Nordmann ES4 Installation Operation & Maintenance

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INSTALLATION- AND OPERATING INSTRUCTIONS

Steam air humidier

Nordmann ES4

2559439 EN 1310

NORDMANN

ENGINEERING

Contents

1 Introduction 4

1.1 To the very beginning 4

1.2 Notes on the installation and operating instructions 4

2 For your safety 6

3 Product Overview 8

3.1 Models overview 8

3.2 Identicationoftheunit 9

3.3 Steamhumidierconstruction 10

3.4 Functional description 11

3.5 Humidicationsystemoverview 13

3.6 Options 15

3.7 Accessories 16

3.7.1 Accessories overview 16

3.7.2 Accessory details 17

3.8 Standarddelivery 20

3.9 Storing/Transportation/Packaging 20

4 Notes for the planning engineer 21

4.1 Selecting the unit version 21

4.1.1 Calculating the maximum required steam capacity 21

4.1.2 Selecting the unit 22

4.2 Selecting the options an accessories 22

4.3 Selecting the control system 23

5 Mounting and installation work 25

5.1 Importantnotesformountingandinstallationwork 25

5.2 Installation overviews 26

5.3 Mounting the unit 28

5.3.1 Notes on locating the unit 28

5.3.2 Mountingthehumidier 30

5.3.3 Inspecting the installed unit 31

5.4 Steam installation 32

5.4.1 Overview steam installation 32

5.4.2 Positioningandmountingofthesteam distribution pipes 33

5.4.3 Installing the steam distributors 37

5.4.4 PositioningandmountingofthefanunitsFAN4N... 38

5.4.5 Installingthesteamhose 39

5.4.6 Common steam and condensate line errors 43

5.4.7 Inspecting the steam installation 44

5.5 Water installation 45

5.5.1 Overview water installation 45

5.5.2 Notes on water installation 46

5.5.3 Inspecting the water installation 47

5.6 Electric installation 48

5.6.1 Wiring diagram Nordmann ES4 48

5.6.2 Notesonelectricinstallation 49

5.6.3 Unitconguration 52

5.6.4 Inspecting the electrical installation 53

6 Operation 54

6.1 Functionofthedisplayandoperatingelements 54

6.2 Commissioning 55

6.3 Notes on operation 56

6.3.1 FunctionoftheLED'sininfomode 56

6.3.2 Remoteoperatingandfaultindication 56

6.3.3 Inspections during operation 57

6.4 Carrying out manual draining 57

6.5 Takingtheunitoutofoperation 57

7 Maintenance 58

7.1 Important notes on maintenance 58

7.2 Maintenancelist 59

7.3 Removingandinstallingpartsformaintenance 60

7.3.1 Removalandinstallationofthesteamcylinder 60

7.3.2 Removalandinstallationofthedraincup 63

7.3.3 Removalandinstallationofthewatercup

and the water hoses 64

7.3.4 Removalandinstallationofthedrainvalve 65

7.3.5 Removalandinstallationoftheinletvalve 66

7.4 Notes on cleaning the unit components 67

7.5 Notes on cleaning agents 68

7.6 Resetting the maintenance indication 68

8 Fault elimination 69

8.1 Faultindication 69

8.2 Malfunctionlists 70

8.2.1 Systemfaults 70

8.2.2 Unitfaults 70

8.3 Notesonfaultelimination 72

8.4 Resettingtheerrorindication(redLEDlights) 72

9 Taking out of service/Disposal 73

9.1 Takingoutofservice 73

9.2 Disposal/Recycling 73

10 Productspecications 74

10.1 Technicaldata 74

10.2 Unitdimensions 75

1 Introduction

1.1 To the very beginning

We thank you for having purchased the steam humidier Nordmann ES4.

The steam humidier Nordmann ES4 incorporates the latest technical ad van ces and meets all recognized safety standards. Nevertheless, improper use of the Nordmann ES4 may result in danger to the user or third parties and/or impairment of material assets.

To ensure a safe, proper, and economical operation of the steam humidier Nordmann ES4, please observe and comply with all information and safety instructions contained in the present installation and operating instructions as well as the instructions given in the manuals for the components used in the humidication system.

If you have questions, which are not or insufciently answered in this documentation, please contact your Nordmann supplier. They will be glad

to assist you.

1.2 Notes on the installation and operating instructions

Limitation

The subject of these installation and operating instructions is the steam humidier Nordmann ES4. The various accessories (e.g. steam

distributor, steam distribution system, etc.) are only described insofar as this

is necessary for proper operation of the equipment. Further information on

accessories can be obtained in the respective instructions.

These installation and operating instructions are restricted to the installa- tion, commissioning, operation, servicing and trouble shooting of the steam humidier Nordmann ES4 and is meant for well trained personnel

being sufciently qualied for their respective work.

These installation and operating instructions are supplemented by various separate items of documentation (spare parts list, manuals for accessories, etc.). Where necessary, appropriate crossreferences are made to these publications in the present documentation.

Explanation of the symbols used in this manual

CAUTION!

The catchword “CAUTION” designates notes in this documentation that, if neglected, may cause damage and/or malfunction of the unit or other

material assets.

WARNING!

The catchword “WARNING” used in conjunction with the general caution symbol designates safety and danger notes in this documentation that, if neglected, may cause to injury to persons.

DANGER!

The catchword “DANGER” used in conjunction with the general caution symbol designates safety and danger notes in this documentation that, if neglected, may lead to severe injury or even death of persons.

Safekeeping

Please safeguard these installation and operating instructions in a safe place, where it can be immediately accessed. If the equipment changes hands, the documentation should be passed on to the new operator.

If the documentation gets mislaid, please contact your Nordmann supplier.

Language versions

The present installation and operating instructions are available in various languages. Please contact your Nordmann supplier for information.

The present installation and operating instructions are protected under the Copyright Act. Passingon and reproduction of the manual (or part thereof) as well as exploitation and communication of the contents are prohibited without written permission by the manufacturer. Violation of copyright terms is subject to legal prosecution and arises liability for indemnication.

The manufacturer reserves the right to fully exploit commercial patent rights.

2 For your safety

General

Every person working with the Nordmann ES4 must have read and understood the present installation and operating instructions before carrying out any work. Knowing and understanding the contents of the installation and operating instructions is a basic requirement for protecting the personnel against any kind of danger, to prevent faulty operation, and to operate the unit safely and correctly.

All ideograms, signs and markings applied to the unit must be observed and kept in readable state.

Qualication of personnel

All actions described in the present Installation and operating instructions (installation, operation, maintenance, etc.) must be carried out only by well

trained and sufciently qualied personnel authorised by the owner.

For safety and warranty reasons any action beyond the scope of this manuals must be carried out only by qualied personnel authorised by the

manufacturer.

It is assumed that all persons working with the Nordmann ES4 are familiar and comply with the appropriate regulations on work safety and the preven-

tion of accidents.

This unit may not be used by persons (including children) with reduced physical, sensory or mental abilities or persons with lacking experience and/ or knowledge, unless they are supervised by a person responsible for their safety or they received instructions on how to operate the unit. Children must be supervised to make sure that they do not play with unit.

Intended use

The steam humidier Nordmann ES4 is intended exclusively for air humidication via a steam distributor or a fan unit approved by the manufacturer within the specied operating conditions (see chapter 10

“Product specications”). Any other type of application without the express written consent of the manufacturer is considered as not conforming with the intended purpose and may lead to the Nordmann ES4 becoming dangerous.

Operation of the equipment in the intended manner requires that all the information in these instructions is observed (in particular the safety instructions).

Danger that may arise from the unit

DANGER! Danger of electric hazard!

The Nordmann ES4 is mains powered. One may get in touch with live

parts when the unit is open. Touching live parts may cause severe injury or danger to life.

Prevention: Before carrying out any work set the Nordmann ES4 out of operation as described in chapter 6.5 (switch off the unit, disconnect it from the mains and stop the water supply) and secure the unit against inadvertent powerup.

WARNING! Hot water vapour - Danger of scalding!

The Nordmann ES4 produces hot water vapour. There is danger of scalding when getting in touch with hot water vapour.

Prevention: Do not carry out any work on the steam system during

operation (steam lines, steam distributor, etc.). If the steam system is leaky set the Nordmann ES4 immediately out of operation as described in chapter 6.5. Correctly seal the steam system before putting the unit

into operation again.

WARNING! Danger of burning!

During operation the components of the steam system (steam cylinder, steam distributor, etc.) get very hot (up to 100 °C). There is danger of burning when touching the hot components.

Prevention: Before carrying out any work on the steam system set the

Nordmann ES4 out of operation as described in chapter 6.5, then wait until the components have cooled down sufciently thus preventing danger of burning.

Behaviour in case of danger

If it is suspected that safe operation is no longer possible, then the Nordmann ES4 should immediately be shut down and secured against accidental power-up according to chapter 6.5. This can be the case under the following circumstances:

– if the Nordmann ES4 is damaged

– if the electrical installations are damaged – if the Nordmann ES4 is no longer operating correctly – if connections and/or piping are not sealed

All persons working with the Nordmann ES4 must report any alterations to the unit that may affect safety to the owner without delay.

Prohibited modications to the unit

No modications must be undertaken on the Nordmann ES4 without the

express written consent of the manufacturer.

For the replacement of defective components use exclusively original ac- cessories and spare parts available from your Nordmann supplier.

3 Product Overview

3.1 Models overview

Steam air humidiers Nordmann ES4 are available with different heating voltages and steam capacities ranging from 5 kg/h up to a max. of 65 kg/h.

Heating voltage ** Max. steam capacity

in kg/h

Model

Nordmann ES4

Unit size

Unit small Unit large

400V3

(400 V/3~/50...60 Hz)

5 534 1

8 834 1

15 1534 1

23 2364 1

32 3264 1

45 4564 1

65 6564 1

400V2

(400 V/2~/50...60 Hz)

5 524 1

8 824 1

230V3

(230 V/3~/50...60 Hz)

5 532 1

8 832 1

15 1532 1

23 2362 1

32 3262 1

230V1

(230 V/1~/50...60 Hz)

5 522 1

8 822 1

** Other heating voltages on request

Key model designation

Example:

Nordmann ES4 4564 400V3

Product designation:

Unit model:

Heating voltage: 400V/3~/50...60Hz: 400V3 400V/2~/50...60Hz: 400V2 230V/3~/50...60Hz: 230V3 230V/1~/50...60Hz: 230V1

3.2 Identicationoftheunit

The identication of the unit is found on the type plate:

Nordmann Engineering AG, CH-8808 Pfäfkon

Type: ES4 4564 Ser.Nr.: XXXXXXX 02.10 Heating voltage: 400V / 3~ / 50...60Hz Power: 33.8 kW

Steam capacity: 45.0 kg/h Ctrl. Voltage: 230V / 1~ / 50...60Hz Water pressure: 1...10 bar

Made in Switzerland

Type designation Serial number (7 digits) Month/Year

Heating voltage

Maximum steam capacity per unit

Admissible water supply pressure

Power consumption

Control voltage

Field with certication symbols

3.3 Steamhumidierconstruction

1 Housing (small, large) 2 Cable openings, top side 3 SC pump (option)

4 Main contactor

5 Power board 6 Terminals heating voltage (option) 7 Remote operating and fault

indication board (option) 8 Control board with ES4 Card 9 Power supply unit 24 V (option)

10 Drain/info key 11 Operation status indicators

12 Unit switch

13 Water cup

14 Filling hose 15 Water supply hose 16 Overow hose 17 Drain valve 18 Inlet valve 19 Water supply connector

20 Drain connector

21 Cable openings, bottom side 22 Type plate 23 Steam cylinder 24 Level sensor 25 Electrode plug 26 Steam outlet

gure shows small unit

3.4 Functional description

The steam humidier Nordmann ES4 is a pressureless steam generator that utilizes an electrode heating. The steam humidier Nordmann ES4 is designed for air humidication via a steam distributor (steam distribution pipe, fan unit or steam distribution system MultiPipe).

