Nortec GS User Manual

Important: Read and save these instructions. This guide to be left with equipment.

1506222-L| 07 JAN 2014

Series

Installation and Operation Manual

Includes installation, operation, maintenance, and troubleshooting information for your GSTC / GHP gas steam humidifier.

− Do not store or use gasoline or other flammable vapors and

liquids in the vicinity of this or any other appliance.

− WHAT TO DO IF YOU SMELL GAS

 Do not try to light any appliance.  Do not touch any electrical switch; do not use any

phone in your building.

 Leave the building immediately.  Immediately call your gas supplier from a phone

remote from the building. Follow the gas supplier’s instructions.

 If you cannot reach your gas supplier, call the fire

department.

− Installation and service must be performed by a qualified

installer, service agency or the gas supplier.

WARNING:

FIRE OR EXPLOSION HAZARD

Failure to follow safety warnings exactly could result in serious injury, death or property damage.

Be sure to read and understand the installation, operation and service instructions in this manual.

Improper installation, adjustment, alteration, service or maintenance can cause serious injury, death or property damage.

INSTALLATION DATE (MM/DD/YYYY)

MODEL #

SERIAL #

Thank you for choosing Nortec.

Proprietary Notice

This document and the information disclosed herein are proprietary data of Nortec Humidity Ltd. Neither this document nor the information contained herein shall be reproduced used, or disclosed to others without the written authorization of Nortec Humidity Ltd., except to the extent required for installation or maintenance of recipient’s equipment. All references to the Nortec name should be taken as referring to Nortec Humidity Ltd.

Liability Notice

Nortec does not accept any liability for installations of humidity equipment installed by unqualified personnel or the use of parts/components/equipment that are not authorized or approved by Nortec.

Contents

4 General 7 Installation

7 Indoor Installation

7 Locating and Mounting

9 Gas Piping

11 Combustion Air Requirements

12 Exhaust Venting

17 Installation As A Category I Appliance

18 Installation As A Category III Appliance

20 Electrical 25 Plumbing 28 Outdoor Installation 35 Operation

36 Start-Up Procedure

38 Taking out of Operation

41 Scale Management

43 Fault Conditions

44 Maintenance

44 Draining the Tank

46 Cleaning the Steel Tank

47 Servicing the Unit

49 Component Replacement

55 Key Pad 73 Troubleshooting 80 Wiring Diagrams &

Spare Parts

CAUTION: Servicing

 Nortec does not accept any liability for installations of humidity equipment installed by

unqualified personnel or the use of parts/components/equipment that are not authorized or approved by Nortec.

 Every person working with the Nortec GS Series must read and understand the

installation and operating instructions before carrying out any work.

 Disconnect main power and shut off gas supply before any servicing.  During and following operation of the humidifier, the steam and components in contact

with the steam can become hot and burn if touched.

 Poorly maintained humidifiers can endanger health of building occupants.  The GS must be serviced in the intervals described in the maintenance section of this

manual.

 Be mindful of weather. Opening a GSTC Outdoor enclosure exposes internal components

that should not come into contact with water. It is not recommended to perform ay service on an Outdoor GSTC during rain, snow, sleep or hail.

CAUTION: Electrical

 All electrical work should be done according to local electrical code.  Electrical connection to be performed by a licensed electrician.

CAUTION: General

 The Nortec GS series must be kept clear and free of combustible materials, gasoline, and

other flammable vapors and liquids.

 The indoor GS humidifier located in an insulated space must be kept free and clear of

insulating material. Do not add combustible insulating material to the appliance.

 The GS humidifier requires proper ducting for combustion air and exhaust ventilation for

safe operation. Avoid blocking or obstructing air openings on the appliance, air openings communicating with the area in which the appliance is installed and the spacing around the appliance.

 Should overheating occur, or the gas supply fails to shutoff, shut off the manual gas valve

to the appliance before switching off the electrical supply.

 Do not use this appliance if any part has been under water. Immediately call a qualified

service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

Introduction

GS Series Installation | 2

CAUTION: Installation

 Installation and service must be performed by a qualified installer, service agency or the

gas supplier

 The GS produces steam at atmospheric pressure. No devices which could block steam

output should be connected to the steam outlet.

 Steam lines must be installed so that no restriction can produce backpressure in the

humidifier. Failure to follow installation instructions will result in improper operation and could void warranty.

 Regardless of selecting On/Off or modulating control method, Nortec humidifiers must

have a closed circuit across its On/Off security loop control terminal to operate. Nortec highly recommends the use of a high limit humidistat and an air proving switch in series for this function.

CAUTION: Plumbing

 Plumbing to be performed by a licensed plumber.  All plumbing work should be done according to local plumbing code.  Unit damage caused by water quality outside of the specified ranges is not covered under

warranty.

Figure 1: GSTC-100

3 | GS Series Installation

General

This installation guide has been designed to provide assistance when installing, mounting, and commissioning a GS Series humidifier. Actual on site application may vary. Consult Technical Services or your local Nortec representative.

Warning

Improper installation, adjustment, alteration, service, maintenance, or use can cause carbon monoxide poisoning, an explosion, fire, electrical shock, or other conditions which may cause personal injury or property damage. Consult a qualified installer, service agency, local gas supplier, distributor, or branch for information or assistance. The qualified installer or agency must use only factory authorized and listed kits or accessories when modifying this product. A failure to follow this warning can cause electrical shock, fire, personal injury, or death.

Should overheating occur, or the gas fails to shut off, shut off the manual gas valve to the appliance before shutting off the electrical supply.

Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

Delivery

The standard delivery includes:

 Gas Steam humidifier equipped with desired options.  In a bag you will find:

o Manuals. o Adapter fittings for water connection. o Steam hose for steam outlet with clamps. o Hose and clamps for drain connection.

The GS Indoor Series offers an optional telescopic stand mounted inside the unit legs. Stand cross bracing are shipped with the unit.

The GS Outdoor Series comes with all required venting to be installed on site.

Desired accessories ordered.

Receiving And Unpacking Equipment

 Check packing slip to ensure ALL material has been delivered.  All material shortages are to be reported to Nortec within 48 hours from receipt of goods. Nortec

assumes no responsibility for any material shortages beyond this period.

 Inspect shipping boxes for damage and note on shipping waybill accordingly.  After unpacking, inspect equipment for damage and if damage is found, notify the shipper promptly.  All Nortec products are shipped on an F.O.B. factory basis. Any and all damage, breakage or loss claims

are to be made directly to the shipping company.

GS Series Installation | 4

Figure 2: Model Designation

High Altitude

A derate in input exists for installations at higher altitudes. For Canadian models, an automatic 10% derate applies to installations from 2000-4500 feet. For U.S. Models, refer to the chart below for high altitudes derate information.

