Herrmidifier Herrtronic 6000 User Manual

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Engineered Humidification Systems

READ AND SAVE THESE INSTRUCTIONS

Herrtronic® 6000 Series

Electrode Steam Humidiers

Herrmidifier® | www.herrmidifier-hvac.com

Page 2

Installation, Operation, & Maintenance Manual

TABLE OF CONTENTS

SECTION I WARRANTY

Preface ...........................................................................................................................................................3

SECTION II UNIT OPERATION

Basic Operation .............................................................................................................................................. 4

Key Features .................................................................................................................................................. 5

Engineering & Application............................................................................................................................... 6

SECTION III INSTALLATION INSTRUCTIONS

Mounting ......................................................................................................................................................... 7

Plumbing.........................................................................................................................................................7

Steam Distribution .......................................................................................................................................... 8

Wiring .............................................................................................................................................................9

Supply Power .................................................................................................................................................9

Control Circuit Connections ............................................................................................................................ 9

SECTION IV OPERATING INSTRUCTIONS

Start-up Instructions .......................................................................................................................................10

Checklist ......................................................................................................................................................... 11

Maintenance ................................................................................................................................................... 12

SECTION V TROUBLESHOOTING GUIDE

Board Test Points ........................................................................................................................................... 13

Unit Detected Faults: (Red Service Light On) ................................................................................................14

Non-fault Activated Problems ......................................................................................................................... 15

Blower Version Wiring Diagram (6000-1 & 6000-2)........................................................................................17

Blower Version Exploded View (6000-1 & 6000-2) .........................................................................................18

Blower Version Parts List (6000-1 & 6000-2) .................................................................................................19

Ducted Version Wiring Diagram (6000-1 & 6000-2) .......................................................................................20

Ducted Version Exploded View (6000-1 & 6000-2) ........................................................................................ 21

Ducted Version Parts List (6000-1 & 6000-2) .................................................................................................22

SECTION VI SUGGESTED SPECIFICATIONS

Suggested Specications ............................................................................................................................... 23

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Herrtronic® Model 6000

Page 3

Installation, Operation, & Maintenance Manual

SECTION I WARRANTY

Warranty

1. Herrmidier warrants to the buyer or any user during the

duration of the Warranty that the humidier described

in this manual will be free from defects of material and workmanship for a period of two (2) years from the date of shipment.

2. For this Warranty to be effective, this humidier must be installed, operated and maintained in accordance with the Installation Instructions, Operations and Mainte-

nance Manual(s) supplied with the humidier.

3. In the event of a defect or malfunction in this product during the Warranty Period, user may contact the Customer Service Department or their Herrmidier Representative for a Material Return Authorization (MRA) number. Items tagged (on the outside of the box) with this number may be returned to Herrmidier for replacement. Incidental expenses such as cost of transporting the humidier to Herrmidier or labor associated with removal/replacement of the parts shall be paid by the user.

Upon completion of the reconditioning, the humidier will

be returned at no cost to the user. Items returned without an MRA number will not be accepted!

4. Every 6000 series steam generating humidier contains a plastic steam generating cylinder which is to be considered a routinely disposable part to be changed at regular maintenance intervals at the user’s expense. This steam generating cylinder is not covered by this Warranty. If,

after the installation of your 6000 humidier, you feel the

steam generating cylinder is not operating normally, you

should contact Herrmidier with an explanation of the

problem. However, in the continuing operation of the hu-

midier, replacements of this part are your responsibility

as part of routine maintenance.

5. This Warranty does not cover eld labor for repairs to this humidier or any special, indirect or consequential damages. Some states do not allow the ex-

clusion or limitation of incidental or consequential damages, so the above limitation may not apply to you.

6. If, after a reasonable number of attempts to do so, Her-

rmidier is unable to remedy any defects or malfunctions in this humidier, then the user may elect either a re-

placement of such product or part which may be defective without charge or a refund of the buyer’s original purchase price.

7. This Warranty gives you specic legal rights, and you

may also have other rights which vary from state to state.

NOTE

Water quality plays a vital role in the performance and maintenance requirement of any humidier. Adjust- ments to the circuit board may be necessary based on the incoming water quality. See pages: 13-16.

Performance problems associated with water quality are not warranty issues!

Herrtronic® Model 6000

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Page 4

SECTION II UNIT OPERATION

Water Level

Output

Basic Operation

Installation, Operation, & Maintenance Manual

Controlled humidication requires a very precise control system. The 6000 utilizes a solid state control to monitor perfor-

mance and maintain humidity. The humidier evaluates the

operation and alerts the operator to problem conditions and prevents undesirable operation.

On initial start-up or a call for humidity, the humidier will attempt to ll to its full load amp rating. The unit will not neces-

sarily have a full cylinder of water. Water level depends on the conductivity of the water. The more conductive the water, the more current that can be passed through the same volume of water.

If the water is not conductive enough to allow the unit to reach full load amps (full capacity) on the initial ll, the cylinder full light will indicate a full cylinder condition. The unit will

operate in this mode with repetitive ll and boil cycles until

the unit has concentrated enough minerals in the water to reach the rated amp level.

Once full load amp (FLA) has been reached, the ll valve will

shut off. The unit will now compare the rate of change of amp draw to a time cycle.

If the water in the cylinder is mineral laden and hence very conductive, a drain cycle will be initiated.

After the drain cycle and/or the time cycle is completed, the

unit will rell and start the process over.

These cycles will repeat until:

•The call for humidity is satised.

•The cylinder is used up.

•A fault condition occurs.