Steam distribution pipe

Condensate hose

with siphon

Steam hose

Water cup

Overow hose

Filling hose

Water supply hose

Inlet valve

Base tub

Drain valve

Steam cylinder

Electrodes

Level sensor

Control board

Power board

Unit switch

Main contactor

Current sensor

Steam generation

Any time steam is requested, the electrodes are supplied with voltage via main contactor. Simultaneously, the inlet valve opens and water enters the steam cylinder from the bottom via water cup and supply line. As soon as the electrodes come in contact with the water, current begins to ow between the electrodes, eventually heating and evaporating the water. The more the electrode surface is exposed to water, the higher is the current consumption

and thus the steam capacity.

Upon reaching the requested steam capacity, the inlet valve closes. If the steam generation decreases below a certain percentage of the required capacity, due to lowering of the water level (e.g. because of the evaporation process or drainage), the inlet valve opens until the required capacity is available again. If the required steam capacity is lower than the actual output, the inlet valve is closed until the desired capacity is achieved by lowering of the water level (evaporation process).

Level monitoring

A sensor provided in the steam cylinder cover detects when the water level gets too high. The moment the sensor comes in contact with water, the inlet valve closes.

Drainage

As a result of the evaporation process, the conductivity of the water increases due to an escalating mineral concentration. Eventually, an inadmissibly high current consumption would take place if this concentration process were permitted to continue. To prevent this concentration from reaching a value, unsuitably high for the operation, a certain amount of water is perio dically drained from the cylinder and replaced by fresh water.

Control

The steam production can be controlled with an external 010V continuous controller or an external humidistat (24 VDC On/Off control).

3.5 Humidicationsystemoverview

System overview duct humidication

 1 Steamhumidier  2 Steamconnector  3 Waterdrainconnector  4 Watersupplyconnector  5 WaterconnectionhoseG3/4"-G3/8"

(includedinthedelivery)  6 Filtervalve(accessory“Z261”)  7 Manometer(installationrecommended)  8 Funnelwithsiphon(buildingside)

 9 Waterdrainhose(includedinthedelivery) 10 Serviceswitchcontrolvoltagesupply(buildingside) 11 Serviceswitchheatingvoltagesupply(buildingside) 12 Steamhose(accessory“DS..”) 13 Condensatehose(accessory“KS10”) 14 Steamdistributionpipe(accessory“DV41-..”/“DV71-..”) 15 Steamdistributionsystem(accessory“MultiPipe”) 16 Humiditycontroller0-10VorHumidistat 17 Safetyhumidistat

125...1250µS/cm

1...10bar

1...40°C

ONOFF

DS35

DS22

Z261

ONOFF

KS10

DV41

DV71

MultiPipe

System overview room humidication

125...1250 µS/cm

1...10 bar

1...40 °C

1 Steam humidier

2 Steam connector 3 Water drain connector

4 Water supply connector

5 Water connection hose G 3/4"- G 3/8"

(included in the delivery) 6 Filter valve (accessory “Z261”) 7 Manometer (installation recommended) 8 Funnel with siphon (building side)

9 Water drain hose (included in the delivery)

10 Service switch control voltage supply (building side) 11 Service switch heating voltage supply (building side) 12 Steam hose (accessory “DS..”) 13 Condensate hose (accessory “KS10”) 14 Ventilation unit (accessory “FAN4 N...”)

15 Humidity controller 010V or Humidistat 16 Safety humidistat

ONOFF

Z261

DS80

KS10

FAN4 N S W

FAN4 N M W

FAN4 N L W

3.6 Options

Nordmann ES4...

522 524 532 534

822 824 832 834

1532 1534

2362 2364

3262 3264

4564 6564

Remote operating and fault indication

PCB with relay contacts for the connection of remote displays for “Operation”, “Steam”, “Fault” and “Service”.

1xRFI

Overpressure set

Kit for mounting the water cup to the unit cover when

operating the steam humidi ers in systems with a duct

air pressure of up to 10 kPa.

1xOPS

Terminals heating voltage

Separate terminals for systems where direct connection of heating voltage to main contactor (standard version) is not permitted by local regulations.

S-THV

M-THV

L-THV

Steam hose connector with condensate trap 1xCT22 1xCT35 2xCT35

Cable glands (with metric thread) CG

Internal control voltage 1x

S-CVI

M-CVI

L-CVI

Transformer (400V/230V) 1xM-Trafo 1xL-Trafo

SC pump (lime management system)

The SC pump keeps the solved minerals in the water of the steam cylinder in motion, in order to discharge them with the automatic drain cycles.

1xSC

24 VDC power supply

24 VDC power supply for the external humidity sensor

1x24VDC

Nordmann ES4... (400 V/3~/50...60 Hz)

534 834 1534 2364 3264 4564 6564

Steam cylinder for low water conductivity from 80 to 125 µS/cm

534A-L1x834A-L1x1534A-L1x2364A-L1x3264A-L1x4564A-L

___

3.7 Accessories

3.7.1 Accessories overview

Accessories for water installation

Nordmann ES4...

522 524 532 534

822 824 832 834

1532 1534

2362 2364

3262 3264

4564 6564

Filter valve Z261 (1 pcs. per system)

Accessories for steam installation

Nordmann ES4...

522 524 532 534

822 824 832 834

1532 1534

2362 2364

3262 3264

4564 6564

Steam distribution pipe

(details see chapter 3.7.2)

1xDV41-... 1xDV71-... 2xDV71-...

Steam distribution system MultiPipe

(details see chapter 3.7.2)

--- System 1 System 2

Fan unit

(details see chapter 3.7.2)

FAN4 N S W FAN4 N M W FAN4 N L W

Steam hose / meter 1xDS22 1xDS35 2xDS35

EcoTherm insulation hose / meter 1xECT22 1xECT60 2xECT60

Condensate hose / meter 1x KS10

Accessories for humidity control

Nordmann ES4...

522 524 532 534

822 824 832 834

1532 1534

2362 2364

3262 3264

4564 6564

Duct humidistat HBC (1 pcs. per system)

Room humidistat HSC (1 pcs. per system)

General accessories

Nordmann ES4...

522 524 532 534

822 824 832 834

1532 1534

2362 2364

3262 3264

4564 6564

All-weather protective housing Layout according to the separate data sheet

3.7.2 Accessory details

3.7.2.1 Steam distribution pipe DV41-.../DV71-...

The steam distribution pipes are selected on the basis of the duct width (for horizontal installation) or the duct height (for vertical installation) and

the capacity of the steam humidier. Important! Always select the longest possible steam distribution pipe (opti

mum humidication distance).

Steam distribution pipes for

Nordmann ES4

Length (L) steam

distribution pipe

Duct width (B)

Type DV41-.. Type DV71-.. in mm

in mm

41-200 200 210...400

41-350 71350 350 400...600

41-500 71500 500 550...750

41650 71650 650 700...900

41-800 71800 800 900...1100

41-1000 711000 1000 1100...1300

41-1200 711200 1200 1300...1600

711500 1500 1600...2000

711800 1800 2000...2400

712000 2000 2200...2600

712300 2300 2500...2900

712500 2500 2700...3100

Material: CrNi steel

special length on request

Note: If the humidication distance (see chapter 5.4.2) has to be reduced for technical reasons, the amount of steam per basic unit must be divided between two steam distribution pipes or the steam distribution system MultiPipe must be used. If this is the case, contact your Nordmann supplier.

3.7.2.2 MultiPipe steam distribution system

The MultiPipe steam distribution system is used in ventilation ducts with a short humidication distance (for the calculation of the humidication distance refer to chapter 5.4.2). When ordering an MultiPipe system the duct dimension must be specied. Please consult the data in the following table.

MultiPipe Number of steam

connectors

Max. steam

capacity

in kg/h

Duct dimensions

Width B

in mm

Height H

in mm

System 1 1 32 (23) 450-1500 4501650

System 2 2 65 (45) 450-2200 450-2200

For duct widths <600 mm the value in brackets apply

3.8.2.3 Fan units FAN4 N...

The fan units FAN4 N... – in combination with the steam humidiers Nordmann ES4 – are used for direct room humidication. They are mounted above the unit to the wall.

The type of fan unit is dependent on the steam capacity and on the type of

the humidier and can be gathered from the table in chapter 3.7.1.

Note: Further information on the fan units FAN4 N... can be found in the separate manual supplied with the fan unit.

3.8 Standard delivery

The standard delivery includes:

– Steam humidier Nordmann ES4 with water drain hose and water con-

nection hose G 3/4"  G 3/8" equipped with the options ordered according to chapter 3.6, xing set and installation and operating instructions (this document), packaged in cardboard box – Unit small (WxHxD): 445 mm x 755 mm x 360 mm, shipping weight:

26 kg

– Unit large (WxHxD): 560 mm x 820 mm x 435 mm, shipping weight:

31 kg

– Ordered accessories with operating instructions according chapter 3.7,

packed separately

– Spare parts list

3.9 Storing/Transportation/Packaging

Storing

Store the unit in a protected area meeting the following requirements:

– Room temperature: 1 ... 40 °C

– Room humidity: 10 ... 75 %rh

Transportation

For optimum protection always transport the unit in the original packaging.

The weight of the small and the large unit is more than 20 kg (weight without packaging: small unit 23 kg, large unit 28 kg). Therefore, always transport the unit with the help of another person or use a forklift or a crane. Always place the unit on its back side.

Packaging

Keep the original packaging of the Nordmann ES4 for later use.

In case you wish to dispose of the packaging, observe the local regulations on waste disposal. Never dispose of the packaging to the environment.