Table 1: High Altitude

Altitude

Derate %

Feet

Meters

0-2000

0-610

2001-3000

610-915

3001-4000

915-1220

4001-4500

1220-1370

4501-higher

1370-higher

Contact Factory

General Specifications

The Nortec GS Series humidifier is a completely new patented design based on leading edge technology. The GS is designed to provide clean steam humidification at an economical price.

The GS Series humidifiers are designed exclusively for humidification in ventilation systems or direct room humidification. Any other type of application, without the written consent of Nortec or your Nortec agent, is considered as not conforming to the intended purposes. The manufacturer/supplier cannot be made liable for any damages resulting from improper use.

Model Designation

The unit specification label indicates the model of gas humidifier according to Figure 2.

5 | GS Series Installation

MODEL GS 100 SPECIFICATIONS

FUEL

BLOWER SPEED

INPUT (BTUH)

STEAM CAPACITY (LBS/HR)

MANIFOLD PRESS. IN W.C.

NATURAL GAS

MAX

140,000

105

-0.05

MIN

45,000

-0.05

PROPANE

MAX

140,000

105

-0.35

MIN

50,000

-0.35

MODEL GS 200 SPECIFICATIONS

FUEL

BLOWER SPEED

INPUT (BTUH)

STEAM CAPACITY (LBS/HR)

MANIFOLD PRESS. IN W.C.

NATURAL GAS

MAX

280,000

210

-0.05

MIN

45,000

-0.05

PROPANE

MAX

280,000

210

-0.35

MIN

50,000

-0.35

MODEL GS 300 SPECIFICATIONS

FUEL

BLOWER SPEED

INPUT (BTUH)

STEAM CAPACITY (LBS/HR)

MANIFOLD PRESS. IN W.C.

NATURAL GAS

MAX

420,000

315

-0.05

MIN

45,000

-0.05

PROPANE

MAX

420,000

315

-0.35

MIN

50,000

-0.35

MODEL GS 400 SPECIFICATIONS

FUEL

BLOWER SPEED

INPUT (BTUH)

STEAM CAPACITY (LBS/HR)

MANIFOLD PRESS. IN W.C.

NATURAL GAS

MAX

560,000

420

-0.05

MIN

45,000

-0.05

PROPANE

MAX

560,000

420

-0.35

MIN

50,000

-0.35

MODEL GS 500 SPECIFICATIONS

FUEL

BLOWER SPEED

INPUT (BTUH)

STEAM CAPACITY (LBS/HR)

MANIFOLD PRESS. IN W.C.

NATURAL GAS

MAX

700,000

525

-0.05

MIN

45,000

-0.05

PROPANE

MAX

700,000

525

-0.35

MIN

50,000

-0.35

MODEL GS 600 SPECIFICATIONS

FUEL

BLOWER SPEED

INPUT (BTUH)

STEAM CAPACITY (LBS/HR)

MANIFOLD PRESS. IN W.C.

NATURAL GAS

MAX

840,000

630

-0.05

MIN

45,000

-0.05

PROPANE

MAX

840,000

630

-0.35

MIN

50,000

-0.35

Table 2: Model Specification

GS Series Installation | 6

Figure 3: Typical Installation Indoor

Installation

Indoor Installation

The installation must conform with local building codes or, in the absence of local codes, with the ANSI Z223.1, National Fuel Gas Code, and/or CSA B149.1installation codes. Refer to the Gas Piping section of this manual.

Locating and Mounting

GS Series humidifiers are designed for floor mounting or on a GS stand (optional). The clearance dimensions shown in this manual are for reference only and are the minimum required for maintenance of the humidifier. Local and national codes should be consulted prior to final location and installation of the humidifier. Nortec cannot accept responsibility for installation code violations.

Figure 3 shows a typical installation with all required connections to the GS humidifier. Careful consideration should be given to all of these connections when choosing a location for the humidifier.

7 | GS Series Installation

Warning: Steam distributor on the built-on and remote mounted blower packs have a hot surface that could result in burns if touched. Nortec recommends mounting at least 8 feet above the floor.

Figure 4: Mounting Clearances

Ambient temperature location for humidifier: 41ºF - 104ºF (5ºC - 40ºC).

Relative humidity location for humidifiers: 5% rh - 80% rh.

All GS humidifiers are rated for the clearance to shown in Figure 4.

Location of the steam distributor should be minimum of 36” above the humidifier.

Do not locate humidifier any further than absolutely necessary from steam distributor location. Net output

will be reduced as a result of heat loss through steam line. Also, increased static pressure (over 12" W.C.)

will result in hot water going down the drain. Consult factory if this situation occurs.

Where possible, mount humidifier at a height convenient for servicing.

Make sure the humidifier is mounted level.

Do not mount humidifier on hot surfaces.

The humidifier must be installed so that all electrical components are protected from exposure to water.

Do not mount humidifiers in an area where freezing may occur.

If humidifiers are mounted outdoors, a properly ventilated, temperature controlled, (above freezing),

weatherproof enclosure must be used.

Do not mount humidifiers on vibrating surface.

The humidifier shall not be installed directly on carpeting, tile or other combustible material other than wood

flooring.

Some insulating materials may be combustible. Prior to installing this appliance examine the area for

insulating material. If this appliance is installed in an insulated space, it must be kept free and clear of

insulating materials. If insulation is added after the appliance is installed, it will be necessary to examine

the area again.

GS Series Installation | 8

Inches w.c.

Gas

Min

Max

Natural

4.5

9.0

Propane

9.0

13.0

Warning: Never use an open flame to check for gas leaks. If a leak does exist, a fire or explosion could occur, resulting in damage, injury or death.

Gas Piping

Installation of piping must be in accordance with local codes, and ANSI Z233.1, “National Fuel Gas Code,” in the United States or CSA B149.1 installation codes in Canada.

The following table indicates the maximum and minimum allowable gas pressures for the gas humidifier.

Table 3: Max & Min Gas Pressure

The gas inlet pipe size to the appliance is:

½” NPT for GS 100 ¾” NPT for GS 200 1” NPT for GS 300 / 400 1 ¼” NPT for GS 500 / 600

Provide an adequate size gas supply line. In all installations, a certified manual shut off valve, located outside the cabinet, must be installed. When black iron gas pipe is used, a sediment trap must be located ahead of the humidifier gas controls. See Figure 5: Gas Connection.

Leak test all gas connections external to the humidifier, using a commercial soap solution made to detect leaks. Bubbles indicate gas leakage. Seal all leaks before placing the humidifier in operation.

The appliance and its individual shut-off valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures equal to or greater than 14” w.c. (3.5 kPa).

The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve during any pressure testing of the gas supply piping system at test pressures equal or less than 14” w.c. (3.5 kPa).

Dissipate test pressure from the gas supply line before re-opening the manual shut off valve to the appliance.

