Nordmann es4 4 Installation And Operation Instructions Manual

NORDMANN

ENGINEERING

Nordmann ES4 4

Steam air humidier

INSTALLATION- AND OPERATING INSTRUCTIONS

2569918 EN 1303

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 Model overview 8

3.2 Identication of the unit 8

3.3 Steam humidier construction 9

3.4 Functional description 10

3.5 Humidication system overview 12

3.6 Accessories 13

3.6.1 Accessories overview 13

3.6.2 Accessory details 14

3.7 Standard delivery 16

3.8 Storing/Transportation/Packaging 16

4 Mounting and installation work 17

4.1 Important notes for mounting and installation work 17

4.2 Installation overview 18

4.3 Mounting the unit 19

4.3.1 Notes on locating the unit 19

4.3.2 Mounting the humidier 21

4.3.3 Inspecting the installed unit 22

4.4 Steam installation 23

4.4.1 Overview steam installation 23

4.4.2 Positioning of the steam distributors in a duct 24

4.4.3 Positioning of the steam distributors in a steam bath 28

4.4.4 Installing the steam distributors 28

4.4.5 Installing the steam and condensate hose 29

4.4.6 Common steam and condensate line errors 33

4.4.7 Inspecting the steam installation 34

4.5 Water installation 35

4.5.1 Overview water installation 35

4.5.2 Notes on water installation 36

4.5.3 Inspecting the water installation 37

4.6 Electric installation 38

4.6.1 Wiring diagram Nordmann ES4 4 38

4.6.2 Notes on electric installation 39

4.6.3 Unit conguration 41

4.6.4 Inspecting the electrical installation 42

6 Maintenance 47

6.1 Important notes on maintenance 47

6.2 Maintenance list 48

6.3 Removing and installing parts for maintenance 49

6.3.1 Removal and installation of the steam cylinder 49

6.3.2 Removal and installation of the drain cup 52

6.3.3 Removal and installation of the water cup and the water
hoses 53

6.3.4 Removal and installation of the drain valve 54

6.3.5 Removal and installation of the inlet valve 55

6.4 Notes on cleaning the unit components 56

6.5 Notes on cleaning agents 57

6.6 Resetting the maintenance indication 57

7 Fault elimination 58

7.1 Fault indication 58

7.2 Malfunction lists 59

7.2.1 System faults 59

7.2.2 Unit faults 59

7.3 Notes on fault elimination 61

7.4 Resetting the error indication (red LED lights) 61

8 Taking out of service/Disposal 62

8.1 Taking out of service 62

8.2 Disposal/Recycling 62

9 Product specications 63

9.1 Technical data 63

9.2 Unit dimensions 64

5 Operation 43

5.1 Function of the display and operating elements 43

5.2 Commissioning 44

5.3 Notes on operation 45

5.3.1 Function of the LED's in info mode 45

5.3.2 Inspections during operation 45

5.4 Carrying out manual draining 46

5.5 Taking the unit out of operation 46

3

1 Introduction

1.1 To the very beginning

We thank you for having purchased the steam humidier Nordmann ES4 4.

The steam humidier Nordmann ES4 4 incorporates the latest technical ad
van ces and meets all recognized safety standards. Nevertheless, improper
use of the Nordmann ES4 4 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 4, 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 4. 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 4 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.

4

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.

Copyright protection

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.

5

2 For your safety

General

Every person working with the Nordmann ES4 4 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 4 are fa­miliar and comply with the appropriate regulations on work safety and the

prevention 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 4 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 9

“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 4 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).

6

Danger that may arise from the unit

DANGER!
Danger of electric hazard!

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 4 out

of operation as described in chapter 5.5 (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 4 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 op-

eration (steam lines, steam distributor, etc.). If the steam system is leaky
set the Nordmann ES4 4 immediately out of operation as described in
chapter 5.5. Correctly seal the steam system before putting the unit into

operation again.

WARNING!
Danger of burning!