4.1 Selecting the unit version

To select the unit version the following planning steps are required:

1. Calculating the required maximum steam capacity according chapter

4.1.1

2. Selecting the unit version from the table in chapter 4.1.2

4.1.1 Calculating the maximum required steam capacity

The maximum required steam capacity must be calculated based on one of the following formulas:

V • ρ

mD = • (x2 - x1)

1000

4 Notes for the planning engineer

mD: maximum steam demand in kg/h V: volume of supply air portion per hour in m3/h (for indirect room humidi-

cation) or room volume to be humidied per hour in m3/h (for direct room humidication)

ρ: specic gravity of air in kg/m

ε: specic volume of air in m3/kg x2: desired absolute room air humidity in g/kg x1: minimum absolute supply air humidity in g/kg

The values for ρ, ε, x

and x1 can be gathered from the h,x-diagram or

the Carrier-Diagram for moist air respectively.

Important notes:

– The required maximum steam capacity depends on the specic ap-

plication and the installation. The calculated steam capacity based on the above formulas, the h,x diagram and the condition of the air to be humidied does not consider any steam loss (e.g. due to condensation in the steam hoses and the steam distributors), any heat loss of the unit as well as any absorption or release of humidity of materials located in the room being humidi ed. In addition, the calculated steam capacity does not consider any losses caused by the draining rate depending on the water quality as well as any losses occur if the steam humidier is operated on a mains circuit with a ground fault circuit interrupter.

The total amount of losses depends on the entire system and must be taken into consideration when calculating the required steam capacity. If you have any questions regarding the calculation of the steam capacity please contact your Nordmann supplier.

– For systems where the max. required steam capacity varies extensively

(e.g. for test facilities or for systems with variable air volume ow, etc.), please contact your Nordmann supplier.

V

= • (x2 - x1)

1000 • ε

4.1.2 Selecting the unit

Heating voltage ** Max. steam capacity

in kg/h

Model

Nordmann ES4 ..

Unit size

Unit small Unit large

400V3

(400 V/3~/50...60 Hz)

5 534 1

8 834 1

15 1534 1

23 2364 1

32 3264 1

45 4564 1

65 6564 1

400V2

(400 V/2~/50...60 Hz)

5 524 1

8 824 1

230V3

(230 V/3~/50...60 Hz)

5 532 1

8 832 1

15 1532 1

23 2362 1

32 3262 1

230V1

(230 V/1~/50...60 Hz)

5 522 1

8 822 1

** Other heating voltages on request

4.2 Selecting the options an accessories

For selecting the options and accessories see chapter 3.6 and 3.7.

Nordmann ES4 4564 400V3

4.3 Selecting the control system

The various control systems

– System 1: Room humidity control

System 1 is suited for direct room humidication and air condition- ing systems with mainly recirculated air. The humidity sensor or

humidistat respectively is preferably located in the room itself or in the exhaust air duct.

– System 2: Room humidity control with continuous limitation of the

supply air humidity

System 2 is suited for air conditioning systems with a large portion of supply air, low supply air temperature, post-humidication, or vari- able airow volume. If the supply air hum idity exceeds the preset value,

the continuous limitation is effected prior to the room hum idity control. The humidity sensor (A1) is preferably located in the exhaust air duct or in the room itself. The humidity sensor (A2) for the limitation of the supply air humidity is located in the supply air duct after the steam distribution pipe. This control system requires a continuous controller with

the option to connect a second humidity sensor.

Attention! The continuous limitation of the supply air humidity is no substitute for the safety humi distat.

A1 humidity sensor

B1 ventilation interlock B2 airow monitor

B3 safety humidistat B4 humidistat PIE External continuous controller

(e.g. PI controller) Y input signal from A1

A1/2 humidity sensor

B1 ventilation interlock B2 airow monitor

B3 safety humidistat PI

External continuous controller (e.g. PI controller) Y input signal from A1 Z input signal from A2

Nordmann

ES4

Nordmann

ES4

– System 3: Supply air humidity control with continuous output limi-

tation

Supply air humidity control (humidity sensor installed in supply air duct) should be used only where room humidity control is impracticable for technical reasons. Such systems always require

a PIcontroller. The humidity sensor (A1) is located in the supply air duct after the steam distribution pipe. The humidity sensor (A2) for the continuous output limitation is located in the supply air duct before the steam distribution pipe. Such a system requires a PIcontroller with the option to connect

a second humidity sensor.

A1/2 humidity sensor

B1 ventilation interlock B2 airow monitor

B3 safety humidistat PIE External PI controller

Y input signal from A1 Z input signal from A2

Which humidity control system for which application?

Application Location of the humidity sensor

room or exhaust air duct supply air duct

Air conditioning systems with:

– supply air portion up to 33% System 1 System 1

– supply air portion up to 66% System 1 or 2 System 2 or 3

– supply air portion up to 100% System 2 System 3

– supply air humidity control — System 3

Direct room humidication System 1 —

Please contact your Nordmann supplier, if your application meets the following conditions:

– Humidication of small rooms up to 200 m

– Air conditioning systems with a high number of air exchanges – Systems with variable air volume ow – Test facilities with extreme control accuracy requirements – Rooms with a high variation in max. steam capacity – Systems with temperature uctuations – Cold rooms and systems with dehumidication

Admissible input signals

– 0...10VDC (external continuous controller) – 24 V On/Off (humidistat)

Nordmann

ES4

5 Mounting and installation work

5.1 Important notes for mounting and installation work

Qualication of personnel

All mounting and installation work must be carried out only by well qualied personnel authorised by the owner. It is the owner’s responsibility

to verify proper qualication of the personnel.

General note

Strictly observe and comply with all information given in the present installation and operating instructions regarding the location of the unit and the installation of water, steam and electricity.

Observe and comply with all local regulations dealing with water, steam and electrical installations.

Safety

Some installation work requires removal of the unit cover. Please note the following:

DANGER! Danger of electric hazard!

You may get in touch with live parts when the unit is open. The steam humidier must be connected to the mains only after all mounting and installation work has been completed and the cover has been relocated properly.

CAUTION!

The electronic components inside the humidier are very sensitive to electrostatic discharge. When the unit is open for installation work, appropriate measures must be taken to protect these components against damage caused by electrostatic discharge (ESD protection).

≥ 40 mm

min. 50 cm

ONOFF

DS35

DS22

Z261

ONOFF

125...1250 µS/cm

1...10 bar

1...40 °C

ø14/7 mm

G 3/4"

G 1/2"

G 3/8"

DV41

DV71

Pmin

1500 Pa

-800 Pa

Pmax

Rmin. 300 mm

Ømin.

200 mm

min. 300 mm

min. 20 % –

KS10

min. 5 %

–

min. 20 %

L1 N SC1 SC2

max.

ES4

ext.

CONT.SIGN

V+ IN GND

+ –

0-10V

CONT.SIGN

V+ IN GND

On/Off

On/Off Mode

JP1

On/Off Mode

JP1

ES4

ext.

ES4

ext.

230V/1~/50...60Hz

L1 N

L1 N SC1 SC2

ES4

ext.

L1 L2 L3

400 V/3~/50..60 Hz 230 V/3~/50..60 Hz

L1 N PE

230 V/1~/50..60 Hz

L1 L2

400 V/2~/50..60 Hz

ES4

ext.

A1 / A2

ø 30 mm

5.2 Installation overviews

Installation overview duct humidication

Water installation

see chapter 5.5

Steam installation

see chapter 5.4

Mounting the unit

see chapter 5.3

Control voltage

Heating voltage

On/Off-ControlContinuous control 0-10V

External safety chain

Electric installation

see chapter 5.6

L1 N SC1 SC2

max.

ES4

ext.

CONT.SIGN

V+ IN GND

+ –

0-10V

CONT.SIGN

V+ IN GND

On/Off

On/Off Mode

JP1

On/Off Mode

JP1

ES4

ext.

ES4

ext.

L1 L2 L3

400 V/3~/50..60 Hz 230 V/3~/50..60 Hz

L1 N PE

230 V/1~/50..60 Hz

L1 L2

400 V/2~/50..60 Hz

ES4

ext.

L1 N SC1 SC2

ES4

ext.

FAN4 N...

L1 N

ONOFF

FAN4 N S W

FAN4 N M W

FAN4 N L W

Z261

125...1250 µS/cm

1...10 bar

1...40 °C

ø14/7 mm

≥ 40 mm

G 3/4"

G 1/2"

G 3/8"

min. 50 cm

Ømin.

100 mm

A1 / A2

ø 30 mm

DS80

KS10

Installation overview room humidication

Water installation

see chapter 5.5

Steam installation

see chapter 5.4

Mounting the unit

see chapter 5.3

Control voltage

Heating voltage

On/Off-ControlContinuous control 0-10V

External safety chain

Electric installation

see chapter 5.6

5.3 Mounting the unit

5.3.1 Notes on locating the unit

Nordmann ES4 ...

522 524 532 534

822 824 832 834

1532 1534

2362 2364

3262 3264

4564 6564

Dimensions

Housing (XxYxZ) in mm 377x279x612 1 1 1

492x351x670 1 1 1 1

Weights

Net weight in kg 19 19 19 28 28 28 28

Operating weight in kg 24 24 30 65 65 65 65

min. 400 mm

min. 600 mm

min. 250 mm

min. 400 mm

min. 600 mm

60...70 °C

1 ... 40 °C max. 75 %rh IP20

The installation site of the steam humidier depends largely on the location of the steam distributor (see chapter 5.4). To ensure proper functioning of the steam humidier and to obtain an optimal efciency, the following points must be considered and observed when choosing the location for the steam humidier:

– Install the steam humidier so that the length of the steam hose is kept

as short as possible (max. 4 m) and that the minimum bend radius

(R= 300 mm) and up-slope (20 %) or down-slope (5 %) of the steam

hose is observed (see chapter 5.4.5).

– The steam humidiers Nordmann ES4 are designed for wallmount-

ing. Make sure that the construction (wall, pillar, oormounted console, etc.) to which the humidiers are to be mounted, offers a sufciently high load-bearing capacity (take notice of the weight information found in the dimensions and weights table above), and is suitable for the installation.

CAUTION!

Do not mount the steam humidier directly to the ventilation duct (insufcient stability).

– The back panel of the Nordmann ES4 is retaining heat during operation

(max. surface temperature of the metal housing approx. 60  70 °C). Make sure, therefore, that the construction (wall, pillar, etc.) to which the units are to be mounted, does not consist of heatsensitive material.

– Install the steam humidier in such a manner that it is freely accessible

with sufcient space available for maintenance purposes (refer to the above illustration for minimum distances).

– The Nordmann ES4 is protected according to IP20. Make sure the units

are installed in a dripproof location and the admissible ambient conditions are complied with.

– The steam humidier Nordmann ES4 may only be installed in rooms

with a oor drain.

CAUTION!

If for some reason the Nordmann ES4 must be installed in a location without oor drain, it is mandatory to provide a leakage monitoring device to safely interrupt the water supply in case of leakage.