On initial start-up, if the water is not conductive enough for

the unit to reach FLA, the water will stop lling when the water

reaches the cylinder full electrode. Once the unit has entered

a cylinder full condition it will operate with ll and boil cycles

only. By eliminating the drain cycle, the water conductivity will be increased by producing pure steam and leaving the minerals behind. The increased mineral levels will raise the conductivity allowing the humidier to draw sufcient amperage to achieve FLA. Normal operation will then commence.

As the electrodes in the cylinder are coated with minerals, the water level will slowly increase to the cylinder full level. Concentration will no longer allow the unit to reach FLA. After a period of time, the unit will display the red “Service” light indicating the need to change the cylinder.

High Drain

Threshold

Capacity Set Point

Low Drain Threshold

Cylinder

Full

1. 2.

Hours of Operation

Steadily Increase

Water Level

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Herrtronic® Model 6000

Page 5

Key Features

Installation, Operation, & Maintenance Manual

Adjustable Setpoints:

Capacity

• Range = 50-100%

• Preset at 100% for 6000-1,3,4

• Preset at 50% for 6000-2

Low Drain Threshold

• Range = 50-100%

• Preset at 90%

Cycle Time

• Range = 30-180 seconds

• Preset at 60 seconds

ADJUSTABLE LOUVER (6000-1, -2 UNIT)

Faults:

Overcurrent

• 138% of Rated Current

• System Shutdown

Fill System

• Fill valve open for 6 hours without achieving capacity setpoint or cylinder full

• System Shutdown

End of Cylinder Life

• 6 hours of operation while on cylinder full without achieving capacity setpoint.

• System Shutdown

• Operation using water of less than 100 micromho

is not recommended.

• Typically 500-2000 hours of cylinder operation can be obtained. Your actual cylinder life may be higher or lower depending on the exact composition of your water supply.

INTEGRAL, QUIET OPERATING FAN (6000-1, -2 UNIT)

"CYLINDER FULL" ELECTRODE (RED WIRE)

CYLINDER - REPLACEABLE GLASS FILLED POLYPROPYLENE

DRAIN SYSTEM (SEALED DRAIN VALVE, ADJUSTABLE DRAIN THRESHOLD AND CYCLE TIME PROVIDE EXTENDED LIFE.)

HERRMIDIFIER

FILL SYSTEM (INTEGRAL 1" AIR GAP PREVENTS REVERSE SIPHONING TO POTABLE WATER SUPPLY; "ADJUSTABLE METERING VALVE ACCOMODATES WATER PRESSURES UP TO 100 PSI."

INTERNAL CIRCUIT BREAKER

INTEGRAL HUMIDISTAT (6000-1, -2 UNIT)

ISOLATED CONTROL COMPARTMENT WITH SOLID STATE CONTROLS

POWER, CYLINDER FULL, AND SERVICE INDICATOR LIGHTS

ON/OFF/DRAIN SWITCH

COVER INTERLOCK SWITCH (PREVENTS UNIT OPERATION WITH COVER OFF)

CONCEALED FILL AND DRAIN CONNECTIONS

Herrtronic® Model 6000

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Page 6

Installation, Operation, & Maintenance Manual

Engineering and Application

The Herrmidier 6000 Series Steam Humidiers can be applied

in a variety of applications. The simplest application is to utilize the model with the built-in blower package (6000-1,2). The steam generated by the unit is distributed into the conditioned space by the built-in blower package (Figure 1).

Alternatively, steam generated by the “6000” unit can be discharged directly into the HVAC system ductwork (6000--3,4). In this application, a steam pipe is preferably installed in the system ductwork at least 5 feet downstream of the supply air

blower. There should be no obstructions within the rst 5 feet

downstream of the steam distributor as shown in Figure 2. An air proving switch and high limit humidistat are provided for better system control in ducted applications. If the heating system

18 INCHES MINIMUM

operates for short periods at a time and the desired relative

humidity level is not achieved, the humidier can be wired to

turn on the blower when there is a call for humidity. In this case an air proving switch will not be necessary, but the high limit humidistat should still be utilized.

NOTE: The steam distributor pipe is inherently sloped to return the condensate to the humidier.

The steam piping from the humidier to the steam distributor should have an 8% slope (1” per foot) up to the steam distributor. Steam hose may be used up to a maximum of 20 feet between the unit and the steam distributor. The hose provided with the unit is 10 feet long. There can be no sags in the steam hose, as this will create a trap and will produce back pressure in the steam cylinder and may blow condensate in the duct.

5 FEET MINIMUM

Figure 1

Allowable Operating Conditions:

Ambient Temperature: 40°F (4°C) to 120°F (50°C) Ambient Relative Humidity: 0% to 90% (non-condensing) Line Voltage: -15% to +10% of Nominal Frequency: 50/60 HZ. Water Supply Pressure: 20psi – 100 psi. Maximum Duct Static Pressure: 1” (6000-4)

Note: Duct liner may be used with a maximum thickness of 1".

Figure 2

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Herrtronic® Model 6000

Page 7

Installation, Operation, & Maintenance Manual

SECTION III INSTALLATION INSTRUCTIONS

Mounting

The cabinet is designed to safely contain the working compo-

nents of the Herrmidier 6000 series humidier and dissipate heat to protect the electronics. Locate humidier, steam pipe

and accessories in a manner to allow routine inspection and any necessary maintenance. DO NOT install the unit above false ceilings or around valuable property, where a malfunction could

cause damage. Correct positioning of the humidier is important

to allow for proper operation and easy maintenance. Minimum clearance around the cabinet should be maintained as follows:

Minimum Clearances

Around Cabinet

Left 6”

Right 12”

Top 18”

Bottom 12”

Remove foam packing from top of tank. Four lag bolts, (2) 5/16” and (2) 1/4”, are supplied with the 6000 unit. Install the top two lag bolts (5/16”) according to the dimensions in Figure 3. Hang the unit on the wall, and then install the bottom two lag bolts (1/4”) and secure all four bolts. Be sure the unit is level and mounted directly to the wall to wood studs at least 2” thick (or equivalent). Operating weights are as follows:

6000-1,2: 35 lbs.