During operation the components of the steam system (e.g. steam
cylinder, steam distributor) 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 4 out of operation as described in chapter 5.5, 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 Nor-
dmann ES4 4 should immediately be shut down and secured against
accidental power-up according to chapter 5.5. This can be the case
under the following circumstances:

– if the Nordmann ES4 4 is damaged

– if the electrical installations are damaged
– if the Nordmann ES4 4 is no longer operating correctly
– if connections and/or piping are not sealed

All persons working with the Nordmann ES4 4 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 4 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.

7

3 Product Overview

3.1 Model overview

The steam air humidiers Nordmann ES4 4 are available in the following

version.

Nordmann ES4 4 230V1 230V/1~/50...60Hz 4 kg/h

Key model designation

Product designation

Max.steam capacity in kg/h

Heating voltage:
230V/1~/50...60Hz: 230V1

Model Heating voltage Max. steam capacity

Nordmann ES4 4 230V1

3.2 Identication of the unit

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

Heating voltage

Maximum steam capacity per unit

Admissible water supply pressure

Field with certication symbols

Power consumption

Control voltage

Type designation Serial number (7 digits) Month/Year

Nordmann Engineering AG, CH-8808 Pfäfkon

Type: ES4 4 Ser.Nr.: XXXXXXX 11.12
Heating voltage: 230V / 1~ / 50...60Hz Power: 3.1 kW

Steam capacity: 4.0 kg/h Ctrl. Voltage: 230V / 1~ / 50...60Hz
Water pressure: 1...10 bar

Made in Switzerland

8

3.3 Steam humidier construction

19

18

17

1

2

10

11

12

13

14

9

20

21

22

15

3

4

5

16

6

7

8

23

1 Housing (small, large)
2 Cable openings, top side
3 Power board (option)
4 Control board with CF Card
5 Terminals supply voltage

6 Drain/info key
7 Operation status indicators

8 Unit switch

9 Water cup

10 Overow hose
11 Filling hose
12 Water supply hose

13 Drain valve
14 Inlet valve
15 Steam cylinder
16 Type plate
17 Electrode plug
18 Level sensor
19 Steam outlet
20 Water supply connector

21 Drain cup
22 Drain connector

23 Cable openings, bottom side

9

3.4 Functional description

The steam humidier Nordmann ES4 4 is a pressureless steam generator
that utilizes an electrode heating. The steam humidier Nordmann ES4 4
is designed for air humidication via a steam distributor.

Steam hose

Water cup

Overow hose

Filling hose

Water supply hose

Control

board

Level sensor

Electrodes

Steam distribution pipe

Condensate hose

with siphon

Current sensor

Heating
relay

Power board

Inlet valve

Steam cylinder

Unit switch

Drain valve

Base tub

Steam generation

Any time steam is requested, the electrodes are supplied with voltage via
the heating relay. 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.

10

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).

11

3.5 Humidication system overview

17

DV41

13

DS22

11

14

18

W21

12

KS10

8

15

W22

16

125...1250 µS/cm

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)

1

2

3

4

DSS22

Z261

6

5

9

7

8

1...10 bar

1...40 °C

10 Service switch control voltage supply (building side)
11 Steam hose (accessory “DS..”/“Z10”)
12 Condensate hose (accessory “KS10”)
13 Steam distribution pipe (accessory “DV41..”)
14 Steam nozzle (accessory “W21”)
15 Steam distributor (accessory “DSS22”)
16 Steam distributor (accessory “W22”)
17 Humidity controller 010V or Humidistat

18 Safety humidistat

10

ONOFF

12

3.6 Accessories

3.6.1 Accessories overview

Accessories for water installation

Nordmann ES4 4

Filter valve Z261 (1 pc. per system)

Accessories for steam installation

Nordmann ES4 4

Steam distribution pipe

(details see chapter 3.6.2.1)

Steam nozzle

(details see chapter 3.6.2.2)

Steam distributor

(details see chapter 3.6.2.3)

Steam distributor

(details see chapter 3.6.2.4)

Steam hose / meter 1x DS22

EcoTherm insulation hose / meter 1x ECT22

Condensate hose / meter 1x KS10

Accessories for humidity control

Duct humidistat HBN (1 pc. per system)

Room humidistat HSN (1 pc. per system)

1x DV41-...

1x W21

1x W22

1x DDS22

Nordmann ES4 4

13

3.6.2 Accessory details

3.6.2.1 Steam distribution pipe DV41-...

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).