– When xing the Nordmann ES4 use only the xing materials supplied

with the unit. If xing with the materials supplied is not possible in your particular case, select a method of xing that is of similar stability.

– The Nordmann ES4 is designed for installation and operation within

buildings (admissible temperature range see chapter 10.1). For outdoor operation the Nordmann ES4 must be placed in a weather protective housing. If ambient temperatures near or below the freezing point have to be expected, the protective housing must equipped with a thermostat controlled heating of sufcient capacity. The water supply pipe must be equipped with a traceheating and must be insulated up to the protective

housing.

5.3.2 Mountingthehumidier

Procedure

1. Mark the attachment point “A” on the wall.

2. Drill hole for attachment point “A” (diameter: 8 mm, depth: 40 mm).

3. Insert the supplied plastic plug, and tighten the screw until the distance between the wall and the screw head is 4 mm.

4. Unlock the two screws xing the front panel to the unit, then remove the front panel.

5. Hang up the unit onto the screw and adjust it horizontally and vertically using a spirit level. Then, mark the xing points “B”.

6. Drill the holes for the xing points “B” (diameter: 8 mm, depth: 40 mm).

7. Insert the supplied plastic plugs, and tighten the screws until the distance between the wall and the screw head is 4 mm.

8. Hang the unit up onto the screws. Before tightening the screws, readjust the unit with the spirit level.

9. Reattach the front panel and secure it with the two screws.

Dimension Housing size

small large

a 189 mm 246 mm b 61 mm 52 mm

c 490 mm 547 mm d 120 mm 180 mm e 120 mm 180 mm

5.3.3 Inspecting the installed unit

Check the following points:

Is the unit installed in the correct place (see chapter 5.3.1)?

Is the supporting surface stable enough?

Is the unit correctly aligned, vertically and horizontally?

Is the unit properly secured (see chapter 5.3.2)?

Has the front panel of the unit been relocated and correctly xed with

the two screws?

5.4 Steam installation

5.4.1 Overview steam installation

DS35

DS22

DV41

DV71

Pmin

1500 Pa

-800 Pa

Pmax

Rmin. 300 mm

Ømin.

200 mm

min. 300 mm

min. 20 % –

KS10

min. 5 %

–

min. 20 %

Ømin.

100 mm

DS80

KS10

FAN4 N S W

FAN4 N M W

FAN4 N L W

min. 20 %

–

The calculation of the humidication distance “BN” is dependent on several factors. For a rough estimation of the humidication distance “BN”, the following table is useful. Recommended standard values listed in this table are based on a supplyair temperature range of 15 °C to 30 °C. The values given in bold type only apply to steam distribution pipes DV41-... and

DV71-..., the values in brackets apply to the MultiPipe steam distribution system.

Humidity at inlet

ϕ1 in %rh

Length of humidication distance BN in m

Humidity at outlet ϕ2 in %rh

40 50 60 70 80 90

5 0,9 (0,22) 1,1 (0,28) 1,4 (0,36) 1,8 (0,48) 2,3 (0,66) 3,5 (1,08)

10 0,8 (0,20) 1,0 (0,26) 1,3 (0,34) 1,7 (0,45) 2,2 (0,64) 3,4 (1,04)

20 0,7 (0,16) 0,9 (0,22) 1,2 (0,30) 1,5 (0,41) 2,1 (0,58) 3,2 (0,96)

30 0,5 (0,10) 0,8 (0,17) 1,0 (0,25) 1,4 (0,36) 1,9 (0,52) 2,9 (0,88)

40 – 0,5 (0,11) 0,8 (0,20) 1,2 (0,30) 1,7 (0,45) 2,7 (0,79)

50 – – 0,5 (0,13) 1,0 (0,24) 1,5 (0,38) 2,4 (0,69)

60 – – – 0,7 (0,16) 1,2 (0,30) 2,1 (0,58)

70 – – – – 0,8 (0,20) 1,7 (0,45)

φ1 in %rh: Relative supply air humidity prior to humidication at the lowest supply air tem-

perature

φ2 in %rh: Relative supply air humidity after the steam distribution pipe at maximum capac-

ity

For duct widths <600 mm the humidication distance for the MultiPipe system increases by approx. 50%

5.4.2 Positioning and mounting of the steam distribution pipes

The location for the steam distribution pipes should be determined at the time of dimensioning the air conditioning system. Please note the following instructions to ensure proper humidication of the duct air.

Calculating the humidication distance

The water vapour, emitting from the steam distribution pipes, requires a certain distance to be absorbed by the ambient air so that it is no longer visible as steam. This distance is referred to as humidication distance

“B

” and serves as a basis for the determination of the minimum distances

from the upstream components in the system.

BN: Humidication distance B

E: Expansion and mixing zone

φ1: Supply air humidity before humidication φ2: Supply air humidity after humidication

Example

given: ϕ1= 30 %rh, ϕ2= 70 %rh

humidication distance B

: 1,4 m

(0.36 m for steam distribution system MultiPipe)

Note: If the humidication distance has to be reduced for technical reasons, the amount of steam per basic unit must be divided between two steam distribution pipes or the steam distribution system MultiPipe must be used. If this is the case, contact your Nordmann supplier.

Minimum distances to be observed

To prevent the water vapour, that is emitting from the steam distribution pipe, from condensing on downstream system components, a minimum distance to the steam distribution pipe must be observed (depends on the humidication distance “B

”).

0.5 x B

50 mm

after expansion

0.5 x B

1 x B

before bend

1 x B

before/after constriction

before branch

before diffuser

before/after lter/register before/after fan, zone exit

* 2,5 x B

before aerosol lter

before control sensor

1.5 x B

N *

50 mm

1 x B

Installation notes and dimensions

The steam distribution pipes are designed for either horizontal installation (on the duct wall) or, with accessories, for vertical installation (in the duct oor). The outlet orices should always point upwards and at right

angles to the airow.

If possible, the steam distribution pipes should be installed on the pressure

side of the duct (max. duct pressure 1500 Pa). If the steam distribution pipes are installed on the suction side of the duct, the maximum vacuum

must not exceed 800 Pa.

Select a location for the installation, tailored to suit your duct (see the following illustrations) and position the steam distribution pipes in the duct so that a uniform distribution of steam is achieved.

1 x B

5 x B

Positioning the steam distribution pipes in the duct

In positioning the steam distribution pipes, the following dimensions should be observed:

Note: When locating the MultiPipe steam distribution system please note

the instructions in the separate documentation for this product.

Guidelines for dimensioning the ventilation ducts

– To facilitate the installation of the steam distribution pipes and for control

purposes, a sufciently sized control opening should be planned.

– Within the range of the humidication distance, the ventilation duct

should be waterproofed.

– Air ducts passing through cold rooms should be insulated to prevent

the humidied air from condensing along the duct wall.

– Poor airow conditions within the air duct (e.g. caused by obstacles,

tight bends, etc.) can lead to condensation of the humidied air.

– Steam distribution pipes must not be mounted to round ducts.

If you have questions relating to the dimensioning of ventilation ducts in combination with steam humidiers Nordmann ES4, contact your Nordmann supplier.

1/2

1/3

2/3

min

2/7

3/7

2/7

3/7

min

1/3

1/2

g min.= 100 mm h min.= 85 mm

H min.= 250 mm H ≥400 mm H min.= 200 mm

H min.= 400 mm H min.= 350 mm H min.= 300 mm

5.4.3 Installing the steam distributors

Detailed information on the installation of steam distribution pipes DV41 .., DV71... and MultiPipe steam distribution system can be found in the

separate mounting instructions for these products.

5.4.4 Positioning and mounting of the fan units FAN4 N...

The fan unit FAN4 N... is mounted on the wall separately above the unit. To allow the steam coming from the fan unit to spread out evenly, without condensing on obstacles (ceilings, joists, pillars, etc.), the following minimum dimensions must be observed when selecting the location for the fan unit.

FAN4 N S W FAN4 N M W FAN4 N L W m

max. 8 kg/h 15 kg/h 23 kg/h 45 kg/h A min. 4.0 m 6.0 m 8.0 m 10.0 m B min. 1.0 m 1.0 m 1.0 m 1.5 m

C approx. 2.2 m 2.2 m 2.2 m 2.2 m D approx. 1.0 m 1.0 m 1.0 m 1.5 m

E min. 1.0 m

E max. (max. steam hose length) 4.0 m (recommended: 2.0 m)

Note: The minimum spaces in the table apply for a room atmosphere of 15 °C and max. 60 %rh. For lower temperatures and/or higher humidity the values should be adjusted accordingly.

In order to achieve a uniform distribution of the humidity within the room, additional factors such as the room size, the room height, etc., must be taken into consideration besides observing the minimum distances for the fan units

FAN4 N.... If you have questions concerning the direct room humidication,

please contact your Nordmann supplier.

Further information is provided in the separate installation and operating

instructions for the fan unit.

5.4.5 Installing the steam hose

Important! Use original steam and condesate hose from your Nordmann supplier exclusively. Other types of hoses can cause undesired operational malfunctions.

Instructions for the hose layout

The hose layout depends on the position of the steam distribution pipe:

– Steam distribution pipe is mounted more than 500 mm above the top

edge of the humidier:

Initially, lead the steam hose with an upslope of at least 20% over a minimum height of 300 mm, then lead the hose with a minimum upslope of 20% and/or a minimum downslope of 5% to the steam

distribution pipe.

The condensate hose is led down to the humidier with a minimum slope of 20 %, in the form of a siphon (min. hose bend diameter Ø200 mm), and inserted into the specied opening until it comes to a stop. Note: If your unit feeds a number of steam distribution pipes, the individual condensate hoses are to be led into a discharge funnel. Important! Before putting the unit into operation, the siphon of the condensate hose must be lled with water.

Rmin. 300 mm

min. 300 mm

max. 4 m

min. 300 mm

Rmin. 300 mm

min. 300 mm

max. 4 m

min. 300 mm

min. 20 %

–

min. 20 %

–

min. 20 %

Ømin. 200 mm

– Steam distribution pipe is mounted less than 500 mm above the top

edge of the humidier:

Rmin. 300 mm

Ømin.

200 mm

min. 300 mm

max. 4 m

min. 300 mm

min. 20 %

–

min. 5 %

–

min. 20 %

Rmin. 300 mm

Ømin.

200 mm

Ømin.

200 mm

max. 4 m

min. 300 mm

min. 20 %

–

min. 20 %

–

min. 20 %

min. 5 %

–

min. 20 %

Obstacle

Install condensate drain (accessory)

at the lowest point

Initially, the steam hose is led with an upslope of at least 20 % over a minimum height of 300 mm above the top edge of the humidier and then down to the steam distribution pipe with a minimum slope of 5 %.

Condensate hose is led down with a minimum slope of 20 %, in the form of a siphon (min. hose bend diameter Ø200 mm), directly into a discharge funnel. Important! Before putting the unit into operation, the siphon of the condensate hose must be lled with water.