9 | GS Series Installation

Figure 5: Gas Connection

Failure to follow this procedure may damage the gas valve. Over pressured gas valves are not covered by warranty.

Do not use Teflon tape on gas line pipe threads. A flexible sealant suitable for use with natural gas and propane gas is recommended.

Plan gas supply piping so that it will not interfere with removal of gas valves, blower assemblies, and front or side service doors.

All gas piping should be adequately supported to prevent any strain on inlet piping.

The gas valve is provided with pressure taps to measure gas pressure upstream and downstream, (manifold pressure). The minimum gas pressure shown is for the purpose of input adjustment.

A 1/8" NPT plugged tapping, accessible for test gage connection, must be installed immediately upstream of the gas supply connection to the appliance.

GS Series Installation | 10

Warning: Air supply line should not obstruct any services going to the humidifier front and right side cabinet panels.

Combustion Air Requirements

General

Provide for adequate combustion and ventilation air in accordance with sections 5.3, air for combustion and ventilation, of the national fuel gas code, ANSI z223.1, or sections 7.2, 7.3, 7.4 of CSA B149.1 installation codes, or applicable provisions of the local building codes.

The required free area of supply air opening is:

13 in. Sq. (8,387 mm2), for GS 100 23 in. Sq. (14,839 mm2), for GS 200 35 in. Sq. (22,581 mm2), for GS 300 47 in. Sq. (30,323 mm2), for GS 400 59 in. Sq. (38,064 mm2), for GS 500 71 in. Sq. (45,806 mm2), for GS 600

Cabinet top and bottom contain air openings to provide combustion air to the forced draft blower. Do not block these openings.

Excessive exposure to contaminated combustion air will result in safety and performance related problems. Known contaminates include halogens, ammonia, and chlorides, excessive dust, lime or dirt. Excessive exposure of electronics to the contaminants will also result in performance related problems. Contact nortec technical services if you have any questions. If contaminants exist, isolate the unit from the contaminated space.

Sealed Combustion Guidelines

Installation of the combustion air supply line must be carried out by adequately qualified personnel. All local regulations relating to the provision of air supply systems must be observed and adhered to.

The air supply line and the exhaust must individually not exceed a respective equivalent length of 70 ft. (21 m). The vent pipe diameter must be maintained over the overall length of the vent.

The air supply line should be approximately as long as the flue gas venting and must be supported at every 5 ft. (1.5 m) and additionally at every pipe bend. At low temperatures, water condensation can form on the outside of the pipe. To prevent this, it is recommended that the supply air line is insulated and an in line heat is added. Consult factory.

Attach the air supply line to the manifold using a hose clamp or hose coupling if required. See Figure 6.

The air intake terminal and the flue gas terminal must end at an outside location. See Figure 8: Location of air intake and glue gas terminal must comply with all local and national regulations.

11 | GS Series Installation

Warning: Horizontal BH type venting must be used in a direct vent application.

Direct Vent Guidelines

Follow “sealed combustion guidelines”

All air piping must be listed type for direct vent application with sealed joints and seams, such as z flex. The air supply line must be installed with air supply terminals provided.

Air hookup may be in plastic provided that it has fully sealed joints per CSA requirements.

Figure 6: Sealed Combustion and Direct Vent Connection

Exhaust Venting

General

The GSTC and GSP are classed category I and III fan assisted gas appliances. This allows two methods of venting. Listed below are instructions for both venting systems, followed by specific requirements for each system.

Review the requirements for both category I and III installations and select the venting method best suited for the installation.

The maximum flue temperature is 400ºF for category I and category III installations. Normal operating range is 360 to 380ºF.

Category I and III class can be used with sealed combustion option

Category III class must be used with direct vent option.

GS Series Installation | 12

General Requirements

The vent systems shall be listed to UL or UL/CSA standard and meet the installation requirements of the national fuel code in the USA (ANSI z223.1) and the Canadian standards CSA B149.1 installation codes. Any local jurisdictions reflecting changes to the above codes should be observed.

In applying the codes, reference should be given to the venting manufactures instructions, the serving gas supplier regulations, and the specific instructions provided in this manual.

This appliance must be installed to comply with national regulations and codes. A qualified technician, competent with these codes and the local requirements of the jurisdiction must carry out the installation.

Proper removal of combustion gases must be assured, and building materials must be protected from degradation by flue gases.

Never mix venting types (B to BH or vice versa.) Never use two different manufacturer’s equipment for the same chimney.

All vent runs should be as direct as possible with no more than 6 elbows in the system. Maintain an upward slope of ¼” per ft on all horizontal vent pipe runs.

This appliance shall not be connected to a chimney flue servicing a separate appliance designed to burn solid fuel.

This appliance may not be used in conjunction with a power venter or draft inducer.

For any vent lengths over 20 feet long, insulate the vent pipe to reduce the amount of condensate that could form in the flue gases.

When the venting passes through a cold area or location that has large amounts of air passing over the venting, it should be insulated to prevent condensation from forming inside the venting.

Vent pipe passing through walls, floors, and ceilings, must be installed with the proper clearances from combustible materials, and venting manufactures fire stop equipment.

The venting shall not pass through any circulation air duct or plenum.

A drip “t” should be used for condensate removal. When a condensate drain is used it will be necessary to install a trap to prevent flue gases from escaping. Install a trap with a minimum 12” standing water column.

Prior to activating the appliance, ensure that the trap is filled with water and that the drain terminates in accordance with local plumbing codes.

Never vent into an unlined masonry or concrete chimney unless the chimney is sized and installed according to the provisions of the national fuel code in the USA (ANSI z223.1) or the Canadian standards CSA B149.

Chimney or vent should extend at least 3’ (1 m) above a roof and at least 2’ (.6 m) above any ridge within 10’ (3 m) of the chimney. Local codes apply.

Install venting so as to prevent accumulation of condensate and have a means for condensate removal.

Plastic, PVC, CPVC and HTPV special gas vents are not approved for use with this appliance.

Select vent material and clearance according to the max vent gas temperature.

All horizontal runs must be adequately supported with hangers or straps to prevent sagging.

The vent must terminate at a sufficient height above the roof to prevent blockage by expected snowfall.

13 | GS Series Installation

Figure 7: Vertical Venting Using B Type

Figure 8: Vertical Venting Using B Type with Sealed Combustion

GS Series Installation | 14

UL Listed Cap

(by others)

Flashing,

4 in. (10 cm) min.

air space between

piping and combustible

materials

BH Vent

Maintain diameter of

exhaust outlet,

any combination of

vertical up / horizontal run,

max 100 ft (30 m),

slope 1/4 in./ft (2 cm/m).