6000-3,4: 35 lbs

Back View

16 1/2"

1 1/2"

4 1/4"

5/16 x 5/8 DIA. KEYHOLE MOUNTING SLOT

1/2"

Plumbing

To make the necessary connections for water ll and drain, the following steps are required: (refer to gure 4 for locations)

1. Install external shutoff valve between the water supply and

the humidier for ease in servicing the unit.

2. Connect water supply to the 1/4’ compression tting on the bottom of the cabinet.

CAUTION!

Do not use reverse osmosis or demineralized water treatment without rst consulting the factory. This water may not be sufciently conductive to allow proper operation. Consult factory if water is outside the range of allowable conductivities. Do not use hot water.

3. Connect the 3/4” tube from the accessory pack to the drain reservoir. Cut the tube to the length necessary to reach the drain.

4. Insert the other end of the tube into a minimum 6” vertical length of the 1-1/4” minimum I.D. drain line. The balance of the drain line should be 1” I.D. minimum with a minimum 1/8” per foot slope. (See Figure 4)

WARNING!

If the drain line is exposed, it is recommended that it be insulated for safety. Do not use PVC drain line unless “Drain Tempering” is enabled (see page 10, step 10).

NOTE: Inlet water pressure must be in the range of 20-100 psig. Consult the factory if you are outside this range. Softened water may be used but requires that the low drain threshold be adjusted (page 13). Drain water can be tempered to lower its temperature (refer to page 10).

DRAIN LINE TO BE 1" MIN. I.D. TERMINATING AT THE UNIT WITH 6" OF 1 1/4" I.D. VERTICAL PLUMBING.

THIS ALLOWS AN AIR GAP BETWEEN THE 1" O.D. DRAIN TUBE FROM THE UNIT AND THE DRAIN.

UNIT HOUSING

5/16" DIA.

Figure 3

WARNING!

Do not mount any controls inside the unit or tap power from any location in the unit, except as stated in these instructions. Do not place objects near the cabinet. Do not attach to dry wall without studs. At least one 5/16” and one 1/4” lag bolt must be located on a stud.

Herrtronic® Model 6000

DRAIN RESERVOIR

1/4" O.D. COPPER OR POLY TUBE WATER FILL LINE

BOTTOM COVER

FILL CONNECTION

3/4" I.D./1" MAX. O.D. FLEXIBLE DRAIN HOSE

Figure 4

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1 1/4" I.D. COPPER OR PVC DRAIN PIPE

1" I.D. COPPER OR PVC DRAIN PIPE

Page 8

Steam Distribution

Installation, Operation, & Maintenance Manual

Blower Version (6000-1,2)

The 6000 Series Steam Humidier with the built-in blower pack

should be mounted a minimum of 18” from the ceiling. There should also be 5 feet of horizontal clearance in front of the unit to prevent steam from condensing on obstructions (See Figure

1). There is an adjustable louver to adjust the direction of the steam plume.

WARNING! Do not adjust this louver to extreme angles as it will restrict the airow causing condensation to form around the steam distribution manifold.

WARNING! Locate away from areas where people can walk into the steam path.

Ducted Version (6000-3,4)

Herrmidier supplies a stainless steel duct distributor for injecting pure steam into the duct. This can be installed in the bottom or the side of the duct (See Figure 5). When installing in the side of the ductwork make sure it is positioned to allow condensate to drain back down the steam hose. The duct distributor pipe has a built-in pitch to allow condensate to drain back into the hose. The hose must be installed with a minimum 8% (1” per

foot) pitch back to the humidier to allow condensate to drain

back to the steam cylinder (See Figures 5 & 6). A minimum of 5 feet downstream clearance before any bends or obstructions is recommended for most applications (See Figure 2 ). However, different psychrometric conditions may require greater or lesser steam absorption distances. A minimum duct temperature of 60° F is recommended. Temperatures below this may cause condensation to form in the duct. Lined duct may be used if the thickness is 1” or less.

Distributor Mounting Instructions

Sheetmetal Duct: Make a 1-1/4” hole in the duct at desired location. Insert duct distributor and secure with self tapping sheetmetal screws (supplied by others).

Fiberboard Duct: Make a 1-1/4” hole in the duct at desired location. Insert duct

distributor and mark the four holes on ange. Drill (4) ¼”- holes

at marked locations. Cut an access hole in duct and install the enclosed tee nuts from the inside of the duct. Fasten distributor

with enclosed ¼” bolts.

MIN. 8%

10.00 MIN. (254 mm)

NO SAGS ALLOWED

HORIZONTAL DUCT

VERTICAL DUCT

Figure 5

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INCORRECT

NO SAGS ALLOWED

HORIZONTAL DUCT

Figure 6

Herrtronic® Model 6000

Page 9

Installation, Operation, & Maintenance Manual

Wiring

All eld wiring should be routed up through the knockout in the

bottom panel or in the back of the unit.

7/8" KNOCKOUT

2" KNOCKOUT

1 1/2"

BOTTOM VIEW

1 3/8"

3 3/4"

Figure 7

Supply Power

1. Insure that minimum circuit ampacity is 15 amps.

2. Terminals are provided in the electrical compartment for

eld connection of the main power supply legs (single

phase) and a ground wire.

3. Install external overcurrent protection and provide wiring in accordance with the NEC, state and local codes.

4. Power supply must be “clean”: free of spikes, surges and

sags: -15% to +10% of nominal.