– The steam hose should be kept as short as possible (max. 4 m) while

observing the minimum bend radius of 300 mm. Important! Allowance must be made for a pressure loss of 10 mm water column (approx.

100 Pa) per meter steam hose. Note: If your particular installation exceeds the maximum steam hose

length of 4 m contact your Nordmann representative. In any case, steam hoses longer than 4 m must be insulated in their entire length (e.g. with

insulation hose “EcoTherm”).

– Reductions in the cross section such as kinks should be avoided through-

out the entire length of the hose. The installation of a stop cock in the steam hose is not permissible.

– Steam hoses must be prevented from sagging (condensate pockets); if

necessary, support with pipe clamps, trough, or wall brackets, or install

a condensate drain in the steam hose.

– Important! When deciding on the length and layout of the hose, it

should be noted that the steam hose may become somewhat shorter with progressive ageing.

Securing the hose

The steam hose must be secured to the steam distribution pipe and humidi er steam outlet by means of hose clamps. Caution! Do not overtighten the hose clamp on the steam connector of the steam humidier.

Steam line with xed piping

For steam lines with xed piping, the same instructions apply to the laying of the piping as already described.

min. 300 mm

max. 4 m

Rmin. 5 x D

min. 20 %

–

min. 20 %

Ømin. 200 mm

The following additional notes should be observed:

– The minimum internal diameter of the steam line (diameter depend-

ent on the steam humidier) should be applied over the whole length of

the piping.

– Use exclusively copper pipe or stainless steel (min. DIN 1.4301).

– To minimize the condensate formation (=loss), the steam pipes must

be insulated.

– The minimum bend radius for solid pipes is 5 x internal diameter.

– Connection of the steam pipes to the steam distribution pipe and steam

humidier is effected by means of short lengths of steam hose secured with hose clamps.

– Important! Allowance must be made for a pressure loss of 10 mm

water column (approx. 100 Pa) per meter length or per 90° bend.

5.4.6 Common steam and condensate line errors

1. Steam hose not led at least 300 mm perpendicularly upwards before rst bend.

2. Minimum bend radius of steam hose of 300 mm not maintained (forming of condesate).

3. Siphon of the condensate hose not at least 300 mm below the steam distribution pipe.

4. No condensate drain installed at vertical transition.

5 . Steam hose not sloped (slope min. 20 %).

5.4.7 Inspecting the steam installation

Use the following check list to ascertain that the steam installation was performed correctly:

– Steam distribution pipe

Steam distributors (steam distribution pipe or MultiPipe steam distri-

bution system) correctly positioned and secured (screws tightened)?

Are the outlet orices at right angles to the air ow direction?

– Steam hose

Maximum length of 4 m?

Minimum bend radius of 300 mm (5 x internal diameter with xed

piping)?

Have the instructions for hose positioning been followed?

Steam hose: no sagging (condensate pocket) or condensate drain

with siphon (hose bend with a minimum diameter of 200 mm) installed at the lowest point?

Rigid steam lines: properly insulated? Correct installation material

used? Minimum internal diameter maintained?

Steam hose(s) securely attached with clamps?

Heat expansion during operation and shortening of the hose with

ageing taken into consideration?

– Condensate hose

Downslope of at least 20 %?

Siphon (min. ø200 mm) existing and lled with water?

Condensate hose correctly xed and not kinked?

5.5 Water installation

5.5.1 Overview water installation

125...1250 µS/cm

1...10 bar

1...40 °C

ø 30 mm

ø14/7 mm

Z261

G 3/4"

G 1/2"

G 3/8"

G 3/4"

ø 30 mm

ø 40/31 mm

≥ 40 mm

min. 50 cm

5.5.2 Notes on water installation

Water supply

The water supply is to be carried out according to the gure found in chapter

5.5.1 and the applicable local regulations for water installations. The indicated connection specications must be observed.

– The installation of the lter valve (accessory “Z261”, alternatively a

shutoff valve and a 5 µm water lter can be used) should be made as close as possible to the steam humidier.

– Admissible mains pressure 1.0 to 10.0 bar (hammer-free system)

For mains pressures >10 bar, the connection must be made via a pressure reducing valve (adjusted to 1.0 bar). For mains pressures <1.0 bar please contact your Nordmann supplier.

– Notes on water quality:

– For the water supply of the Nordmann ES4, use exclusively untreated

drinking water.

– The use of additives such as corrosion inhibitors, disinfectants,

etc. is not allowed, since these additives may endanger health and affect proper operation.

– If the Nordmann ES4 shall be operated with softened or partly sof-

tened water, please contact your Nordmann supplier.

– The connection material must be pressure-proof and certied for use

in drinking water systems.

– Important! Before connecting the water line, the line should be well

ushed out.

CAUTION!

The thread at the humidier connection is made of plastic. To avoid overtightening, the union nut of the water pipe must be tightened by

hand only.

Water drain

The water drain is to be carried out according to the gure found in chapter

5.5.1 and the applicable local regulations for water installations. The indicated connection specications must be observed.

– Make sure that the drain pipe is correctly xed and easily accessible for

inspections and cleaning purposes.

– The draining temperature is: 80…90 °C. Use temperature-resistant

installation materials only!

5.5.3 Inspecting the water installation

Check the following topics:

– Water supply

Has lter valve (accessory “Z261”) or shutoff valve and 5 µm water

lter respectively been installed in supply line?

Have admissible water pressure (1 – 10 bar) and admissible tem-

perature (1 – 40 °C) been observed?

Does the supply capacity match the humidier and is the minimum

inside diameter of the supply pipe maintained throughout the entire length?

Are all components and pipes properly secured and are all threaded

connections securely tightened?

Is the water system properly sealed?

Does the water supply installation meet the requirements of the local

regulations for water installations?

– Water drain

Is the minimum inside diameter of the drain pipe of 40 mm maintained

throughout the entire length?

Has drain pipe been installed with a downslope of at least 10 %?

Has the heat resistance of the material used been veried to be at

least 100 °C?

Is the drain hose properly secured (hose clamps at unit connection

tightened)?

Does the water drain installation meet the requirements of the local

regulations for water installations?

5.6 Electric installation

5.6.1 Wiring diagram Nordmann ES4

A1 Continuous controller (active 010V) A2 On/Off controller (passive 24VDC), set jumper on JP1 A3 On/Off control (active 230VAC) B1 Ventilation interlock B2 Airow monitor

B3 Safety humidistat

F1 Internal fuse power board (6.3 A, slow acting) F2 External fuse heating voltage supply F3 External fuse control voltage supply F4 External fuse 230V On/Off control H1 Remote operating and fault indication (option “RFI”) J Short circuited, if no external monitoring devices are connected JP1 Jumper On/Off mode K External safety chain (230V/5A) K1 Main contactor (for connecting the heating voltage supply to the unit)

M Fan unit FAN4 N...

Q2 External service switch heating voltage supply Q3 External service switch control voltage supply S1 Rotary switch "Cylinder type” S2 Potentiometer “Drain factor” S3 Potentiometer “Power limitation” S4 DIP switch “General unit settings” X0 Connection terminal heating voltage (option THV) X1 Connection terminal control signal X2 Connection terminal On/Off control active X3 Connection terminal control voltage

Control board Power board

ES4 Card

red yellow green

(6.3 AT)

CONT.SIGN

V+ IN GND

X2 X3

MAIN SUPPLY

L1 N SC1SC2

LEV.SENSOR

Driver board

CPU board

CURRENT SENSOR

CPU BOARD

1 2

On/Off

JP1 must be plugged

230 V/1~/50..60 Hz

L1 N

On/Off Mode

JP1

+ –

0-10V

230V

L1’

1 2 3 4 5 6 7 8 9 10

Error Service Steam Unit On

Cylinder

Drain Factor

Power Limit

Manual Drain

Low Conduct. Standby Drain Force Drain Cylinder A/D GFCI-Mode Offset

Settings

DriverRFI

1 2 3 4 5 6

V+ IN GND

1 2 3 4

SWITCH

1 2 3 4

INLET

1 2

CONTACTORDRAIN

∆p

max.

L1 N

L1 L2 L3

400 V/3~/50..60 Hz 230 V/3~/50..60 Hz

L1 N PE

230 V/1~/50..60 Hz

L1 L2

400 V/2~/50..60 Hz

ES4

ext.

5.6.2 Notes on electric installation

Important notes

– The electric installation must be carried out according to the wiring dia-

gram in chapter 5.6.1, the notes on electric installation as well as the applicable local regulations. All information given in the wiring diagram must be followed and observed.

– All cables must be lead into the unit via the cable openings equipped with

cable glands (e.g. option “CGcable gland”). The cable for the heating voltage supply must be lead into the unit from the bottom via the cable opening equipped with the clamp strap. Fix the cable with the clamp

strap.

– Make sure the cables do not scrub on any components.

– Maximum cable length and required cross section per wire must be

observed.

– The supply voltages must match the respective voltages (heating and

control voltage) stated in the wiring diagram.

Heating voltage supply

CAUTION!

Before connecting, ensure that the mains voltage corresponds with the heating voltage for the unit (see type plate).

The Nordmann ES4 is to be connected to the mains supply in accordance with the wiring diagram, via a service switch “Q2” (disconnecting device with a minimum contact opening of 3 mm is an essential requirement) and an fuse group “F2” (essential requirement, fuses are to be as detailed in the following table). The supply wiring is to be fed into the unit via a tension relieving device (cable gland) and connected to the terminals of the main

contactor “K1”.

Heating voltage Max. steam

capacity

[kg/h]

Nordmann

ES4 ..

Nominal power

[kW]

Nominal

current

[A]

Main fuses F2

[A]

400V3

(400 V/3~/50...60 Hz)

5 534 3.8 5.4 3x 10

8 834 6.0 8.7 3x 16 15 1534 11.3 16.2 3x 25 23 2364 17.3 24.9 3x 35 32 3264 24.0 34.6 3x 50 45 4564 33.8 48.7 3x 80

65 6564 48.8 70.4 3x 100

400V2

(400 V/2~/50...60 Hz)

5 524 3.8 9.4 2x 16

8 824 6.0 15.1 2x 25

230V3

(230 V/3~/50...60 Hz)

5 532 3.8 9.4 3x 20

8 832 6.0 15.1 3x 25 15 1532 11.3 28.2 3x 40 23 2362 17.3 43.3 3x 63 32 3262 24.0 60.2 3x 100

230V1

(230V/1~/50...60Hz)

5 522 3.8 16.3 25

8 822 6.0 26.1 40

The crosssection of the mains cable must comply with the applicable local regulations.

Control voltage supply

CAUTION!

– Before connecting, ensure that the mains voltage corresponds with

the control voltage of the unit (230 V/1 50…60 Hz).

– The humidier must only be connected to a mains supply with a

protective conductor.