2 ft (60 cm) min. above any ridge within 10 ft (3 m)

3 ft (90 cm)

min. above roof

Drain (Note: Condensate may require treatment, consult local codes)

Support venting so

that weight is not

on exhaust outlet.

Condensate tee

(by others)

within 2 ft (60 cm)

of unit.

2 ft (30 cm)

min.

BH Vent Exhaust

Exhaust outlet Install male to male adapter (by others).

Terminate Vertically

Horizontally

Horizontal exhaust terminal must be certified and can be ordered from Nortec. If BH venting used, orient vertically, 6 in from wall.

Chose only one terminal location (2 shown for illustration only)

Figure 9: Vertical and Horizontal Venting Using BH Type

15 | GS Series Installation

Figure 10: Vertical and Horizontal Venting Using BG Type With Sealed Combustion

Use BH Vent for exhaust and direct vent air intake.

- Maintain diameter of exhaust outlet and intake.

- seal joints to meet CSA 2.19.7,

- any combination of vertical up / horizontal run,

- max 70 ft (20 m),

- slope 1/4 in./ft (2 cm/m).

Drain (Note: Condensate may require treatment, consult local codes)

Support exhaust and

air intake lines.

Condensate tee

(by others)

within 2 ft (60 cm)

of unit.

2 ft (30 cm)

min.

Direct Vent Installation

Exhaust outlet

Install male to male

adapter (by others).

Terminate exhaust and intake horizontally only in same face of building.

- orient vertically,

- 6 in from wall.

Install Nortec or by

other certified terminals

Direct Vent may only be installed with horizontal BH Venting and with horizontal exhaust and air intake termination as shown.

Air Intake

Connect to intake

with hose cuff and

hose clamps

(by others).

Min 4 ft (1.2 m), max 6 ft (1.8 m)

Figure 11: Direct Vent Installation

Figure 12: Vertical Co-Venting Using B Type

GS Series Installation | 16

Installation As A Category I Appliance

General

The GS Series humidifiers have a fan-assisted combustion which operates with a non-positive vent static pressure when installed with the appropriate vent diameter.

Category I appliances must be vented vertically or nearly vertical (see Figure 7, 8, 9, 10 & 11).

This category appliance is restricted to vertical venting installations with limits placed on horizontal lengths and vent diameters. Refer to the tables in local and/or national codes. No sidewall termination is accepted.

Vent piping must be UL or UL/CSA listed Type B. Required clearance for Type B vent is piping is 1” (25 mm).

A minimum equivalent vent length of 7 feet must be connected to the humidifier. Vent lengths must not exceed 70’ (21 m). Each 90° elbow is equivalent to 10’ and each 45° elbow equals 5'. The vent run should be as direct as possible with no more than 6 elbows in the system. Contact Nortec Technical Services if you have any questions.

The vent pipe exiting the humidifier is sized for category III installations. A field supplied adapter is required to increase the pipe immediately at the exit of the humidifier. The vent pipe must be expanded to the minimum sizes listed below for each model, increasing as code requires.

GS 100 4” minimum diameter GS 200 5” GS 300/400 7” GS 500/600 8”

The termination at the humidifier is a male connection. Standard venting hook-ups require a female path. It is highly recommended that a female to female adapter be assembled onto the humidifier to establish the proper venting sequence. Consult with the venting manufacturer for proper hook up.

Vent connectors shall not be connected into any portion of a mechanical draft system operating under positive pressure.

Use only double wall (aluminum inner wall) b vent. Single wall venting cannot be used due to the increased wet time in the lining. If the vent connector attaches to a lined masonry chimney, the chimney must be sized and installed according to the provisions of the national fuel gas code or Canadian CSA B149.1 standards. An approved venting manufacturer’s termination cap for the stack outlet must be used.

When the category I installation is selected it may be commonly vented with other listed gas fire appliances. Total input rates of all appliances will determine the vent size the chimney must be sized and installed according to the provisions of the national fuel gas code or Canadian CSA B149.1 standards.

A maximum of 4 gas appliances may be common vented on the same floor. Multiple story common venting is not recommended.

Refer to the vent manufacturer’s instructions for proper clearances to combustibles.

Recommended B-Venting Manufacturers

Simpson Dura-vent

Selkirk Canada corporation

American metal products

Metal-fab Inc.

17 | GS Series Installation

Warning: Provide a screen or barrier to prevent personal injury in areas where inadvertent personnel contact with vent pipe can occur.

Figure 13: Exhaust Connection

Installation As A Category III Appliance

General

This venting system can be installed horizontally or vertically and can terminate on a rooftop or sidewall provided the NFGC (Nation Fuel Gas Code) and CAN/CGA- B149 codes are followed. The venting manufacturer instructions must also be followed.

Venting must be UL or UL/CSA listed, tested to ULC-5636 standard. Venting may be BH, L vent or Special Gas Vent. The vent shall be listed and installed in accordance with the terms of the vent listing and the manufacturer’s instructions. The instructions listed below should be followed as well.

This category installation may not be common vented with any other natural draft gas appliance or power assist appliance. All joints must be sealed using high temperature rtv silicone.

The gas humidifier is supplied with the following exhaust outlets. GS 100 3” GS 200 4” GS 300/400 5” GS 500/600 6”

The venting must remain the same diameter throughout the installation. Horizontal BH type venting must be used in a direct vent application.

GS Series Installation | 18

Warning: Provide a screen or barrier to prevent personal injury in areas where inadvertent personnel contact with vent pipe can occur.

BH Vent Manufacturers

Flex-l international

Fas-n seal

Heat-fab Inc.

Z flex

Additional requirements when venting through a sidewall.

For sidewall venting, locate the humidifier as close as possible to the wall being used.

Locate the vent terminal at least three feet above any forced air inlet located within ten feet; or at least four feet below, four feet horizontally from, or one foot above any door, window, or gravity air inlet into any building.

A minimum horizontal clearance of four feet from electric meters, gas meters, regulator and relief equipment is required.

For sidewall vent terminations, the humidifier must be installed with a certified vent terminal that can be purchased from Nortec.

GS 100 3” Nortec P/N 1502321 GS 200 4” Nortec P/N 1502322 GS 300/400 5” Nortec P/N 1507320 GS 500/600 6” Nortec P/N 1507321

Locate the vent terminal at least 7 feet or 2.1 m above grade from public walkways, adjacent buildings, operable windows and building openings, consistent with the National Fuel Gas Code ANSI Z223.1 and/or CSA B149.1 Installation codes.

Locate the bottom of the vent terminal at least twelve inches above grade or ground, or normally expected snow accumulation level. The snow level may be higher on walls exposed to prevailing winds.

Locate terminal at least 4 feet or 1.22 m from electric meter, gas meters, regulators, and relief equipment.