L

B

Steam distribution pipes for

Nordmann ES4 4

1)

Type DV41-.. in mm

41-200 200 210...400

41-350 350 400...600

41-500 500 550...750

41-650 650 700...900

41-800 800 900...1100

41-1000 1000 1100...1300

41-1200 1200 1300...1600

1)

Material: CrNi steel

Length (L) steam

distribution pipe

2)

2)

special length on request

Duct width (B)

in mm

14

3.6.2.2 Steam nozzle W21

The steam nozzle W21 can be mounted in the ventilation duct horizontally
or vertically. Keep a minimum distance clearance (A) of 200 mm between
nozzle opening and the opposite duct wall.

64 mm

64 mm

max. 19 mm

ø22.5 mm

ø48.5 mm

A

A

1/2

1/2

3.6.2.3 Steam distributor DSS22 (for steam bath)

64 mm

ø22.5 mm

ø48.5 mm

2/3

1/3

64 mm

max. 19 mm

3.6.2.4 Steam distributor W22 (for steam bath)

ø43 mm

ø22.5 mm

15

3.7 Standard delivery

The standard delivery includes:

– Steam humidier Nordmann ES4 4 with water drain hose and water

connection hose G 3/4"  G 3/8", xing set and installation and operating
instructions (this document), packaged in cardboard box
– Cardboard box: 550 mm x 360 mm x 300 mm,

shipping weight: ?? kg

– Ordered accessories with operating instructions according chapter 3.6,

packed separately

– Spare parts list

3.8 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 unit is less than 20 kg. Always place the unit on its back side.

Packaging

Keep the original packaging of the Nordmann ES4 4 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.

16

4 Mounting and installation work

4.1 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).

17

4.2 Installation overview

A1 / A2

External safety chain

X6

12

ES4 4

SC1SC2

SAFETY

ext.

SC1SC2

Pmax
Pmin

W21

Steam installation

see chapter 4.4

800 Pa

-800 Pa

DV41

W21

min. 300 mm

KS10

min. 20 %
–

Ømin.

200 mm

W21

min. 5 %

–

Rmin. 300 mm

DS22

min. 20 %

B3

B3

B2

B1

On/Off-ControlContinuous control 0-10V

JP4

JP3

X1

123

ES4 4

CTRL V+

GND

0-10V

On/Off

A1

CONT.SIGN

– +
0-10V

+

ext.

V+GND CTRL

JP4

JP3

0-10V

On/Off

CONT.SIGN

A2

GND

CTRL V+

On/Off

X1

123

ES4 4

ext.

V+GND CTRL

Heating voltage

ONOFF

X9

MAIN SUPPLY

Mounting the unit

see chapter 4.3

Water installation

see chapter 4.5

Electric installation

see chapter 4.6

125...1250 µS/cm

1...10 bar

1...40 °C

ø 30 mm

G 3/4"

G 1/2"

ø14/7 mm

Z261

G 3/8"

≥ 40 mm

min. 50 cm

L

N PE

PWR

Q3

F5

L1

N

230V1~ 50..60Hz

ES4 4

ext.

18

4.3 Mounting the unit

4.3.1 Notes on locating the unit

min. 250 mm

60...70 °C

Y

min. 400 mm

min. 400 mm

X

1 ... 40 °C
max. 75 %rh
IP20

Z

min. 600 mm

min. 600 mm

Nordmann ES4 4 230V1

Dimensions housing (X x Y x Z) in mm 285 x 205 x 430

Net weight in kg 8

Operating weight in kg 13

19

The installation site of the steam humidier depends largely on the location
of the steam distributor (see chapter 4.4). 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 4.4.5).

– The steam humidiers Nordmann ES4 4 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 4 is retaining heat during opera-

tion (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 4 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 4 may only be installed in rooms

with a oor drain.

CAUTION!

If for some reason the Nordmann ES4 4 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 4 use only the xing materials sup-

plied 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 4 is designed for installation and operation inside

buildings.

20

4.3.2 Mounting the humidier

a

b

c

e

d

Dimension Nordmann ES4 4 230V1

a 175 mm
b 35 mm
c 335 mm
d 130 mm
e 75 mm

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.