The connection to the control voltage is made in accordance with the wir-

ing diagram, to the terminal “X3” on the power board. The customer is to install a service switch Q3 in the supply line (all pole disconnecting device with a minimum contact opening of 3 mm) and an F3 fuse (max. 10 A slow acting) (these are both essential requirements).

The crosssection of the mains cable must comply with the applicable local regulations (minimum of 1.5 mm

External safety circuit

To guarantee the safety of the humidication system, monitoring the operation by means of a safety circuit is an absolute requirement.

To accomplish this, the potential-free contacts (max. contact loading 250V/5A) of external moni t or ing devices (e.g. safety high limit humidistat, airow monitor, ventilation interlock, etc.) are connected in series to the

contacts “SC1” and “SC2” of the terminal block “X3” in accordance

with the wiring diagram.

DANGER! Danger of electric hazard!

The mains voltage is connected to terminal block “X3” (up to 240 V). The steam humidier must therefore be isolated from the mains supply (heating and control voltage), before starting the connection work.

If, for whatever reason, no external monitoring devices are connected, a connecting bridge “J” must be installed on the contacts “SC1” and “SC2” of the terminal block “X3”.

Do not apply any extraneous voltage to the terminals.

The crosssection of the cable must comply with the applicable local regula-

tions (minimum of 1 mm

Remote operating and fault indication H1 (Option “RFI”)

The optional remote operating and fault indication PCB is to be connected to the control board via the terminal “J1”. The optional remote operating and fault indication PCB contains four potentialfree relay contacts for the connection of the following operating and fault indications:

– “Error”: This relay is activated if an error is present.

– “Service”: This relay is activated when the set service interval has

expired.

– “Steam”: This relay closes as soon as the unit produces steam.

– “Unit On”: This relay closes as soon as the unit is switched on via the

main switch.

The maximum contact loading is 250V/5A.

Appropriate suppressor modules are to be used for the switching of relays

and miniature contactors.

Note: The minimum cross section of the supply cable must comply with the local regulations.

Control signal

– External continuous humidity controller 0-10V (A1)

An external humidity continuous controller is to be connected to the contacts “IN” (+) and “GND” (–) of the terminal block “X1”.

– 24 VDC On/Off humidistat (passive)

An 24 VDC On/Off humidistat is to be connected to the contacts “V+” and “IN” of the terminal block “X1”. Note: for the 24 VDC On/Off control a jumper must be set on “JP1”.

– 230V On/Off control (active)

The signal line of a 230V On/Off control is to be connected to the contact “VD” of the terminal block “X2” via external fuse “F4” (max. 10 A, slowacting).

Connecting the fan unit FAN4 N...

Refer to the separate documentation of the corresponding fan unit.

5.6.3 Unitconguration

All setting components for the unit congration are located on the control

board:

– Rotary switch “Cylinder”: cylinder type

– Potentiometer “Drain Factor”: drain factor

– Potentiometer “Power Limit”: power limitation

– DIP switch “Settings”: general settings

Setting the steam cylinder type (“Cylinder”)

Use the rotary switch “Cylinder” to select the type of steam cylinder used:

Voltage/ Phase

200/1 230/1

400/2

200/3 230/3

400/3

200/3 230/3

400/3

200/3 230/3

400/3

200/3 230/3

400/3 400/3 400/3

Position 0 1 2 3 4 5 6 7 8 9 A B

Cylinder ype

522A 822A

524A 824A

532A 832A

534A

534A-L

834A

834A-L

1532A 1534A

1534A-L

2362A 2364A

2364A-L

3262A 3264A

3264A-L

4564A

4564A-L

6564A

Setting the drain factor

Use the potentiometer “Drain Factor” to set the drain factor (setting range:

0.5...2.0, factory setting: 1.0).

Setting the power limitation

Use the potentiometer “Power Limit” to set the power limitation in % of the maximum capacity (setting range: 30...100%, factory setting: 100%).

General settings (“Settings”)

With the DIP switches “Settings” you can set different unit parameters. The

unit parameters are preset in the factory and may only be modied by the

client after consulting the Nordmann representative.

Switch Factory setting Description

1 OFF ON: low water conductivity <125 µS/cm

OFF: normal water conductivity ≥125 µS/cm

2 OFF ON: standby draining (72 hours) activated

OFF: standby draining (72 hours) deactivated

3 OFF ON: forced draining (72 hours) activated

OFF: forced draining (72 hours) deactivated

4 OFF ON: steam cylinder replacement interval 2500 h.

OFF: steam cylinder replacement interval 1500 h.

5 ON ON: the heating voltage is interrupted during draining

of the steam cylinder OFF: the heating voltage is interrupted during draining

and relling of the steam cylinder

6 OFF ON: Offset control signal activated (2-10V)

OFF: Offset control signal deactivated (0-10V)

5.6.4 Inspecting the electrical installation

Check the following points:

Do the supply voltages for heating and control comply with the relevant

voltages given in the wiring diagram?

Is the correct ES4 Card inserted?

Are the voltage supplies (heating and control voltage) correctly fused?

Is the service switch “Q..” installed in the supply line for to the heating

and control voltage?

Are all components correctly connected according to the wiring diagram?

Are all connecting cables fastened?

Are the connecting cables free of tension (passed through cable glands?)

Does the electric installation meet the applicable local regulations for

electric installations?

Is the front panel mounted and correctly xed with the two screws?

6 Operation

6.1 Function of the display and operating elements

Drain/Info key

– press key shortly: Opens and closes the drain valve (manual drain-

ing). Note: the drain valve is automatically closed after 10 minutes.

– press key for a extended period of time (>3 sec.): activating the

info mode

red LED “Error”

– in normal operating mode

– The LED lights in case of a malfunction of the unit. Further opera-

tion is no longer possible, the heating voltage is interrupted.

– The LED ashes alternately with the green LED if the external

safety chain (ventilation interlock, safety humidistat, etc.) is open.

– in info mode

LED ashes in intervals if a malfunction is present. The number of “ashes” per interval indicates the left digit of the error code.

yellow LED “Warning and info indication”

– in normal operating mode

The LED lights if the cylinder maintenance is due (see chapter 7) or

the maintenance indication is not reset after the maintenance (see

chapter 7.6).

– in info mode

LED ashes in intervals if a malfunction is present. The number of “ashes” per interval indicates the right digit of the error code.

green LED “Steam”

– in normal operating mode

– The LED lights if the unit produces steam.

– The LED ashes alternately with the red LED if the external safety

chain (ventilation interlock, safety humidistat, etc.) is open.

– in info mode

LED ashes in intervals. The number of “ashes” per interval multiplied by 10 indicates the current steam output in %.

Unit switch

Switches the unit on and off. The switch is illuminated when the unit is switched on.

6.2 Commissioning

Proceed as follows when putting the unit into operation:

1. Examine the steam humidier and installation for possible damage.

DANGER!

Damaged devices or devices with damaged installation may present danger to human life or cause severe damage to material assets.

Damaged units and/or units with damaged or faulty installation must not be operated.

2. Check whether the front panel is mounted and xed with the two screws.

3. Open the shutoff valve in the water supply line.

4. Verify the set humidity value at the humidity controller or at the humidistat, and readjust as required.

5. Switch on the service switches for mains supplies (heating and control voltage).

6. Actuate the unit switch of the steam humidier.

The steam humidier carries out a system test, during which all the LED’s light up.

If, after the system test: – the yellow LED lights permanently, the steam cylinder maintenance

is due (see chapter 7) or the maintenance indication has not been reset (see chapter 7.6).

– the red LED lights permanently, a fatal malfunction has occurred (see

chapter 8).

After the system test the unit is in normal operation mode.

As soon as the humidity controller or the humidistat requires humidity, power is switched on for heating. The inlet valve opens (slight delay) and the steam cylinder lls with water. As soon as the submerged electrodes heat the water up the green LED lights up and after a few minutes (approx. 5–10 minutes, depending on the conductivity of the water) steam is produced. Note: If the Nordmann ES4 is operated with water of low conductivity it may happen that the maximum steam capacity is not reached in the rst few hours of operation. This is normal. As soon as the conductivity has reached a sufcient level (due to the vaporisation process) the humidier will reach the maximum steam capacity.

6.3 Notes on operation

6.3.1 Function of the LED's in info mode

The info mode is activated by pressing the drain/info key for an extended period of time (> 3 seconds). After activating the info mode:

– rst, the green LED ashes. The number of ashes indicates the current

steam output in % of the maximum steam capacity.

Green LED ashing ...

1x 2x 3x 4x 5x 6x 7x 8x 9x 10x

Steam output

in %

10 20 30 40 50 60 70 80 90 100

Note: if no steam production is in progress when the info mode is activated the green LED lights for 3 seconds, then it turns off again.

– then, if a malfunction is present (warning or error) the red and the yellow

LED ash successively. The number of ashes of the red LED indicates the left digit of the error code while the number of ashes of the yellow

LED indicates the right digit of the error code.

Note: If the red LED lights when the info mode is activated the malfunction indicated is an error (E..) otherwise a warning (W..).

This indication procedure is repeated until the info mode is exited automatically after 5 minutes or the info mode is exited by pressing the drain/Info

key again.

Examples:

Indication in normal

operating mode

green LED lights no yes yes no

red LED lights no no no yes

Indication in info mode

green LED ashes .. –– 5x 5x ––

red LED ashes .. –– –– 3x 2x

yellow LED ashes .. –– –– 6x 1x

Steam output 0 % 50 % 50% 0 %

Error code –– –– W36 E21

6.3.2 Remote operating and fault indication

If your unit is equipped with the optional operating and fault indication “RFI” the following operating status are shown remotely:

Activated remote indication relay

When? Display on unit

“Error” A malfunction is present, further

operation is not possible, the heating voltage is interrupted

Red LED lights

“Service” Steam cylinder must be re-

placed. The unit remains operational for a certain time

Yellow LED lights

“Steam demand” Steam demand/Steam produc-

tion

Green LED lights

“Unit on” Unit switched on Unit switch lights

6.3.3 Inspections during operation

During operation the Nordmann ES4 and the humidication system have to be inspected weekly. On this occasion check the following:

• the water and steam installation for any leakage.

• the steam humidier and the other system components for correct xing

and any damage.

• the electric installation for any damage.

If the inspection reveals any irregularities (e.g. leakage, error indication)

or any damaged components take the Nordmann ES4 out of operation as

described in chapter 6.5. Then, contact your Nordmann representative.

6.4 Carrying out manual draining

Proceed as follows to drain the unit manually:

1. Briey press the drain/info key. The heating voltage is interrupted and the drain valve opens. The yellow LED ashes. Note: the drain valve closes after 10 minutes automatically

2. To stop the drain cycle briey press the drain/info key again.

6.5 Taking the unit out of operation

In order to take the steam humidier out of operation, perform the following

steps:

1. If the unit has to be switched off because of a malfunction, please note the error code (number of ashes of the red and yellow LED) of the actual error.