Avoid areas where local experience indicates that condensate drip may cause problems such as above planters, patios, or over public walkways, or over an area where condensate or vapor could create a nuisance or hazard, or could be detrimental to the operation of regulators, relief valves, or other equipment. Refer to the vent manufacturer's installation instructions.

The vent terminal must be installed in the same atmospheric pressure zone as the combustion air inlet of the humidifier. If this is not possible (as in cases of positive or negative room pressures) the humidifier should be installed with the sealed combustion or direct vent option.

19 | GS Series Installation

Warning: The electrical parts inside the humidifier are very sensitive to electrostatic discharge. Appropriate measures against electrostatic discharge (esd protection) must be taken when carrying out installation work.

Electrical and Plumbing

Electrical

Primary Wiring

All work concerning the electrical installation must be performed by qualified personnel.

The humidifier should only be connected to primary power (main power) after all installation work has been completed.

An external disconnect switch must be installed close to the unit to allow for power interruption during servicing and/or maintenance.

Humidifiers require field wiring to primary voltage terminal blocks. Depending on the unit, power requirement must be 120 Vac or 208-240 Vac, 15 A, 20 A or 30 A separately fused circuit, single phase. See Table 4 for details. Use only copper wire with a minimum 70 °C (158 °F) temperature rating. Wiring can be fed through a 7/8" hole on the bottom or the top of the control compartment.

When installed, the appliance must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70, and/or the CSA C22.1 Electrical Code, if an external electrical source is utilized.

External wiring sizes must be in accordance with NEC and/or CEC and existing local electrical codes and bylaws.

Low Voltage Control Wiring

All GS models require at least one type of input control signal for unit operation. Refer to the sections below that detail the types of controls that can be used with each model.

Low voltage control terminal strips are provided in the electrical compartment. Internal sides are factory wired. External sides are to be field wired. Refer to the specific control-wiring diagram supplied with each unit.

Field wiring from humidistat to humidifier and between devices should be shielded 18 AWG or heavier and kept as short as possible.

Controls are available from NORTEC as accessories and can be ordered with the humidifier. Controls by others may also be used as long as they meet the criteria noted below. The following is a summary of the common types of controls that may be used with NORTEC Gas Humidifiers.

Wall or Duct Mounted Control On/Off Humidistat: Wired to make on drop in humidity, break on rise to setpoint. Set to desired RH. Can be a make/break set of contacts from a Building Automation System.

Duct Mounted Safety High Limit On/Off Humidistat: Wired to make on drop in humidity, break on rise to safety setpoint. Set to approximately 85% RH as a safety to prevent saturation and wetting in the duct. Highly recommended for ducted applications.

Duct Mounted Safety Air Proving On/Off Switch: Wired to make when sensing air flow, break when no air flow. Used as a safety to prevent saturation when there is no air flow. Highly recommended for ducted applications.

GS Series Installation | 20

Voltage (V)

Rated Amps (A)

Suggested Breaker (A)

GSTC/GSP 100 Indoor

120

2.1

208-240

1.1

GSTC/GSP 200 Indoor

120

3.7

208-240

1.9

GSTC/GSP 300 Indoor

120

5.3

208-240

2.7

GSTC/GSP 400 Indoor

120

6.8

208-240

3.5

GSTC/GSP 500 Indoor

120

8.4

208-240

4.3

GSTC/GSP 600 Indoor

120

208-240

5.2

GSTC Outdoor 100

120

6.3

208-240

3.2

GSTC Outdoor 200

120

7.4

208-240

GSTC Outdoor 300

120

13.7

208-240

6.9

GSTC Outdoor 400

120

15.2

208-240

7.7

GSTC Outdoor 500

120

208-240

10.6

GSTC Outdoor 600

120

22.6

208-240

11.5

Wall or Duct Mounted Modulating Humidistat: Provides a modulating signal to the unit that represents the output (up to 100%) required from the humidifier. Signal type can be changed in the field.

All GS models may be configured for either single or dual channel modulation. Control signals can be 0-10 VDC or 0-20 mA (0-5 VDC, 1-5 VDC, 4-20 mA and 2-10 VDC are also available). The unit must be ordered from the factory for the desired signal type and number of channels. When configured for 2-channel modulation the humidifier will generate steam only if both channels indicate a demand. If both channels are demanding steam the humidifier will satisfy the lower demand signal.

Table 4: Current and Breaker Requirements for GS Series Units

21 | GS Series Installation

Figure 14: Primary 208-240 V 1 Phase Line Voltage Wiring To Unit

GS Series Installation | 22

NORTEC SERIES EXTERNAL CONTROLS WIRING CONNECTIONS LOW VOLTAGE TERMINAL STRIPS

May 27 2008

NORTEC SERIES

EXTERNAL CONTROLS WIRING CONNECTIONS

LOW VOLTAGE TERMINAL STRIP

WARNING: Failure to wire the controller

in accordance with the wiring diagram supplied with the unit could permanently damage the electronics. Such errors will void the unit warranty.

- www.humidity.com -

EXTERNAL INTERNAL

Security Loop

24Vac

Signal

Input

"2”

Signal

Input

"1”

On/Off Control Humidistat

Air Proving Switch

High Limit Humidistat

Blower Pack

Other On / Off Device

NOTE: If no On/Off Control is used then a field jumper must be connected across terminals 1 and 2 in order for the humidifier to operate.

5 Vdc

+ +

Single

Dual

POWER TO CONTROLLER OR

TRANSDUCER BY OTHERS

Both inputs to the

humidifier must be

the same type of

signal

Transducers:

Controllers (Humidistat):

Output signal across 3 - 4 and 3 - 5 increase on RH rise

To be complete with RH set point adjustment, sensor circuit, sensing element, power source and 2 wire varying output signal. RH demand are viewed on display

Output signal across 3 - 4 and 3 - 5 decrease on RH rise

To be complete with sensing element, power source and 2 wire varying output signal. RH set point adjustment is made at unit keypad. RH set point and % RH sensed are viewed on display

For all controller and transducer signals by others

24 Vac

Terminal 8 is a 24Vac input. Upon receiving 24Vac a full tank blowdown will be initiated

Figure 15: GS Series External Controls and Wiring Connections Low Voltage Terminal Strip

23 | GS Series Installation

Control Installation

Mount any wall humidistat (control or high limit) over standard electrical box at height similar to typical thermostat. Any wall humidistat should be in location representative of overall space being humidified and not in path of blower pack or air supply grill. Do not mount on an outside wall where temperature fluctuations can affect control response.

Mount duct humidistat in location representative of overall air humidity, usually in return duct. Do not mount it directly in front of steam distributor or in turbulent or mixing zone. Mount humidistat where air's humidity and temperature are uniform and representative of spaces being humidified.

Mount duct high limit humidistat downstream of steam distributors far enough that, under normal humidity and air flow conditions, steam will have been fully absorbed (typically at least 10 feet). It must be located to sense high humidity only when uniform and representative air is over-humidified or approaching saturation.