21

4.3.3 Inspecting the installed unit

Check the following points:

Is the unit installed in the correct place (see chapter 4.3.1)?

Is the supporting surface stable enough?

Is the unit correctly aligned, vertically and horizontally?

Is the unit properly secured (see chapter 4.3.2)?

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

the two screws?

22

4.4 Steam installation

4.4.1 Overview steam installation

800 Pa

Pmax
Pmin

-800 Pa

DV41

min. 300 mm

min. 20 %
–

W21

min. 5 %

–

DS22

Rmin. 300 mm

min. 20 %

+

W22

200 mm

min. 5 %

–

Rmin. 300 mm

Ømin.

KS10

min. 300 mm

DSS22

23

4.4.2 Positioning of the steam distributors in a duct

The location for the steam distributor in the duct 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 distributors, 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

serves as a basis for the determination of the minimum distances from the

upstream components in the system.

” and

N

BN: Humidication distance B

E: Expansion and mixing zone
φ1: Supply air humidity before humidication
φ2: Supply air humidity after humidication

N

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.

Humidity at inlet

ϕ1 in %rh

40 50 60 70 80 90

5 0.9 1.1 1.4 1.8 2.3 3.5

10 0.8 1.0 1.3 1.7 2.2 3.4

20 0.7 0.9) 1.2 1.5 2.1 3.2

30 0.5 0.8 1.0 1.4 1.9 2.9

40 – 0.5 0.8 1.2 1.7 2.7

50 – – 0.5 1.0 1.5 2.4

60 – – – 0.7 1.2 2.1

70 – – – – 0.8 1.7

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 capacity

Length of humidication distance BN in m

Humidity at outlet ϕ2 in %rh

24

Example

given: ϕ1= 30 %rh, ϕ2= 70 %rh

humidication distance B

: 1,4 m

N

Minimum distances to be observed

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

”).

N

before/after constriction

50 mm

N

0.5 x B

before bend

N

1 x B

after expansion

before branch

N

1 x B

N

0.5 x B

before diffuser before control sensor

N

1 x B

5 x B

N

25

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

+

50 mm

N *

1.5 x B

N

* 2,5 x B

before aerosol lter

N

1 x B

Installation notes and dimensions

50 mm

1 x B

N

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.

26

Positioning the steam distributors in the duct

In positioning the steam distribution pipe DV41.. and the steam nozzle
W21, the following dimensions should be observed:

H

1/2

1/2

2/3

H

1/3

min

h

H

1/2

1/2

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

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

A

A

1/2

1/2

2/3

1/3

min

h

A min.= 200 mm

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 4, contact your Nord­mann supplier.

27

4.4.3 Positioning of the steam distributors in a steam bath

The positioning of the steam distributors DSS22 and W22 in a steam bath
belongs to the clients responsability.

4.4.4 Installing the steam distributors

Detailed information on the installation of steam distributors can be found

in the separate mounting instructions for these products.

28

4.4.5 Installing the steam and condensate 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:

Ømin.

200 mm

min. 20 %

–

min. 300 mm

Rmin. 300 mm

min. 20 %

+

min. 20 %

max. 4 m

min. 300 mm

+

Rmin. 300 mm

max. 4 m

min. 300 mm

min. 20 %

–

200 mm

Ømin.

min. 300 mm

min. 20 %

–

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.

29

min. 20 %

+

max. 4 m

Rmin. 300 mm

min. 300 mm

min. 5 %

–

min. 20 %

–

Ømin.

200 mm

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

edge of the humidier:

min. 300 mm

Obstacle

min. 20 %

+

Rmin. 300 mm

max. 4 m

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.

min. 5 %

–

Rmin. 300 mm

min. 20 %

–

Ømin.

200 mm

min. 20 %

min. 300 mm

+

min. 300 mm

Ømin.

200 mm

min. 20 %

–

30

– 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.

31

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. 20 %

+

max. 4 m

200 mm

Rmin. 5 x D

min. 300 mm

Ømin.

min. 300 mm

min. 20 %

–

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.

32

4.4.6 Common steam and condensate line errors

2.