2. Close the shutoff valve in the water supply line.

3. Start manual draining (see chapter 6.4) and wait until the steam cylinder

is empty.

4. Actuate the unit switch.

5. Disconnect steam humidier from the mains: Switch off all service

switches to mains supplies (heating and control voltage) and secure switches in “off” position against accidentally being switched on, or clearly mark the switches.

6. If ambient temperatures ≤ 0°C must be expected when the unit is out

of operation (operation of the Nordmann ES4 in a protective housing

outside the building): drain the water supply pipe and the water lter (lter valve).

WARNING! Danger of burning!

If steam was produced just before the unit is taken out of operation, wait before opening the unit and let the steam cylinder cool down to prevent danger of burning.

7 Maintenance

7.1 Important notes on maintenance

Qualication of personnel

All maintenance work must be carried out only by well qualied and trained personnel authorised by the owner. It is the owner’s responsibility to verify

proper qualication of the personnel.

General note

The instructions and details for maintenance work must be followed and upheld.

Only the maintenance work described in this documentation may be car-

ried out.

Only use original Nordmann spare parts to replace faulty parts.

Safety

Some maintenance work requires removal of the unit cover. Please note the following:

DANGER! Danger of electric hazard!

You may get in touch with live parts when the unit is open. Touching live parts may cause severe injury or even lethal violation. Prevention: Before carrying out any maintenance work set the Nordmann ES4 out of operation as described in chapter 6.5 (switch off the unit, disconnect it from the mains and stop the water supply) and secure the unit against inadvertent powerup.

CAUTION!

The electronic components inside the humidier are very sensitive to electrostatic discharge. Prevention: Before carrying out any maintenance work to the electrical or electronic equipment of the humidier, appropriate measures must be taken to protect the respective components against damage caused by electrostatic discharge (ESD protection).

7.2 Maintenance list

To maintain operational safety the Nordmann ES4 steam humidier must be maintained at regular intervals. This is differentiated between the first

maintenance after approx. 500 operating hours (I), steam cylinder replacement after the yellow LED lights (II) and annual maintenance (III).

Below you will nd a summary of the work to be carried out for each of the

three maintenance stages.

Components Interval Work to be done

I II III

Replacement steam cylinder X Remove and replace.

Drain valve X Remove, disassemble and clean, replace if neces-

sary.

Steam cylinder receptacle X Inspect, clean if necessary.

Inlet valve X Remove and clean lter insert, replace if necessary.

Drain cup X Remove and clean if necessary

Drain pipe and siphon X Inspect, clean if necessary (decalcify and rinse out).

Steam installation X X Inspect steam and condensate hoses for cracks and

to see that they are correctly attached, replace faulty

hoses.

Water installation X X Inspect water hoses in the unit for cracks and to see that

they are correctly attached, replace faulty hoses Check supply pipe is tight, make tight if necessary. Clean water lter, if available.

Electrical installation X X Check all cables in the unit are rmly positioned and

examine status of insulation.

7.3 Removing and installing parts for maintenance

7.3.1 Removal and installation of the steam cylinder

1. Undo the two screws xing the front panel to the unit using a screwdriver, then remove the front panel.

2. Release the hose clamp on the steam hose using a screwdriver, then detach the steam hose from the steam outlet connection of the steam cylinder.

3. Remove all plugs from the electrodes and from the level sensor.

4. Loosen the screw of the steam cylinder xing device by a few turns, then push the xing device upwards until it comes loose and remove it.

1 2

3 4

5 6

5. Carefully lift steam cylinder away from the cylinder receptacle, then

remove it to the front.

CAUTION!

Put steam cylinder down carefully to avoid damage to the lower connection piece!

6. Carefully pull the drain screen out of the drain outlet of the steam cylinder.

Note: this step must only be carried out if the drain screen is clogged (see chapter 8.2.2 “Unit faults”) and the steam cylinder can still be used.

Installation of the steam cylinder follows the reverse sequence. Observe the following:

– Before installing the steam cylinder in the unit, check the Oring of the

cylinder receptacle for damage and replace if necessary.

– Moisten the Oring of the cylinder receptacle with water (do not use

grease or oil), then insert steam cylinder into the receptacle and push it down to the stop.

– Attach the electrode plugs and the level sensor plug to the respective

electrode and sensor connections according to the following table.

Steam cylinder type

522A / 524A 822A / 824A

532A / 534A 832A / 834A

1532A / 1534A

2362A / 2364A 3262A / 3264A

4564A / 6564A

Sensor

white

black

red

brown

black

red

brown

Sensor

white

brown

black

red

Sensor

white

black

brown

Sensor

white

black

red

brown black

red

brown

– Fasten steam hose on the connector of the steam cylinder with hose

clamps.

CAUTION!

– A leaky steam hose can cause damage due to moisture inside the

unit.

– The outlet connector of the steam cylinder is made of plastic. Do

not overtighten the hose clamp on the steam connector of the

steam cylinder.

7.3.2 Removal and installation of the drain cup

1. Release the hose clamp, then remove water drain hose from the connector on the water cup.

2. Undo the three screws xing the drain cup to the unit using a screwdriver, then remove the drain cup downwards.

3. Remove Oring from the annular groove of the drain cup.

Installation of the drain cup follows the reverse sequence. Before assem- bling check Oring of the drain cup for damage and replace if necessary.

7.3.3 Removal and installation of the water cup and the water hoses

For removing the water cup and the water hoses the steam cylinder must be removed rst (see chapter 7.3.1).

1. Release hose clamps using pliers, then disconnect all hoses from the

corresponding connectors and remove the hoses.

Note: The hoses connected to the water cup may also be removed together with the water cup (see illustration) and then disconnected from the connectors of the water cup outside the unit.

2. Carefully pull xing clip of the water cup to the front, then push water

cup down from the holding device and remove it to the front.

The installation of the water cup and the water hoses follows the reverse sequence. Before xing the water hoses to the connector using the hose clamps, align the hoses in a way that they are not twisted.

7.3.4 Removal and installation of the drain valve

For removing the drain valve the steam cylinder must be removed rst (see chapter 7.3.1).

1. Detach electric cables (polarity of the cables must not be observed).

2. Release hose clamp and remove the hose from the connector.

3. Loosen the two screws with Phillips screwdriver, then remove the drain valve.

4. Disassemble the drain valve.

The assembly and the installation of the drain valve follows the reverse sequence. Before assembling the valve, check all Orings and gaskets for damage and replace if necessary.

7.3.5 Removal and installation of the inlet valve

For removing the inlet valve the steam cylinder must be removed rst (see chapter 7.3.1).

1. Detach electric cables (polarity of the cables must not be observed).

2. Release hose clamp and remove the hose from the connector.

3. Unlock union nut of the water pipe and remove water pipe.

4. Loosen the two screws with Phillips screwdriver, then remove inlet valve.

5. Remove strainer insert with pointed pliers

The installation of the inlet valve follows the reverse sequence. The union nut of the water pipe must be tightened by hand only.

7.4 Notes on cleaning the unit components

Unit component What to clean and how to clean

Water hoses • Remove any limescale by slightly knocking on the tubes

using a rubber hammer. Then, rinse the tubes well with hot tap water.

Inlet valve

strainer insert

• Use a brush (do not use a wire brush) to remove any limescale inside the inlet valve and on the strainer.

• Wash inlet valve and strainer insert with a lukewarm soap solution, then rinse well with tap water.

Let the inlet valve dry before reinstallation!

Drain valve

valve housing

valve stem

• Use a brush to remove any limscale from the valve housing, the bores and the valve seat on the valve stem (do not use a wire brush).

• Wash the valve housing and the valve stem with a lukewarm soap solution, rinse the parts well with tap water and let them dry.

Water cup • Remove any limscale from the water cup and its con-

nectors using a brush (do not use a wire brush).

If the water cup is heavily calcied, place it in an 8% formic acid solution (observe safety notes in chap- ter 7.5), until the limescale comes off.

• Wash the water cup with a lukewarm soap solution and rinse well with tap water.

Drain screen of the steam cylinder • Remove any limscale from the drain screen using a brush

(do not use a wire brush) and remove loose limescale inside the drain connector of the steam cylinder. If the drain screen is heavily calcied, place it in an 8% formic acid solution (observe safety notes in chap- ter 7.5), until the limescale comes off.

• Wash the drain screen with a lukewarm soap solution and rinse well with tap water.

Unit component What to clean and how to clean

Drain cup • Use a brush to remove any limscale from the drain cup

and the receptacle on the bottom side of the unit (do not use a wire brush).

If the drain cup is heavily calcied, place it in an 8% formic acid solution (observe safety notes in chapter 7.5), until the limescale comes off.

• Wash the drain cup and the receptacle on the bottom side of the unit with a lukewarm soap solution, rinse the parts well with tap water.

Interior of the unit (water side only)

Wipe the interior of the unit with a damp cloth without using any cleaning agent.

CAUTION: Take care that the electrical connections and the electronic components remain dry!

7.5 Notes on cleaning agents

Only use cleaning agents stated in the table above. The use of disinfect-

ants is only permitted if they do not leave any toxic residues. In any case the parts must be thoroughly rinsed with water after cleaning.

WARNING!

Formic acid is indeed harmless to the skin, but it attacks the mucous membranes. Therefore prevent your eyes and respiratory tracts from getting in touch with the acid and its vapours (wear goggles and work in a well ventilated room or outside).

CAUTION!

Do not use any solvents, aromatized or halogenized hydrocarbons or other aggressive substances as they may cause damage to the

components of the unit.

It is mandatory to observe and comply with the information and instructions regarding cleaning agents. Observe in particular: all information relating to the protection of personnel, environmental protection and restrictions

regarding usage.

7.6 Resetting the maintenance indication

After completing maintenance work, the maintenance indication (yellow LED lights) must be reset as follows:

• Press drain key with the unit switched off and hold down.

• Switch on steam humidier via the unit switch.

• Hold drain key down until the system test is completed (approx. 10 seconds).

8 Fault elimination

Important! Most operational malfunctions are not caused by faulty equipment but rather by improper installation or disregarding of planning guidelines. Therefore, a complete fault diagnosis always involves a thorough examination of the entire system. Often, the steam hose connection has not been properly executed, or the fault lies with the humidity control system.

8.1 Fault indication

In case of malfunction during operation, the unit control checks whether there is a temporary problem or whether it can resolve the problem by taking necessary measures. Such malfunctions are not indicated in the normal operation mode. However an appropriate error code with the status

“Warning” is generated.

Note: If the cause of the malfunction disappears of its own accord or if the controls can repair the malfunction, the alarm will automatically reset.

If the control, after several attempts, fails to solve the problem (number of attempts depends on the type of malfunction) or if the problem obstructs further operation, the heating voltage is interrupted via the main contactor.

The red LED lights in normal operation mode and an appropriate error code with the status “Error” is generated.