Mount duct air-proving switch so that it is able to sense air flow or lack of it. Wire it to make when air flow is sensed and break when air flow fails.

Check operation of all on/off controls before starting humidifier.

Calibration of controls (on/off or modulation) in the field may be necessary due to shipping and handling. Verify humidistat accuracy before commissioning system.

GS Series Installation | 24

Figure 16: Plumbing Connections

Plumbing

Note: All water supply and drain line connections should be installed in accordance with local plumbing codes.

Fill Water Supply Line

Each unit is supplied with an adapter for the fill valve (½”NPT). Fill rate 10 l/min all unit sizes. Size of piping is a minimum ½” copper; recommend ¾” up to within 4 feet of unit.

Standard fill valves are sized for water pressure ranging from 30 to 80 psig (ideally 55 to 60 psig). For other pressures, consult factory. This pressure should be measured at the humidifier if the water pressure is suspect.

It is recommended to have a faucet installed close to the humidifier to allow quick filling of the system on initial start up. This can also be very useful for mandatory cleaning of the unit.

ALWAYS supply and install a shut off valve and union in the water supply line dedicated to the humidifier to facilitate servicing.

If water hammer occurs, install a shock arrester on the fill water line just before the inlet to the fill valve. Water hammer will damage the fill valve.

A 1” air gap is designed into the fill system of the GS humidifier. Some local plumbing codes may still require the installation of a double check valve on the fill line to the humidifier to prevent contamination of the supply water system. Verify with local codes and install if necessary.

25 | GS Series Installation

Drain Line

The humidifier is equipped with a ¾”O.D. unthreaded drain outlet connection on the side of the humidifier. A vacuum break valve is installed internal to the unit on the drain line. The drain water line must be piped to a drain funnel to provide an air gap before connection to the building drainage system.

The air gap must be within 3 ft (1 m) of the humidifier. The drain line should not end in a sink used frequently by personnel, or where plumbing codes prohibit it.

Route to a floor drain or equivalent for safety reasons. Internal drain water tempering will ensure a maximum of 140ºF (60ºC) exiting water temperature.

Never install PVC piping as a drain line material. Always use material suitable for with-standing 140ºF (60ºC).

Keep drain lines as short as possible. Keep drain lines sloped down, not level and not up since low spots in drain lines will accumulate sediment and cause backup. The drain line should be 1-1.5" O.D. or larger. Consult local codes.

When the drain pump is activated, the tank drains at a rate of 4.5-5.3 gal/min (18-20 l/min).

Aux Drain Port

An auxiliary drain port is also provided on the side of the humidifier. It can be used to manually drain the unit, if required. The unit is shipped with this connection plugged. It is recommended to install a shut off valve on this line (see Figure 16).

The auxiliary drain port is used with the standard freeze protection on Outdoor units. Install a shut off valve on this line and pipe to the drain funnel (see Figure 16). The manual shut off valve must always be in the open position when the unit is operating but can be closed for servicing of the unit.

Steam Lines and Condensate Line

Steam hoses and clamps are provided with the GS humidifier for connection to the steam lines. Refer to Figure 17 for connection details.

For steam line installation between the humidifier and distribution system, consult the distribution system installation manual. Steam Distributor Installation Manual. See Table 5: Steam Line Sizing for details on the sizing and lengths of steam lines.

The GS Series of Gas-Steam humidifiers can develop steam pressures up to 12”w.c. to overcome duct and steam line pressures. An enclosed trap on the drain line prevents steam from going to drain. Duct pressures above 12” will cause steam to exits through the drain line. Consult factory.

GS Series Installation | 26

Humidifier

Steam output

[ lb ]

MED-L copper tube

nominal steam

line size

Stainless steel tube

diameter (wall

thickness 0.065”)

Steam loss per foot

in condensation

[ lb/ft ]

Steam line

maximum

equivalent length

GS 100

100

1-1/2”

1-3/4”

0.11

90 ft

GS 200

200

3”

0.16

90 ft

GS 300

300

3”

0.16

180 ft

GS 400

400

4”

0.22

180 ft

GS 500

500

4”

0.22

220 ft

GS 600

600

4”

0.22

260 ft

Nominal tube

size

Standard

90°-elbow

Standard

45°-elbow

Side-outlet

tee

Gate valve*

Globe valve*

1-1/2”

3.5 ft

1.75 ft

7 ft

0.8 ft

34 ft

1- 3/4”

3.5 ft

1.75 ft

7 ft

0.8 ft

34 ft

3”

5 ft

2.5 ft

11 ft

1.1 ft

54 ft

4”

8 ft

4 ft

15 ft

1.6 ft

80 ft

Figure 17: Steam Line Connection

Table 5: Steam Line Sizing

• Based on 3” duct static pressure, Maximum duct static pressure for GS is 12” w.c.

*Valve in full open position.

27 | GS Series Installation

Table 6: Effective Lengths of Typical Steam-Line Fittings

Outdoor Installation

GS Outdoor units are CSA certified for outdoor installation and come complete with exhaust venting and internal ventilation (cooling) for the electronics. Heaters for freeze protection are standard with outdoor units. All installations must conform with local building codes or, in the absence of local codes, with the National Fuel Gas Code ANSI Z223.1 in the United States or CSA B149.1Installation codes in Canada. NORTEC cannot accept responsibility for installation code violations.

Mounting

NOTE: Whenever possible do not expose drain water within the outdoor cabinetry. This could result in water damage to electronic components. If a drain pan needs to be inside the cabinetry be sure to seal around it so the cabinet doesn’t become over humidified during the drain cycles.

Typical rooftop installations are shown in Figure 18 & 19.

The GS Outdoor unit comes standard with cutouts in the base to allow for lifting by a forklift. When lifting by this method, ensure that the forks extend across the entire base to prevent tipping or damage to the unit.

The enclosure also comes complete with four (4) removable lifting lugs fastened to the base. All four lugs must be utilized if moving the unit in this manner. Protect the cabinet from damage from the lifting cables/chains during lifting. The lifting lugs should be removed from the base once the unit has been correctly positioned on the curb mounting.

See Figure 20 for clearance details.

The integral base of the GS Outdoor model is designed to mount on a curb. The curb must be built to structurally support the entire weight of the humidifier when in operation. Required curb dimensions are given in Figure 21.

Ensure that the humidifier is mounted level.

The pan in the bottom of all outdoor models has a pipe chase for routing of services into the humidifier from below.

It is not necessary to make the hole in the roof the same size as the curb. The curb drawing shows the location and size of the pipe chase required. The pipe chase should be sealed when the installation is complete to ensure positive or negative pressure from the building.

The panels of the outdoor model have louvers to provide ventilation for the electronics and air for the combustion process. Locate the unit so that louvered panels are a minimum of 10 ft from any mechanical exhaust outlet.

When mounted on the curb, the lowest air intake louvers must be a minimum of 12” above any surface where snow or ice could accumulate. In areas where normal snow accumulation is higher, mount the unit accordingly.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of the humidifier.

The humidifier may be installed directly on combustible flooring or, in the U.S., on wood flooring or Class A, Class B or Class C roof covering materials.

GS Series Installation | 28

Figure 18: GSTC Outdoor Typical Installation Rooftop with AHU

29 | GS Series Installation

Figure 19: GSTC Outdoor Typical Installation Rooftop without AHU

Figure 21: Roof Curb Dimensions

Figure 20: GSTC Outdoor Clearance

GS Series Installation | 30

Figure 22: Gas Piping

Figure 23: Gas Piping with Over Pressure Device

Gas Piping

Installation of piping must be in accordance with local codes, and the National Fuel Gas Code ANSI Z223.1 in the United States or CSA B149.1 Installation Codes in Canada.

Refer to the indoor gas piping installation guidelines for gas line sizes, pressures, leak testing procedures, and safety instructions.

Gas lines are to be routed to the outside connection on the right side near the back of the unit. The installation of a sediment trap and a certified manual shut-off valve are required outside of the unit. The gas piping must not block access to or prevent opening of the right side service door. Refer to Figure 22 for details.

Nortec recommends that each Gas Fired Humidifier has its own regulator installed in line to the unit. The operating Natural Gas pressure supplied for the GS units must be in the range of 5-9” of Water Column and propane version 10-14” of Water Column.

Over pressure protection devices shall be provided to prevent the pressure in the piping system from exceeding that value that would cause unsafe operation of any connected and properly adjusted Gas utilization equipment. See Figure 23.

If the system has a pressure that is higher than the max working pressure of our humidifier, then an Over pressure protection system is required. If there is an Over pressure protection device installed, it MUST consist of 2 devices in Series. (A pressure regulator plus one other device) Both these devices must be able to work on their own without damaging any downstream piping or appliance, and the only way the downstream system can be damaged is by the failure of both devices.

31 | GS Series Installation

Figure 24: Exhaust - Outdoor Units

Figure 25: Electrical Box

Exhaust Venting – Outdoor Units

All required exhaust venting is provided with each GS Outdoor model, by Nortec, including rain cap and storm collar. All venting components external to the unit are shipped with the unit and must be installed on site. Refer to Figure 24 for venting components.

Each vent length and the rain cap have a built-in mechanical locking band and gasket. Simply push together each component to the stop bead, which provides an air & water-tight seal. Then tighten the integrated locking band on each component to complete the installation of the exhaust venting.

The rain cap must extend at least 2 feet above any ridge within 10 feet of the unit. The exhaust venting can be extended using additional vent lengths purchased from Nortec.

Electrical Installation

Power and control wiring is to be routed into the humidifier through the pipe chase in the base pan of the outdoor models located in the burner area.

Installation details for primary and low voltage control wiring are the same as for indoor units.

A field supplied NEMA rated weatherproof disconnect switch must be mounted external to the GS Outdoor unit to allow for power interruption during servicing and/or maintenance. A mounting plate, located on the front of each outdoor model above the electrical access door, is available for mounting of the disconnect switch. Two electrical conduits are provided for routing the primary wiring to the disconnect switch and then back inside the enclosure to the main power terminal strip. See Figure 25 for details.

GS Series Installation | 32

Figure 26: Fill Water Connection

Figure 27: Drain Connection

Fill Water Supply Line

Each unit is supplied with a ½” NPT male connection to the fill valve. Refer to Figure 26 for connection details. A minimum fill rate of 10 l/min (2.6 gal/min) is required for all unit sizes. Allowable pressure range is 30-80 psig.

Always install a manual shut off within the building to allow isolation of the water to the unit. A union must be installed on the fill line prior to the fill valve to allow for servicing.

Heat trace fill line piping above rooftop from the pipe chase up to the fill valve.

Drain Line

GS Outdoor units have an integrated 12”w.c. trap and vacuum break valve on the drain line. A drain hose, connected to the outlet of the internal trap, terminates at the pipe chase in the burner section.

Route the drain hose to a drain funnel in the building to provide an air gap before entering main building drain/sewage system.

When the drain pump is activated, the tank drains at a rate of 18-20 l/min (7-8 gal/min).

Drain piping must be rated for 212ºF (100ºC).

33 | GS Series Installation

Auxiliary Drain

Standard GS Outdoor units come with a capped ¾”NPT auxiliary drain connection at the bottom of the tank. It is recommended to install a manual shut-off valve on this connection and route to drain (field supplied air gap required).

GS Outdoor units standard with a freeze protection package have a normally open drain valve mounted at the auxiliary drain connection and piping that terminates at the pipe chase in the base pan. This valve opens and will drain the contents of the tank in the event of a power failure. Install a manual shut off valve on this line and pipe to the drain funnel. This valve must always be left in the open position when in operation but can be closed for servicing of the unit.

Drain pipe should be capable of withstanding 212°F (100°C) temperatures.

Steam Lines

The steam outlet connection is located at the back of the GS Outdoor unit. Steam hose(s) and clamps are supplied with the unit and are intended to provide a flexible coupling outside of the unit to the building steam lines. See Figure 28.

Figure 28: Steam Connection

GS Outdoor models can develop steam pressures up to 12”w.c. to overcome duct and steam line pressures. Pressures above 12”w.c. will cause steam to exit through the drain line.

Steam lines can be routed to an air handler on the roof or pipe chased (external to the unit) through the rooftop to enter the building.

All steam lines must be insulated to reduce losses.

For steam line installation guidelines, consult the distribution system installation manual (Steam Distributor Installation Manual.

GS Series Installation | 34

Operation

Combustion

The combustion system is based on a fully modulating forced draft combustion air blower(s), a negative pressure regulated gas valve, and a 100% premix burner. On a call for humidity, the combustion air blower(s) starts and creates a negative pressure(s) across an orifice located at the air inlet. The blower is energized to purge the system, and then the hot surface igniter is activated. During this time the electronic ignition module does a diagnostic check of safety systems including the air proving switch which senses the negative pressure at the air inlet orifice. After the function of the safety systems has been verified, the gas valve(s) will open and the gas/air mixture is ignited by the hot surface igniter. If a flame is sensed by the flame sensor, the gas valve(s) remains open and combustion continues. If a flame is not sensed, the above sequence is repeated to a maximum of three times after which the ignition module will lock out. The gas valve(s) maintains a constant ratio air to gas independent of blower speed or external conditions. This air and fuel is thoroughly mixed in the blower(s) and then forced through the burner ports where ignition occurs.