1.

3.

4.

5.

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 %).

33

4.4.7 Inspecting the steam installation

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

– Steam distribution pipe

Steam distributors correctly positioned and secured (screws tight-

ened)?

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?

34

4.5 Water installation

4.5.1 Overview water installation

ø 30 mm

G 3/4"

G 3/4"

ø14/7 mm

G 1/2"

125...1250 µS/cm

1...10 bar

1...40 °C

Z261

G 3/8"

≥ 40 mm

min. 50 cm

G 3/4"

ø14/7 mm

G 3/8"

ø 30 mm

ø 40/31 mm

35

4.5.2 Notes on water installation

Water supply

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

4.5.1 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 4, use exclusively un-

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

– If the Nordmann ES4 4 shall be operated with softened or partly

treated drinking water.

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

softened 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

4.5.1 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!

36

4.5.3 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?

37

4.6 Electric installation

4.6.1 Wiring diagram Nordmann ES4 4

Control board Power board

CF Card

Service

Steam

Driver

J8

RFI

PRO

BASIC

JP4

0-10V

JP3

On/Off

A1

1AT

200mAF

JP2

JP1

5V

24V

GND

CONT.SIGN

– +

0-10V

A2

Set JP2
Remove JP1

F2

F1

CTRL V+

J1 CPU
BOARD

J1

Cylinder

0

Settings

1 2 3 4 5 6

ON

Low. Conduct.
Standby Drain
Force Drain
Cylinder A/D
CFGI-Modus

Drain Factor

1.0

Power Limit

75%

Drain switch

red yellow green

Error

MAIN CONTACT

X1 X6

12 123

V+GND CTRL

V+GND CTRL

On/Off

J7L

J6N

CYLINDER LEVEL SENSOR

REL4

F3

1AT

SC1SC2

SAFETY

SC1SC2

J

K

B3

B2

B1

J4N

X9

MAIN SUPPLY

L

PWR

Q3

F5

L1

230V1~ 50..60Hz

N PE

N

PE

DRAIN

S1

INLET

L N L N

F4 1AT

N L SWN SWL

SWITCH

X7

Cylinder RD 422

Inlet valve

Drain valve

X8

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

B3 Safety humidistat

F1 Internal fuse power board: control signal (200 mA, fast acting)
F2 Internal fuse power board: control 5 V (1 A, träge)
F3 Internal fuse power board: control 24 V (1 A, träge)
F4 Internal fuse power board: control voltage (1 A, träge)
F5 External fuse supply voltage (see table in chapter 4.6.2)
J Short circuited, if no external monitoring devices are connected
JP1 Set jumper for voltage output on X1, V+ = 5 V (remove jumper JP1)
JP2 Set jumper for voltage output on X1, V+ = 24 V (remove jumper JP2)
JP3 Jumper must be removed
JP4 Jumoper must be set
K External safety chain (24 VDC)
Q3 External service switch voltage supply
S1 Unit switch
REL4 Relay heating
S1 Rotary switch "Cylinder type”
S2 Potentiometer “Drain factor”
S3 Potentiometer “Power limitation”
S4 DIP switch “General unit settings”
X1 Connection terminal control signal
X6 Connection terminal safety chain
X7 Connection terminal inlet and outlet valve
X8 Connection terminal unit switch
X9 Connection terminal voltage supply

38

4.6.2 Notes on electric installation

Important notes

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

gram in chapter 4.6.1, 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”).

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

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

observed.

– The supply voltage must match the unit voltage stated on the type plate.

Voltage supply (heating voltage)

CAUTION!

Before connecting, ensure that the mains voltage corresponds with the
unit voltage stated on the type plate.

The Nordmann ES4 4 is to be connected to the mains supply in accordance
with the wiring diagram, via a service switch “Q3” (disconnecting device
with a minimum contact opening of 3 mm is an essential requirement) and a
fuse “F5” (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 “X9”.

Heating voltage Max. steam

capacity

[kg/h]

230V1~ / 50..60Hz 4 3.1 13.5 16

Nominal

power

[kW]

Nominal

current

[A]

Main

fuse F5

[A]

The crosssection of the mains cable must comply with the applicable local
regulations (minimum of 1.5 mm2).

39

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 “X6” in accordance

with the wiring diagram.

DANGER!
Danger of electric hazard!

The mains voltage is connected to terminal block “X6” (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 “X6”.

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

2

).

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” and
the jumper on “JP2” msut be removed.

40

4.6.3 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:

Unit type ES4 4 230V1

Steam cylinder type RD 422

Position rotary switch “Cylinder” 0

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)

41

4.6.4 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 CF 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?

42

5 Operation

5.1 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 6) or

the maintenance indication is not reset after the maintenance (see

chapter 6.6).

– 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.

43

5.2 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 switch for mains supply.

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 6) or the maintenance indication has not been reset
(see chapter 6.6).

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

chapter 7).

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 4 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.

44

5.3 Notes on operation

5.3.1 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

Indication in info
mode

Steam output 0 % 50 % 50% 0 %

Error code –– –– W36 E21

green LED lights no yes yes no

red LED lights no no no yes

green LED ashes .. –– 5x 5x ––

red LED ashes .. –– –– 3x 2x

yellow LED ashes .. –– –– 6x 1x

5.3.2 Inspections during operation

During operation the Nordmann ES4 4 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 4 out of operation

as described in chapter 5.5. Then, contact your Nordmann representative.

45

5.4 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.

5.5 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 5.4) and wait until the steam cylinder

is empty.

4. Actuate the unit switch.

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

to mains suppy and secure switch in “off” position against accidentally
being switched on and clearly mark the switch.

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.

46

6 Maintenance

6.1 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 4 out of operation as described in chapter 5.5 (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).

47

6.2 Maintenance list

Components Interval Work to be done

Steam cylinder X Remove and replace.

Drain valve X Remove, disassemble and clean, replace if necessary.

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

To maintain operational safety the Nordmann ES4 4 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.

I II III

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.

48

6.3 Removing and installing parts for maintenance

6.3.1 Removal and installation of the steam cylinder

1 2

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 4

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.

49

5

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!

50

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 RD 422

brown

Sensor

white

black

– 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.

51

6.3.2 Removal and installation of the drain cup

3

2

1

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 assem­bling check Oring of the drain cup and the gasket of the water supply hose
for damage and replace if necessary.

52

6.3.3 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 6.3.1).

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.

53

6.3.4 Removal and installation of the drain valve

4

1

3

2

For removing the drain valve the steam cylinder must be removed rst (see
chapter 6.3.1).

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.

54

6.3.5 Removal and installation of the inlet valve

1

3

5

4

3

For removing the inlet valve the steam cylinder must not be removed.

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.

55

6.4 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

Drain valve

valve housing

valve stem

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

• 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!

• 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.

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 6.5), until the limescale comes off.

56

• Wash the water cup 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 6.5),
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)

6.5 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.

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.

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!

WARNING!

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.

6.6 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).

57

7 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.

7.1 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 5.3.1 for further information regarding the info mode).

Examples:

Normal operation

mode

Info mode

Error code E2 W21 E21 E37

red LED lights yes no yes yes

red LED ashes .. –– 2x 2x 3x

yellow LED ashes .. 2x 1x 1x 7x

58

7.2 Malfunction lists

7.2.1 System faults

Warning Error Cause Remedy

Code Malfunction Code Malfunction

E1 CF Card missing No CF Card installed on the control

board.

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

––– ––– E3 CF Card is defective Invalid data stored on the CF Card. Install new CF Card.

––– ––– E4 CF Card is

incompatible

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

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

7.2.2 Unit faults

Install CF Card or start test run.

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

Warning Error Cause Remedy

Code Malfunction Code Malfunction

W20 External safety

chain is open

W21 Max. lling level of

steam cylinder
reached

W22 Permissible lling

time exceeded

(20 minutes)

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

E21 Max. lling level of

steam cylinder
reached but
no heating current

E22 Permissible lling

time exceeded

(more than 4 hours)

tion system.

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

tion system.

Safety humidistat triggered. Wait. If applicable, check safety

humidistat

Water conductivity too low (after initial
operation).

Water conductivity too low for type of
steam cylinder.