Electrical Characteristics:

Capacity Steam Output

Lbs. / hr 4 8

Kg / hr 1.8 3.7

Input KW

1.33 2.66

Volts/Ph: Amps

120/1 11.8 N/A

230/1 5.9 11.8

Control Circuit Connections

WARNING!

Do Not install any controls inside the Herrmidier 6000 cabinet. Installations of any extraneous devices inside the electrical compartment rnay cause erratic behavior of the circuitry and will VOID the warranty.

6000-1,2

The 6000 units with built-in blowers require no external control wiring since the humidistat is built-in.

6000-3,4

The control wiring for the ducted version is to be connected to the 5 pole controls terminal strip located in the low voltage compartment. Terminals #1 and #2 are for connecting the control and high limit humidistats as well as the air proving switch in series (all included). If desired, terminals #3 and #4 are relay contacts to energize your fan relay (Relay contact rating 12 Amps at 125 VAC, 8 Amps at 250 VAC). With this optional wiring, on a

call for humidity, the humidier will close the interlock relay and

energize the fan blower. The air proving switch must not be used if the fan interlock is utilized. All control wiring should be 22 AWG

or larger (See gure 8). Consult with the factory if you have any

special wiring requirements.

TERMINAL

STRIP

HUMIDISTAT

HIGH LIMIT

SWITCH

AIR-PROVING

SWITCH

1 2 3 4

FAN INTERLOCK (OPTIONAL)

Herrtronic® Model 6000

NOTE: AIR PROVING SWITCH MUST NOT BE USED

WHEN INCORPORATING FAN INTERLOCK OPTION.

Figure 8

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Page 10

Installation, Operation, & Maintenance Manual

SECTION IV OPERATING INSTRUCTIONS

Start-up Instructions

1. Check that the humidier is properly mounted and level.

2. Check that the water ll and drain are properly connected.

3. Check that the correct voltage and amperage service are supplied.

4. Check all controls are wired properly.

5. Check that the steam distributor is properly installed and that the steam hose has been properly routed without any

kinks or at spots.

6. With power off, double check all electrical connections and plumbing connections to insure that they did not loosen during shipment.

7. With the “on-off-drain” switch in the “off” position, and the control and high limit (ducted versions only) humidistats at their lowest settings, turn on the main disconnect. The contactor should remain deenergized and the power light should remain “off”. Place the “on-off-drain” switch in the “on” position and the power light should illuminate.

8. Turn the control and high limit (ducted versions only) humidistats up to their highest setting. The contactor should pull in.

9. After approximately a 5 second delay, the ll valve ener-

gizes and water begins to ll the cylinder to the preset amp

level or cylinder full condition, depending on the incoming water supply. When starting up the unit, it is best to put an amp clamp on the power leg that passes through the

toroid transformer. Insure that the humidier lls to “cylinder

full” (approximately 1.5” from the top of the cylinder), or that

the amperage reaches the data plate maximum and the ll

valve de-energizes.

10. All units are equipped with a drain tempering feature which

mixes cold ll water with the hot drain water to protect drain piping. Depending on your ll water pressure, some adjustment of the ll metering valve may be necessary to insure

drain water of less than 140°F (See Figure 9). To deactivate, remove diode from socket CRI8 from circuit board (See Figure 12).

11. Reset control and high limit humidistats to their desired settings. Typical control humidistat settings are 30-40% and the high limit humidistat settings are 65-70%.

NOTE:

The capacity of the humidier can be adjusted between 50% and 100% of the maximum level by adjusting the capacity adjustment potentiometer (labeled R39) on the main circuit board. All blower versions are set from the factory to produce 4 lbs/hr. If the psychrometric conditions permit, the 6000—2 may be increased to 8 lbs/hr by adjusting R39 from 50% to 100% capacity. Refer to gure 12.

CAUTION!

NOTE:

If upon initial start-up of this humidier the cylinder is slow in heating and/or the service light continues to come on, drain the tank to 1/4 full. Turn off power at breaker, obtain some Alka-Seltzer tablets and crumble 1/2 of one tablet (Alka-Seltzer) into the grey ll tee. Change the middle blue dial on the left side of the circuit board, R18, from 90% to 87%. Then turn the breaker on and run the unit. If you have had to use these this step on a 240V unit (60002,4), it is advisable that you order a GT-176-1 replacement cylinder rather than the standard replacement cylinder in the future so this procedure will not need to be repeated. Upon receipt of the GT-176-1 cylinder, adjust the dial, R18, on the circuit board back to 90%.

Inadequate airow may allow humidity to collect in areas causing condensation.

RELAY

FILL VALVE

CYLINDER FULL INTERFACE

TERMINAL BLOCK

VIEW IN FROM RIGHTSIDE OF UNIT

TRANSFORMER

MOUNTING SCREWS

FILL VALVE ADJUSTING SCREW

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Figure 9

Herrtronic® Model 6000

Page 11

Installation, Operation, & Maintenance Manual

MAKE SURE LOUVER IS ADJUSTED TO PREVENT STEAM FROM CONDENSING ON COVER.

MAKE SURE ALL HIGH VOLTAGE ELECTRICAL CONNECTIONS ON STEAM CYLINDER ARE TIGHT.

MAKE SURE ALL HIGH VOLTAGE ELECTRICAL CONNECTIONS ARE TIGHT, 10-15 IN-LBS.

Installation Checklist

POWER SUPPLY:

1. MATCHES DATA PLATE

2. IS PROPERLY GROUNDED

3. CAN CARRY AT LEAST 15 AMPS

4. EXTERNAL FUSED DISCONNECT PROVIDED BY OTHERS.

3/4" MIN. I.D./ 1" MAX. O.D. FLEXIBLE DRAIN CONNECTION

DRAIN RESERVOIR

DURING FILL CYCLE, CHECK TO SEE IF ANY WATER IS DRAINING FROM UNIT. A LOT OF WATER FLOWING OUT OF THE UNIT WOULD INDICATE EXCESSIVE WATER PRESSURE. TURN OFF POWER AND REDUCE THROUGH METERING FILL SOLENOID OR SUPPLY VALVE TO HUMIDIFIER. A SMALL AMOUNT OF WATER IS NOT UNCOMMON.

6" MIN. LENGTH OF 1 1/4" MIN. I.D. VERTICAL COPPER LINE. IF PVC IS USED, ADD DRAIN TEMPERING.

BALANCE OF DRAIN LINE TO BE 1" MIN. I.D.

DRAIN WATER TEMPERATURE IS SUITABLE FOR PLUMBING.

NOTE:

The Herrmidier 6000 Humidier checklist is provided to help the installer insure a successful installation. If further assistance is needed from the Herrmidier representative or the factory, the checklist is expected to be completed. If a jobsite visit is required from the Herrmidier representative or the factory, and the checklist has not been accurately completed, additional charges may be applied by the individual(s) representing Herrmidier. If the visit uncovers a component malfunction, the parts will be replaced under warranty.

_____________________________________________ ____________________________________________ Project Name Checklist completed by

_____________________________________________ ____________________________________________

Humidier Installer (Company) Checklist completion date

Herrtronic® Model 6000

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Page 12

Installation, Operation, & Maintenance Manual

Maintenance

To maintain output, the water level in the cylinder will slowly move upwards, exposing new electrode to the water as the electrodes become coated with minerals. Eventually, all of the usable electrode surfaces will be coated and the cylinder will be full of water. At this point, the output will begin to drop and the red “service” light will come on. The unit will shutdown. This indicates the need to change the cylinder, typically 500-2000 hours

of operation, depending on the quality of the ll water supply.

To replace the cylinder

1. Drain cylinder completely using the ‘on-off- drain” switch.

2. Turn off power to the unit at the external disconnect. Disconnect electrode power wires (#38 & #39) and cylinder full electrode wire (#29) from the tank. These connections are 1/4” quick connects. (See Figure 11B, 11C, & 11D)

3. Disconnect 1” hose at top of tank.

4. Remove tank, clean out the drain cup and insert the

new tank. Be sure that “o” ring is in place on the cylinder ll/

drain port prior to installation (See Figure 11A). New o-ring is included with each replacement cylinder.

5. Clean and check both the ll and drain valves while servicing the unit.

6. Check the strainer. If it is dirty or restricting the water-replace it.

7. Install cylinder in unit by pushing downward with a slight twisting motion, while ensuring proper orientation of tank within cabinet.

8. Reconnect electrode power wires (#38 & #39) and cylinder full electrode, wire (#29). Make sure that all electrical connections are securely tightened. (See Figure 11B, 11C, & 11D)

9. Follow cold start-up instructions on page 10. Monitor amp draw for several cycles. .

Extended Shutdown

Always drain cylinder completely if unit will be off for an extended period of time. This will preserve the life of the cylinder.

CYLINDER FILL/DRAIN PORT

EST-1060-3 O-RING

Figure 11A

CYLINDER FULL ELECTRODE CONNECTION

PROTECTIVE BOOT

(SHOWN TRANSPARENT FOR CLARITY)

POWER WIRE CONNECTIONS

CYLINDER FULL ELECTRODE WIRE #29

POWER WIRE #38

ELECTRODE CONNECTION

PROTECTIVE BOOT

(SHOWN TRANSPARENT FOR CLARITY)

Figure 11B

POWER WIRE #39

RED POWER WIRE

1/4" MALE QUICK CONNECT

1/4"-20 NUT

1/4" LOCK WASHER

GROMMET

Figure 11C

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BLACK POWER WIRE

1/4" MALE QUICK CONNECT

1/4"-20 NUT

1/4" LOCK WASHER

Figure 11D

Herrtronic® Model 6000

Page 13

Installation, Operation, & Maintenance Manual

SECTION V TROUBLESHOOTING GUIDE

All Herrmidier 6000 Series Humidiers are manufactured under

strict quality control and are subjected to a complete operational test before shipment. All circuit board adjustments are made at the factory and should not be adjusted beyond the guidelines set in this troubleshooting guide without rst consulting a factory representative. The following information is for your help

and reference. If you still experience difculty after trying these remedies, contact your Herrmidier representative.

WARNING!

The Herrmidier 6000 Series Electronic Steam Humidier cabinet was designed to house and shield the components from outside interference. Absolutely NO other components may be mounted inside or be electrically tapped into the humidier without Herrmidier’s express written permission. Failure to heed this warning will void your warranty.

TEST POINTS

Each circuit board (See Figure 12) features three test points to aid in the troubleshooting process. Each of these test points works on a 0-4 VDC scale. “0 VDC” = 0%. “4 VDC” = 100%. All readings are between the test point and ground (Molex J1, terminal 11 [far right of molex connector, wire #11).

Test Point #1:

Provides exact reading of drain threshold setting.

Test Point #2:

Provides circuit board reference voltage. Should always read 4 VDC +/-2%.

Test Point #3:

Provides actual percentage of output. For example, a unit running at 80% of maximum output would have a Test Point #3 to ground reading of 3.2 VDC.

Capacity adjustment pot

Maximum Capacity Setpoint

The potentiometer labeled “R39” located in the top left-hand corner of the board allows adjustment of the unit’s capacity in the range of 50-100% of maximum.

NOTE:

All blower units have their capacity set from the factory at 4 lbs/hr. These units can have their capacity increased by increasing the capacity adjustment potentiometer. Ensure there is sufcient air circulation in the conditioned space to prevent condensation on walls or ceiling when increasing the capacity above 4 lbs/hr.