The error code can be queried in the info mode. Press drain/info key at least 3 seconds to enter the info mode. In the info mode the number

of ashes of the red LED indicates the decade of the error code while the number of ashes of the yellow LED indicates the digit of the error code (refer to chapter 6.3.1 for further information regarding the info mode).

Examples:

Normal operation

mode

red LED lights yes no yes yes

Info mode

red LED ashes .. –– 2x 2x 3x

yellow LED ashes .. 2x 1x 1x 7x

Error code E2 W21 E21 E37

8.2 Malfunction lists

8.2.1 System faults

Warning Error Cause Remedy

Code Malfunction Code Malfunction

E1 ES4 Card missing No ES4 Card installed on the con-

trol board.

Install ES4 Card or start test run.

––– ––– E2 ES4 Card is empty No data stored on the ES4 Card. Install new ES4 Card.

––– ––– E3 ES4 Card is

defective

Invalid data stored on the ES4

Card.

Install new ES4 Card.

––– ––– E4 ES4 Card is

incompatible

The installed ES4 Card is not compatible with the hardware of the unit or with the basic settings of the control electronics.

Install correct ES4 Card. Let your Nordmann service technician adjust the basic settings.

––– ––– E10 Hardware fault Control board defective. Replace control board.

8.2.2 Unit faults

Warning Error Cause Remedy

Code Malfunction Code Malfunction

W20 External safety

chain is open

––– ––– Ventilation interlock open. If applicable, check/turn on ventila-

tion system.

Air ow monitor triggered. Check ventilator/lter of the ventila-

tion system.

Safety humidistat triggered. Wait. If applicable, check safety

humidistat

W21 Max. lling level of

steam cylinder reached

E21 Max. lling level of

steam cylinder reached but no heating current

Water conductivity too low (after initial operation).

Wait until the mineral content of the cylinder has increased

Water conductivity too low for type of steam cylinder.

Select correct steam cylinder type.

Phase failure heating voltage. Check service switch in the mains

supply line and switch on if applicable. Check mains fuse(s) and replace if applicable.

W22 Permissible lling

time exceeded (20

minutes)

E22 Permissible lling

time exceeded (more

than 4 hours)

Water supply obstructed/shutoff valve closed/water pressure too low.

Inspect water supply (lter, water piping, etc.), check/open shutoff valve, check water pressure.

Inlet valve blocked or defective. Inspect strainer insert in the inlet valve,

if applicable clean strainer insert or replace inlet valve.

Excessive back pressure in the steam line (duct pressure too high, steam line too long or kinked), causing water loss via lling cup.

Check duct pressure, inspect steam installation. If applicable install pressure compensation kit (see options).

Leakage in the water system. Inspect water system and seal if

necessary.

Warning Error Cause Remedy

Code Malfunction Code Malfunction

W23 No electrode current

for more than 20 minutes

E23 No electrode cur-

rent for more than 4 hours

Phase failure heating voltage. Inspect/turn on service switch of

the mains supply line. Inspect the fuses of the mains supply, replace

if necessary.

Water supply obstructed/shutoff valve closed/water pressure too low.

Inspect water supply (lter, water piping, etc.), check/open shutoff valve, check water pressure.

Inlet valve blocked or defective. Inspect strainer insert of the inlet

valve, if applicable clean strainer insert or replace inlet valve.

Excessive back pressure in the steam line (duct pressure too high, steam line too long or kinked), causing water loss via lling cup.

Check duct pressure, inspect steam installation. If applicable install pressure compensation kit (see options).

Leakage in the water system. Inspect water system and seal if

necessary.

W24 Electrode current in

relation to the steam demand too high

E24 Electrode current in

relation to the steam demand too high

Humidity demand has decreased too

fast.

Automatic adaptation of the operating point.

Drain valve defective. Inspect drain valve, replace if nec-

essary.

Drain screen in the drain outlet of the steam cylinder clogged.

Clean drain screen (see chapter 7.3.2 and 7.4) or replace steam cylinder.

Water conductivity too high for this

type of steam cylinder.

Select correct steam cylinder type.

W25 Max. admissible

electrode current exceeded

E25 Max. admissible

electrode current exceeded

Drain valve defective. Inspect drain valve, replace if nec-

essary.

Drain screen in the drain outlet of the steam cylinder clogged.

Clean drain screen (see chapter 7.3.2 and 7.4) or replace steam cylinder.

Water conductivity too high for this

type of steam cylinder.

Select correct steam cylinder type.

––– ––– E26 Main contactor

jammed

Main contactor jammed in activated

position.

Inspect main contactor, replace if

necessary.

W27 Foam detection E27 Foam detection (4

automatic drainings within 24 hours)

Foaming in steam cylinder. Drain steam cylinder via drain key

(several times, if necessary). Check quality of the supply water.

W28 Steam cylinder

needs service

E28 Service interval for

steam cylinder exceeded

Mineral deposits and/or electrodes

spent.

Replace steam cylinder.

Important: After the replacement of the steam cylinder, reset the maintenance counter (see chapter 7.6).

W29 Steam cylinder

needs service

E29 Max. operating

hours of the steam cylinder reached

Maximum operating hours of the steam cylinder reached.

Replace steam cylinder.

Important: After the replacement of the steam cylinder, reset the maintenance counter (see chapter 7.6).

W36 Standby draining of

steam cylinder active

––– ––– Automatic standby draining of

steam cylinder active.

No measures must be taken.

W37 Forced draining of

steam cylinder active

––– ––– Forced draining of steam cylinder

active.

No measures must be taken.

8.3 Notes on fault elimination

DANGER! Danger of electric hazard!

For the elimination of faults set the steam humidier out of operation as described in chapter 6.5, separate the unit from the mains and secure

it against inadvertent power-up.

The elimination of faults must be carried out by qualied and well trained professionals only. Malfunctions relating to the electrical installation (e.g. replacement of fuses) must be repaired by authorized personnel or by your Nordmann representative’s service technician only.

Repair work and the replacement of faulty components must be carried out by your Nordmann representative’s service technician only!

8.4 Resetting the error indication (red LED lights)

To reset the error indication:

Disconnect the steam air humidier from the mains. Wait approx. 5 seconds, then reconnect the unit to the mains.

Note: If the fault has not been eliminated, the error indication reappears after a short while.

9 Taking out of service/Disposal

9.1 Taking out of service

If the Nordmann ES4 must be replaced or if the humidication system is not needed any more, proceed as follows:

1. Take the unit out of operation as described in chapter 6.5.

2. Have the unit (and all other system components, if necessary) unmounted by a qualied service technician.

9.2 Disposal/Recycling

Dismantled components must be disposed of and/or recycled according to the local regulations. In case of doubt please contact your Nordmann supplier.

10 Productspecications

10.1 Technicaldata

Steam capacity in kg/h 5 8 15 23 32 45 65

Capacity range in kg/h 1...5 1.6...8 3...15 4,6...23 6,4...32 9...45 13...65

Nominal power in kW 3,8 6,0 11,3 17,3 24,0 33,8 48,8

Heating voltage 230V/1~/50..60Hz *

Unit model 522 822

Nominal current in A 16,3 26,1

Steam cylinder type ** 522A 822A

Heating voltage 400V/2~/50..60Hz *

Unit model 524 824

Nominal current in A 9,4 15,0

Steam cylinder type ** 524A 824A

Heating voltage 230V/3~/50..60Hz *

Unit model 532 832 1532 2362 3262

Nominal current in A 9,4 15,1 28,2 43,3 60,2

Steam cylinder type ** 532A 832A 1532A 2362A 3262A

Heating voltage 400V/3~/50..60Hz *

Unit model 534 834 1534 2364 3264 4564 6564

Nominal current in A 5,4 8,7 16,2 24,9 34,6 48,7 70,4

Steam cylinder type ** 534A 834A 1534A 2364A 3264A 4564A 6564A

Steam cylinder type *** 534A-L 834A-L 1534A-L 2364A-L 3264A-L 4564A-L ---

Control voltage 1 x 230V / 50-60 Hz

Operating conditions

Admissible water pressure 1...10 bar

Water quality Untreated drinking water with a conductivity of 125...1250 µS/cm

Admissible water temperature 1...40 °C

Admissible ambient temperature 1...40 °C

Admissible ambient humidity max. 75% rh (non condensing)

Admissible duct air pressure -0.8 kPa...1.5 kPa; overpressure kit (option) up to 10.0 kPa

Type of protection IP 20

Conformity CE, VDE, GOST

Dimensions/Weights

Housing (WxHxD) in mm 377x612x279 1 1 1

492x670x351 1 1 1 1

Water supply connector G 3/4" (outside thread)

Water drain connector ø 30 mm

Steam connector 1 x ø 22 mm 1 x ø 35 mm 2 x ø 35 mm

Net weight in kg 19 19 28 28 28 28

Operating weight in kg 24 30 65 65 65 65

Options

Cable gland 1xCG

Overpressure set 1xOPS

Remote operating and fault indication 1xRFI

Steam hose connector with condensate trap 1xCT22 1xCT35 2xCT35

Internal control voltage supply 1xS-CVI 1xM-CVI 1xL-CVI

Transformer (400 V/230 V) 1xM-Trafo 1xL-Trafo

Terminals heating voltage 1xS-THV 1xM-THV 1xL-THV

SC pump 1xSC

24 VDC power supply 1x24VDC

Accessories

Filter valve Z261

Steam distribution pipe 1x DV41-... 1x DV71-... 2x DV71-...

Steam distribution system MultiPipe ––– 1xSystem 1 1xSystem 2

Fan unit 1xFAN4 N S W 1xFAN4 N M W 1xFAN4 N L W

Steam hose / meter 1xDS22 1xDS35 2xDS35

EcoTherm insulation hose 1xECT22 1xECT60 2xECT60

Condensate hose / meter KS10

Duct humidistat 1xHBC

Room humidistat 1xHSC

All-waether protective housing Layout according to the separate data sheet

* Other heating voltages on request ** Steam cylinder for water conductivity from 125 to 1250 µS/cm (standard version) ***

Steam cylinder for low water conductivity from 80 to 125 µS/cm

10.2 Unit dimensions

Nordmann ES4 5/8/15 (dimensions in mm)

187

127

176

ø30

377

61269

279

144

130

120 120

189

490

Nordmann ES4 23/32/45/65 (Dimensions in mm)

ø30

492

670

351

246

180 180

547

223

163

118

229

180

182

Notes

Technical modiﬁcations reserved

NORDMANN

ENGINEERING

Reg.No. 40002-2

Manufacturer: Nordmann Engineering Ltd. Talstrasse 35-37, 8808 Pfäﬃkon, Switzerland Ph. +41 55 416 66 06, Fax +41 55 416 62 46 www.nordmann-engineering.com, info@nordmann-engineering.com

Nordmann ES4 Installation Operation & Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual