Herrmidifier Herrtronic 6000 User Manual

Page 1
Engineered Humidification Systems
Herrtronic® 6000 Series
Electrode Steam Humidiers
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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
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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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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
3.
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
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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
5 FEET MINIMUM
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
1"
Back View
16 1/2"
1 1/2"
4 1/4"
5/16 x 5/8 DIA. KEYHOLE MOUNTING SLOT
1/2"
9"
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
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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"
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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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
L2
L1
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
copyright 1986 HERRMIDIFIER CO, INC.
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
R4
%
TP1
R18
TP2
SEC R23
J1 Connector
CR17
CR18
J1
CR18 diode drain tempering socket
Figure 12
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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
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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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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
53
27
WHT
RED
19
20
WHT
2
8
9
RELAY/TIMER
BLK
BLK
BLK
30
34
16
BLK
16
15
BLK
OHM
RED
BLK
14
RED
WHT
20
LIGHT
RED
25
18
WHT
FILL
VALVE
WHT
WHT
6
22
21
WHT
SERVICE
LIGHT
17
WHT
RED
WHT
11
7
DRAIN
VALVE
ORG
12
HUMIDISTAT
DOOR
RED
27
BLUE
28
INTERLOCK
BLUE
BLK
24
10
RED
25
BLK
ORG
SWITCH
1
3
2
4
5
6
BLK
ORG
9
5
15
12
2A BREAKER
TRANSFORMER
BLK
31
L2
L1
(240 VAC FOR 6000-2 AND 6000-4)
GND
POWER INPUT (120 VAC FOR 6000-1 AND 6000-3)
WHT
BLK
23
22
(24 RET)
(24 VAC)
BLK
35
RED
CYLINDER FULL
2
1
29
INTERFACE
3
ORG
3
8
BLK
4
87
16 PIN DIP PLUG
J1
11
WHT
BLK
BLK
BLK
RED
WHT
ORG
ORG
RED
RED
11
10
9
8
765
MOLEX
4
3
2
1
CYLINDER
FULL
BLK
BLK
(240V)
(240V)
40
BLK (120V)
32
32
(120V)
BLK
32
(240V)
BLK
BLK
31
32
33
BLK
35
BLK
GRN
ELECTRODE
19
WHT
BLK
13
BLK
13
BLK
BLK
36
34
BLK
37
RELAY
WHT
BLK
BLK
18
38
39
BLK
30
RED
RED
TOROID
POWER ELECTRODES
10
9
8
7
6
5
3
2
1
GROUNDED
TO CHASSIS
POWER
TERMINAL BLOCK
Herrtronic® Model 6000
FAN
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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-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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Installation, Operation, & Maintenance Manual
SWITCH
AIR PROVING
6000-3, -4 WIRING DIAGRAM
HIGH-LIMIT
SEE NOTE 1
HUMIDISTAT
TERM STRIP
CONTROLS
ORG
28
27
RED
RELAY
FAN INTERLOCK
BLK
WHT
16
20
21
WHT
15
BLK
FAN INTERLOCK (OPTIONAL)
2
3
1
RED
ORG26BLK
BLUE
28
16
FIELD WIRING
USED WHEN FAN INTERLOCK IS USED.
1. AIR PROVING SWITCH MUST NOT BE
NOTE:
5
4
27
LIGHT
FULL IND.
CYLINDER
OHM
237
RED
RED
20
WHT
POWER
RED
25
18
WHT
VALVE
FILL
WHT
19
WHT
WHT
6
22
21
WHT
LIGHT
SERVICE
17
WHT
RED
WHT
11
7
VALVE
DRAIN
ORG
12
DOOR
BLUE
26
INTERLOCK
BLUE
BLK
24
10
RED
25
SWITCH
1
3
2
4
5
6
BLK
ORG
9
5
15
BLK
12
ORG
TRANSFORMER
BLK
L2
L1
(240 VAC FOR 6000-2 AND 6000-4)
GND
POWER INPUT (120 VAC FOR 6000-1 AND 6000-3)
2A BREAKER
BLK
(24 VAC)
31
POWER
TERMINAL BLOCK
WHT
23
22
(24 RET)
BLK
35
INTERFACE
CYLINDER FULL
2
1
RED
29
3
ORG
3
8
BLK
4
BLK
13
87
16 PIN DIP PLUG
J1
11
WHT
SENSOR
FULL
BLK
BLK
(240V)
(240V)
40
BLK (120V)
32
32
(120V)
BLK
32
(240V)
BLK
BLK
31
TO CHASSIS
GROUNDED
32
33
BLK
35
BLK
GRN
CYLINDER
BLK
14
BLK
13
BLK
36
RELAY
18
WHT
38
BLK
39
BLK
WHT
19
RED
RED
TOROID
POWER ELECTRODES
10
9
8
7
6
5
3
2
1
11
BLK
10
BLK
98
BLK
RED
7
WHT
6
ORG
5
MOLEX
42 3
ORG
RED
RED
1
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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-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
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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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
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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
Form No. OM-273 09/11 ©Herrmidier 2011. All Rights Reserved.
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