Circuit Board Settings

Models Time Cycle

R23

Low Drain Setting, R18

Capacity, R39

Standard Settings

All 60 sec 90 100%

High Conductivity Settings (> 1000 micromho)

All 84 sec 93 90%

Softened Water Settings (750-1000 micromho)

All 60 sec 92 95%

Low Conductivity Settings (<100 micromho)

All 60 sec 85 100%

CR17 LED - overamp condition indicator if illuminated

Test point #3

(Output capacity)

R4 Capacity

resistor socket

Low drain

threshold pot

Test point #1

(Drain threshold reading)

(Equilibrium voltage reading)

Test point #2

Cycle timer pot

Herrtronic® Model 6000

CAP ADJ

TP3

PROP DISPLAY

TP1

R18

TP2

SEC R23

J1 Connector

CR17

CR18

CR18 diode drain tempering socket

Figure 12

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Page 14

Installation, Operation, & Maintenance Manual

Unit Detected Faults: (Red Service Light is ON)

Problem / Symptom Probable Cause Reason - Correction

Overcurrent

The alarm condition occurs when an overcurrent situation (>138% of rated

current) has occurred and the humidier

has shut down to prevent any damage. This alarm indicates that there has been a signicant reduction in resistance between the main legs of the supply power

and the humidier has been shut down to

prevent damage and should be serviced before it is restarted. Overcurrent LED CR 17 (Figure 12) is illuminated.

End of Cylinder

This alarm condition occurs if the humidi-

er is unable to reach full output over a 6

hour timeframe. It is constantly switching

between “ll” and “cylinder full” modes.

This alarm indicates a need to change the cylinder, that the water supply is low in conductivity, or that a foaming condition exists:

Fill System Fault

This alarm condition occurs when the ll

valve has been energized for a 6 hour

timeframe. The humidier has been

shutdown to prevent any damage.

Dead short between electrodes. Replace the steam cylinder. Check re-

sistance between electrodes with power “off”

Restricted or blocked drain. Clean and inspect drain system.

Restricted ll system Clean and inspect the ll system. Check

for restriction or loss of supply pressure.

Incoming water conductivity is outside the range of normal circuit board settings.

Check amp draw to unit during start-up. If amp draw greatly exceeds rated amp draw, the drain threshold pot, labeled “% adj.” (R18), must be increased 2% to increase the frequency and duration of drains to reduce the conductivity inside the cylinder.

End of cylinder life – Cylinder life is typically between 500 and 2000 hours, depending on incoming water supply.

If incoming water supply is less than 100 micromho, the unit may not be able to pass the rated current through the water.

Foaming condition exists. Flush and ll the steam cylinder several

Loss of or restricted water supply Check ll system.

Leaking drain system. Check drain system.

Defective drain valve. Repair and replace as required.

Defective ll valve. Repair and replace as required.

Consult the factory for options.

Manually drain the unit and restart.

For emergency use, you may restart the

humidier with the capacity setpoint,

R39, at a lower level to allow operation until a replacement steam cylinder can be obtained. To clear the fault, turn the main disconnect to the unit “off” and then back “on”.

See – NON-FAULT ACTIVATED PROB-

LEMS GUIDE – “Unit lls to the cylinder

full condition and remains cold”

times and restart. If it persists, you must

lter or treat the water to remove the

foaming agent. See circuit board settings on previous page if supply water is softened. See NON – FAULT ACTIVATED PROBLEMS GUIDE – “Water foaming inside the cylinder”

NOTE: The three fault conditions outlined above will cause the humidier to shut down and the service light on the front of the unit to illuminate. To clear these faults, the main power must be turned “off” and back “on” again.

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Herrtronic® Model 6000

Page 15

Installation, Operation, & Maintenance Manual

Non-Fault Activated Problems:

Problem / Symptom Reason - Correction

24 VAC circuit breaker trips as soon as power switch is turned “on”.

24 VAC circuit breaker trips after the unit is turned on for about 15 seconds.

24 VAC Circuit breaker trips whenever the drain valve activates

Humidier turned on but will not

operate. Power lamp is “off”.

Unit turned “on”. Contactor pulled in, but no water is entering the cylinder.

Excessive arcing in cylinder Check drain valve and insure that when it activates it drains freely. Clean if necessary.

Unit lls to the cylinder full condition and remains cold.

Unit turned on and cycles for a short period of time. Then it stops

in the middle of a ll cycle and

won’t reset until boiling stops.

Check the wiring at the 24 VAC breaker for a short or loose connection.

Disconnect the contactor coil from the circuit and repeat. If 24 volt breaker doesn’t blow, replace the contactor.

Replace the main circuit board.

Disconnect ll valve from electrical circuit. If circuit breaker doesn’t trip, replace the ll

valve.

Replace the main circuit board

Disconnect drain valve from electrical circuit. If circuit breaker doesn’t trip, replace the drain valve.

Remove the drain valve and insure that it is clean and free of any obstructing mineral deposits.

Replace the main circuit board.

Check power supply.

Check circuit breaker.

Check connector J1 on the circuit board and insure that it is plugged into the circuit board properly and that no wires are loose.

Insure that there is 24 VAC between pole #9 and #11 connector J1. If not, check wiring.

Place jumper between controls terminal strip #1 and #2. If unit operates, check controls settings and wiring (control stat, high limit humidistat, air proving switch.)

Check door interlock.

Check external shutoff valves and open if closed.

Check strainer and ll valve for clogs. Turn adjusting screw (g. 9, page 10)

Check ll valve coil to determine if it is receiving 24 VAC. If so, replace the valve.

Check for break in wiring.

Replace valve if defective.

Check water supply. If it is softened, increase the drain threshold pot, “% adj.” (R18), up to 92%. (See Figure 12)

Use high conductivity settings if water supply is very hard, >750 micromho.

Unit lling slower or at the same rate as the water is boiling, causing over concentration and foaming. Check restriction in ll line. Adjust the metering ll valve to allow greater ow of

water. ( See Figure 9)

Have water analyzed. If iron content is greater than .1 mg/liter, a lter will have to be used.

Consult factory with water analysis

Check between Test Point #3 and ground with a multimeter set on VDC scale. Conrm the circuit board is seeing low current ow (<2.8 VDC). Proceed to next step.

If on initial ll, unit reaches less than 70% of rated capacity (2.8 VDC on Test Point #3),

adjust the drain threshold pot, “% adj.” (R18), down 2-3%. Manually drain the unit down

completely and add ½ Alka Seltzer tablet via the ll tee(GT-120). Restart the unit while monitoring the amp draw. Fill unit ¼ full and turn “off” for several minutes to allow tablets to

dissolve. Restart unit. If amperage rises rapidly, it may be necessary to dilute the water. If amperage rises slowly, add another Alka-Seltzer tablet.

Check that drain valve is sealing properly.

Check the water conductivity and consult the factory.

Check cylinder ll interface connections.

Check cylinder connections (See Figure #11)

Check items in next troubleshooting tip concerning foaming.

Check amperage between cylinder full electrode and cylinder full interface terminal #1. If it

is greater than 7.0 mA AC, take a ll water sample and consult the factory.

Herrtronic® Model 6000

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Page 16

Installation, Operation, & Maintenance Manual

Problem/Symptom Reason - Correction

Water “foaming” inside the cylinder.

Cylinder lls and overows Check cylinder wiring (See Figure #11)

Unit turned on, lls to full amp draw, stops lling, and after a

delay, the circuit breaker trips and the service light comes on.

Unit cycle “on” and “off” rapidly Check location and setting of high limit humidistat

Cabinet leaks Check for loose connections

Check drain valve and insure that water drains freely. If necessary, clean or replace valve if defective.

Check water supply. If it is commercially softened, either increase the drain threshold (R18) to 92% or reconnect the unit to raw water. Drain and restart the unit. If the unit is connected to a hot water line, reconnect to the cold water line.

If steam line is hard copper, drain cylinder and test unit operation disconnected from steam

line to insure ux from solder joints is not causing foaming.

Observe the ll tee(GT-120). If water is going down the overow and the water level is low: Check to insure that static pressure in the duct is not forcing water down the overow in-

stead of allowing water to enter the cylinder.

Adjust the ll metering valve to regulate the water ow to the cylinder. ( Figure 9) Unit lling slower or at the same rate as it is boiling off, causing over concentration and

foaming. Fill rate must be increased. Open metering valve.

If the ll valve is already fully open, get a water analysis and consult the factory.

Check wiring of cylinder full interface.

If more than 1.9 mA AC is passing between the cylinder full electrode and interface terminal #1, and when placing multimeter between terminal #3 and ground yields approximately negative 11 VDC, replace the interface.

Replace the circuit board.

Consult the factory after obtaining a water analysis

Use the “On-Off Drain” switch to drain the cylinder. Turn the capacity adjustment pot(R39)

on the main circuit board to 80% and restart the humidier.

Check the drain valve and clean or replace if necessary.

If the drain valve doesn’t come on before the service light illuminates, replace the main circuit board.

Fill tube out of ll tee

Steam cylinder out of drain cup

Cabinet drain backing up, kink in drain line

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Herrtronic® Model 6000

Page 17

Installation, Operation, & Maintenance Manual

6000-1, -2 WIRING DIAGRAM

POWER

CYLINDER

FULL IND.

237

WHT

RED

WHT

RELAY/TIMER

BLK

OHM

RED

BLK

RED

WHT

LIGHT

RED

WHT

FILL

VALVE

WHT

SERVICE

LIGHT

WHT

RED

WHT

DRAIN

VALVE

ORG

HUMIDISTAT

DOOR

RED

BLUE

INTERLOCK

BLUE

BLK

RED

BLK

ORG

SWITCH

BLK

ORG

2A BREAKER

TRANSFORMER

BLK

(240 VAC FOR 6000-2 AND 6000-4)

GND

POWER INPUT (120 VAC FOR 6000-1 AND 6000-3)

WHT

BLK

(24 RET)

(24 VAC)

BLK

RED

CYLINDER FULL

INTERFACE

ORG

BLK

16 PIN DIP PLUG

WHT

BLK

RED

WHT

ORG

RED

765

MOLEX

CYLINDER

FULL

BLK

(240V)

BLK (120V)

(120V)

BLK

(240V)

BLK

GRN

ELECTRODE

WHT

BLK

RELAY

WHT

BLK

RED

TOROID

POWER ELECTRODES

GROUNDED

TO CHASSIS

POWER

TERMINAL BLOCK

Herrtronic® Model 6000

FAN

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Page 18

Installation, Operation, & Maintenance Manual

EST-1405

EST-1409

EST-1517-1 (115V)

121800-004

EST-1518-1 (230V)

EST-1514

EST-1409

EST-003P

EST-1512

EST-105A

EST-1530

EST-207

EST-353

EST-1519

EST-1001B

EST-1146

EST-353

8260R

EST-1407

EST-1142

EST-1141

1845

EST-1143

EST-1516

EST-1513

GT-116

GT-118

EST-1522A

FILL SUB-ASSEMBLY

EST-207

EST-1415

DRAIN SUB-ASSEMBLY

G-157

165203-001

EST-1415

1095

GT-122

G-125

TANK ASSEMBLYTANK ASSEMBLY

GT-116

GT-262

GT-120

GT-176-1

GT-202

(6000-1)

(6000-2)