Phase failure heating voltage. Check service switch in the mains

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

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

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

Wait until the mineral content of the
cylinder has increased

Select correct steam cylinder type.

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

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

if applicable clean strainer insert or
replace inlet valve.

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

necessary.

59

Warning Error Cause Remedy

Code Malfunction Code Malfunction

W23 No electrode current

for more than 20
minutes

W24 Electrode current in

relation to the steam
demand too high

W25 Max. admissible

electrode
current exceeded

––– ––– E26 Main contactor

W27 Foam detection E27 Foam detection (4

W28 Steam cylinder

needs service

W29 Steam cylinder

needs service

W36 Standby draining of

steam cylinder
active

W37 Forced draining of

steam cylinder
active

E23 No electrode cur-

rent for more than
4 hours

E24 Electrode current in

relation to the steam
demand too high

E25 Max. admissible

electrode
current exceeded

jammed

automatic drainings
within 24 hours)

E28 Service interval for

steam cylinder
exceeded

E29 Max. operating

hours of the steam
cylinder reached

––– ––– Automatic standby draining of

––– ––– Forced draining of steam cylinder

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.

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

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

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

Humidity demand has decreased too

fast.

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

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

Water conductivity too high for this

type of steam cylinder.

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

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

Water conductivity too high for this

type of steam cylinder.

Main contactor jammed in activated

position.

Foaming in steam cylinder. Drain steam cylinder via drain key

Mineral deposits and/or electrodes

spent.

Maximum operating hours of the
steam cylinder reached.

steam cylinder active.

active.

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

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

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

necessary.

Automatic adaptation of the operat­ing point.

essary.

Clean drain screen (see chapter 6.3.2
and 6.4) or replace steam cylinder.

Select correct steam cylinder type.

essary.

Clean drain screen (see chapter 6.3.2
and 6.4) or replace steam cylinder.

Select correct steam cylinder type.

Inspect main contactor, replace if

necessary.

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

Replace steam cylinder.

Important: After the replacement of
the steam cylinder, reset the main­tenance counter (see chapter 6.6).

Replace steam cylinder.

Important: After the replacement of
the steam cylinder, reset the main­tenance counter (see chapter 6.6).

No measures must be taken.

No measures must be taken.

60

7.3 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 5.5, 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!

7.4 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.

61

8 Taking out of service/Disposal

8.1 Taking out of service

If the Nordmann ES4 4 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 5.5.

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

8.2 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.

62

9 Product specications

9.1 Technical data

Heating voltage

Steam capacity 4 kg/h

nominal power

Max.

Control voltage

Operating conditions

Admissible water pressure

Water quality Untreated drinking water

Admissible water temperature

Admissible ambient temperature

Admissible ambient humidity

Admissible back pressure in steam hose

Type of protection

Conformity

Dimensionen/Gewichte

Housing (WxHxD)

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

Water drain connector ø 22 mm

Steam connector ø 22 mm

Net weight

Operating weight

Equipment

Steam cylinder type

Accessories

Filter valve

Steam distribution pipe DV41...

Steam distributor

Steam distributor

Steam hose

EcoTherm insulation hose ECT22

Condensate hose

Duct humidistat

Room humidistat

Nordmann ES4 4 230V1

230V/1~/50..60Hz

3.1 kW

230V/1~/50..60Hz

1...10 bar

with a conductivity of 125...1250 µS/cm

1...40 °C

1...40 °C

max. 75% rh (noncondensing)

-0.8 kPa...0.8 kPa

IP 20

CE, VDE

285 mm x 430 mm x 205 mm

8 kg

13 kg

RD 422

Z261

DSS22

W22

DS22

KS10

HBN

HSN

63

9.2 Unit dimensions

Nordmann ES4 4 (dimensions in mm)

147

205

140

36

G 3/4"

430

69

101

285

ø30

80

175

75 130

35

335

49

64

Notes

65

Notes

© Nordmann Engineering Ltd., Printed in Switzerland

Technical modifications reserved

NORDMANN

ENGINEERING

Reg.No. 40002-2

Manufacturer:
Nordmann Engineering Ltd.
www.nordmann-engineering.com, [e-mail]