Ultra-sorb panel.
mc_101410_0955
2" (50 mm)
Ceiling line
Mounting and support
INSTALLATION
Where allowed, screws and drill bits must not penetrate more than 3/4" (20
mm) into the header assembly. See Figure 10-1 for allowable drill and
screw locations.
Ultra-sorb Model XV must be installed in horizontal airfl ows only.
MOUNTING IN A DUCT
Mounting fl anges on both sides of the unit and the header and frame can be
used as mounting surfaces (see Figure 10-1). A matching fl ange or metal frame
is required on the ductwork for connection to the Ultra-sorb fl anges. Use a #12
self-drilling and tapping screw 3/4" (20 mm) long, spacing not to exceed 12"
(305 mm). If an angle-iron frame is provided on the duct section, a longer
screw may be required.
MOUNTING IN AN AIR HANDLER
Metal support frames should be anchored to the air handler casing. When
mounting the Ultra-sorb to a metal support frame, use 1/4 - 20 nuts and bolts
or #12 self drilling and tapping screws. Fastener spacing should not exceed
6" (150 mm).
FIGURE 9-2: PREVENTING DUCT AIR LEAKS
Duct smoke detector
Do not install a duct smoke detector
downstream from the Ultra-sorb panel. If
downstream installation is required, install it far
enough from the Ultra-sorb panel to avoid false
alarms.
Dispersion tube orientation
Verify that the steam discharge tubelets are
perpendicular to the airstream (see Figure
9-1). The spring-loaded dispersion tubes
easily rotate for proper orientation.
FIGURE 9-1:
DISPERSION TUBE ORIENTATION
Tubelet Dispersion tube
Airfl ow
Airfl ow
OM-150a
Perimeter of top frame along duct fl ange
Four inside corners
Ultra-sorb panels that penetrate a duct section
must be sealed with HVAC caulking or a similar
weather sealant to prevent air leakage. Panels
should be sealed at locations shown.
Top outside corners
Both sides of cover seam
OM-7482
mc_101410_0845
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
9
INSTALLATION
Installation drawings:
FIGURE 10-1: ULTRA-SORB MODEL XV IN A DUCT (HORIZONTAL AIRFLOW ONLY)
Humidifi cation steam
Connection end
of header
Float switch, optional header overfl ow/
access port (1/2" NPT, internal thread)
Pressurized boiler
steam inlet
(3/4" NPT, internal
thread)
inlet:
• 1" or 2" NPT
(DN25 or DN50),
determined by
maximum steam
capacity
• 3" (DN80) fl ange,
STS humidifi er
connection only
Pressurized condensate outlet
(3/4" NPT, internal thread)
Mounting in a duct
Attach duct fl ange to top frame assembly
No screws
Screws OK
Screws OK
1/2"
(13 mm)
Screws OK
Attach duct fl anges to 1.5"
(38 mm) mounting fl anges
No screws
through top
of header
Attach duct fl ange
to header assembly
Screws OK
No screws through
end of header
assembly
OM-7490
mc_101310_1030
Notes:
1. See Figure 12-1 for trap clearance.
2. Steam supply line to unit and piping are not included.
3. Dispersion tubes are available on 3", 4", 6", 9" and 12" (76, 102, 152, 229, and 305 mm) centers.
4. Ultra-sorb steam dispersion panels will be assembled, crated, and shipped intact in all sizes up to 98" (2490 mm) overall height. Any Ultra-sorb
can be shipped unassembled by request, requiring fi eld assembly.
5. Standard sizes are 12" x 12" up to 144" x 144" in 1" increments (305 x 305 mm up to 3660 x 3660 mm in 25 mm increments). Larger sizes are
available.
6. Install the panel level. If slope cannot be avoided, ensure that the slope is toward the drain end of the panel.
7. Drill or screw through the header assembly only where shown.
Screws and drill bits must not penetrate more than 3/4" (20 mm) into the header assembly. Use 1/4–20 nuts and bolts or #12 self drilling and
tapping screws for mounting the Ultra-sorb to a metal support frame.
3/4" (20 mm) max length (See Note 7)
Add center support required for all units
greater than 60" (1524 mm) wide.
No screws through bottom
of header assembly
assembly
1/2" (13 mm)
No screws
through end of
header assembly
ULTRA-SORB MODEL XV INSTALLATION, OPERATION, AND MAINTENANCE MANUAL
10
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