FV-17

EST-207

4060

GT-262

EST-1501

EST-1012

EST-1533-1

EST-1225-KIT

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Herrtronic® Model 6000

Page 19

Installation, Operation, & Maintenance Manual

Blower Version Parts List (6000-1 and 6000-2)

1845 Door Interlock 8620R Humidistat Element 1860 KEP Nut, 6-32 121800-004 KEP Nut, 8-32 EST-003 A Cylinder Full Interface EST-105A Toroid Transformer EST-1001B Main Circuit Board EST-1141 Red Lamp EST-1142 Green Lamp (2) EST-1143 On Off Drain Switch EST-1225-KIT Drain Reservoir Kit EST-1405 Timer/Relay EST-1407 Knob EST-1409 Universal Bushing EST-1501 Steam Manifold EST-1512 Transformer 120/240 to 24 VAC EST-1513 Distribution Louver EST-1514 Relay, 2 pole, 20 A EST-1516 Steam Hose EST-1517-1 Fan, 120V EST-1518-2 Fan, 240V EST-1519 Circuit Breaker, 2A EST-1530 Terminal Block EST-1533-1 Drain Valve Kit EST-1542 Power Wire Assembly EST-1543 Grommet, Vibration Dampening EST-207 Clamp EST-353 Bushing GT-116 Celcon Compression Nuts GT-118 Fill Valve GT-125 Conical Filter GT-202 Steam Cylinder Assembly (Standard 240V Units) GT-176-1 Low Conductivity Steam Cylinder Assembly (Standard 120V Units)

Herrtronic® Model 6000

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Page 20

Installation, Operation, & Maintenance Manual

SWITCH

AIR PROVING

6000-3, -4 WIRING DIAGRAM

HIGH-LIMIT

SEE NOTE 1

HUMIDISTAT

TERM STRIP

CONTROLS

ORG

RED

RELAY

FAN INTERLOCK

BLK

WHT

BLK

FAN INTERLOCK (OPTIONAL)

RED

ORG26BLK

BLUE

FIELD WIRING

USED WHEN FAN INTERLOCK IS USED.

1. AIR PROVING SWITCH MUST NOT BE

NOTE:

LIGHT

FULL IND.

CYLINDER

OHM

237

RED

WHT

POWER

RED

WHT

VALVE

FILL

WHT

LIGHT

SERVICE

WHT

RED

WHT

VALVE

DRAIN

ORG

DOOR

BLUE

INTERLOCK

BLUE

BLK

RED

SWITCH

BLK

ORG

BLK

ORG

TRANSFORMER

BLK

(240 VAC FOR 6000-2 AND 6000-4)

GND

POWER INPUT (120 VAC FOR 6000-1 AND 6000-3)

2A BREAKER

BLK

(24 VAC)

POWER

TERMINAL BLOCK

WHT

(24 RET)

BLK

INTERFACE

CYLINDER FULL

RED

ORG

BLK

16 PIN DIP PLUG

WHT

SENSOR

FULL

BLK

(240V)

BLK (120V)

(120V)

BLK

(240V)

BLK

TO CHASSIS

GROUNDED

BLK

GRN

CYLINDER

BLK

RELAY

WHT

BLK

WHT

RED

TOROID

POWER ELECTRODES

BLK

RED

WHT

ORG

MOLEX

42 3

ORG

RED

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Herrtronic® Model 6000

Page 21

Installation, Operation, & Maintenance Manual

EST-1522A

GT-116

GT-134

GT-118

EST-1409

EST-1415

EST-1514

EST-1409

165203-001

G-157

EST-003A

G-125

GT-116

EST-1512

EST-105A

4060

EST-1530

EST-353

EST-1519

EST-1001B

1860

EST-353

153742-001

EST-1141

EST-1142

EST-1225-KIT

1845

EST-1143

FILL SUB-ASSEMBLY

EST-1415

1095

DRAIN SUB-ASSEMBLY

GT-122

EST-596

EST-207

GT-262

GT-120

TANK ASSEMBLY

FV-17

GT-176-1

GT-202

EST-207

EST-1012

GT-262

EST-1533-1

(6000-3)

(6000-4)

Herrtronic® Model 6000

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Page 22

Installation, Operation, & Maintenance Manual

Ducted Version Parts List (6000-3 and 6000-4)

1845 Door Interlock 1860 KEP Nut, 6-32 121800-004 KEP Nut, 8-32 EST-003A Cylinder Full Interface EST-105A Toroid Transformer EST-596 Steam Hose EST-1001B Main Circuit Board EST-1141 Red Lamp EST-1142 Green Lamp (2) EST-1143 On Off Drain Switch EST-1225-KIT Drain Reservoir Kit EST-1409 Universal Bushing EST-1512 Transformer 120/240 to 24 VAC EST-1514 Relay, 2 pole, 20 A EST-1519 Circuit Breaker, 2A EST-1530 Terminal Block EST-1533-1 Drain Valve Kit EST-1542 Power Wire Assembly EST-1543 Grommet, Vibration Dampening EST-207 Clamp EST-353 Bushing GT-116 Celcon Compression Nuts GT-118 Fill Valve GT-134 Fan Interlock Relay GT-125 Conical Filter GT-202 Steam Cylinder Assembly (Standard 240V Units) GT-176-1 Low Conductivity Steam Cylinder Assembly (Standard 120V Units)

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Herrtronic® Model 6000

Page 23

Installation, Operation, & Maintenance Manual

Herrtronic® Model 6000

www.herrmidifier-hvac.com

Page 24

Engineered Humidification Systems

Herrmidifier

101 McNeill Rd. | Sanford, NC 27330

P: 800.884.0002 | F: 800.458.2379 | www.herrmidifier-hvac.com | cs@herrmidifier-hvac.com