Hot products of combustion are forced through a baffle inside the heat exchanger and then vented outside. The heat exchanger has a large flat surface to minimize scale build-up and promote scale shedding to the bottom of the tank. This self-cleaning action helps to maintain the efficiency of the heat exchanger while the smooth surfaces allow for easy cleaning when necessary. The heat exchanger has been heat treated to protect against possible stress-corrosion cracking.

The GS 100 has a single removable combustion chamber/heat exchanger. The combustion system is duplicated on larger units with multiple chambers inside a common tank.

Water Management

The GS Series of humidifiers is equipped with a unique float chamber water level monitoring device. Two magnetic floats (one is a backup) measure 5 different water levels in the humidifier for proper operation. The float chamber and board are located away from the boiling action to increase reading accuracy and reduce mineral build-up since it is not in the boiling water. The float chamber is connected to the tank under the water level and above the water level to ensure equalization of pressure between the tank and float chamber. In addition, cooling water is introduced in the float chamber to reduce scale build-up. The unit also includes an internal 1” air gap and a vacuum breaker to prevent siphoning effect.

On initial start-up, the solenoid operated fill valve fills the tank. The water level reaches the backup float first and then the main float. If the backup and main floats do not read the same water level during the operation of the unit, the unit will shut down on a fault. The unit will continue to fill the unit to the top green position. The drain pump will then be energized to drain the water level down to just below the bottom red position and then the fill valve will energize again to fill the unit to the middle yellow position. During this time the software is performing a test on the fill valve and drain pump.

If a demand signal is present, the unit will then begin the combustion sequence. As the unit operates, the fill valve with be pulsed to maintain the water level between the yellow and green positions. During steam production the unit will also check if the floats and drain pump are operational by activating a drain sequence every 24 hours (adjustable to time of day).

35 | GS Series Installation

Start-Up Procedure

Start-Up Checklist

Before the GS humidifier is operated for the first time, a complete inspection must be performed to ensure that the installation and all water, gas, steam, electrical and venting connections to the humidifier conform to the guidelines in this manual. Complete the checklist before commissioning the unit.

Qualified personnel must correct any deficiencies with the installation before commissioning takes place.

Prior to starting the humidifier, it is necessary to ensure that no dirt or dust has accumulated in the electronics compartment or the burner area. A build up of dust on the electronics can cause overheating and early failure of the components. If necessary, clean the area around the humidifier to prevent contaminants from being drawn into the combustion blowers.

Filling The System

Before the GS unit will initiate combustion it must be filled with water and the internal controller must have completed a self-test to verify that the water fill system, level controller, and drain pump are functioning correctly.

Close the shut-off valve in the gas supply line.

Figure 29: Plumbing Connections

Remove any demand signal to the unit.

Open the shut-off valve in the water supply line.

Switch the humidifier on.

The fill valve will energize and the tank will begin to fill (fill time is approximately 10 to 30 minutes depending on unit size). Once the float chamber has registered low water level, the unit will perform an internal test of the fill and drain system as described in the Water Management section.

At the completion of the test, the float chamber will indicate middle float position (green LED) and the unit will go into standby mode until a demand signal is received.

Proceed to the safety shut-off test.

GS Series Installation | 36

Testing the Ignition Safety Shut-Off

Test the ignition system safety shut-off in the following method.

Close the shut-off valve in the gas supply line.

Set the demand signal to the humidifier to 100%.

Ensure all external controls connected to the security loop are closed.

Switch the humidifier on.

At the completion of the float test, the humidifier will begin the combustion sequence by energizing the combustion blowers.

All blowers will run at full output for 30 seconds to pre-purge the combustion chamber. During this time the controller will monitor that all air proving switches closed to prove air flow.

The igniter(s) will be energized for 15 seconds, allowing it time to heat to the appropriate ignition temperature and the gas valve will be energized.

After 4 seconds both the gas valve(s) and the igniter will be de-energized.

After three trials for ignition (complete with pre-purge) the red LED on the ignition control module will begin blinking to indicate a safety lockout and a fault message will be displayed on the humidifier display.

Note: On multiple burner models, each burner tries to ignite in sequence. It is necessary to wait for all burners to cycle to complete the test. Manually re-open the gas supply to the humidifier. No gas should flow to the burner(s).

To reset the humidifier, shut off the power switch, and then turn the power back on.

Starting the Humidifier

Once the tank has been filled and the ignition safety test has been performed as outlined above, the humidifier is ready to be put into operation.

Verify that the inspection checklist has been completed and all deficiencies with the installation have been corrected.

Open the shut-off valve in the gas supply line.

Open the shut-off valve in the water supply line.

Ensure all external controls connected to the security loop are closed.

Verify that the building demand signal is connected to the humidifier.

Install and secure all cabinet service doors.

Switch the humidifier on.

At the completion of the float test, the humidifier will begin the combustion sequence and each burner will ignite in sequence.

Depending on the system demand the combustion blowers will modulate faster or slower to control the burner input.

The water in the tank will heat up and begin to boil, delivering steam to the distribution system.

During the boiling sequence the water fill valve will periodically activate to replenish water that has evaporated from the tank.

Once the humidity requirements have been satisfied (demand drops below minimum %) all gas valves will be de-energized and the blowers will be shut off after performing a post purge of the combustion chamber.

37 | GS Series Installation

The humidifier will go into standby mode until the next call for humidity (demand rises above minimum %) at which time the unit will again begin the combustion sequence.

Taking Out Of Operation

If it is required that the humidifier be taken out of operation (e.g. for service or end of season shut-down), proceed as follows:

If the unit is firing, remove the demand signal or open the security loop, allowing the burners to shut off and the blowers to perform a post purge of the heat exchangers before shutting off.

Switch the main power switch from On to Off and then to the Drain position. The drain pump will be energized and the tank will begin to drain.

Once the tank has completely emptied shut off the drain switch.

Close the shut-off valve in the gas supply line.

Close the shut-off valve in the water supply line.

Isolate the humidifier from the electrical power supply at the main disconnect switch.

GS Series Installation | 38

Humidifier Mounting



Verify proper clearances around the unit.



Humidifier mounted level.



Humidifier properly secured to stand and stand bolted to floor.



All service doors accessible.



Roof curb sized correctly (Outdoor Model Only).

Gas Piping



Correct gas line size installed.



Certified manual shut off valve and union installed.



Sediment trap installed.



Gas piping leak tested.



Air purged from lines.



Proper gas supply pressure.



Regulator dedicated for each gas unit.

Exhaust Gas Venting



Comply with local regulations.



Proper venting materials used (B or BH) – refer to gas codes.



Maximum vent length of 100 feet (70 feet for direct vent models).



Proper pipe diameter used.



Condensate tee installed.

Steam Lines



Slope up 2” per 12”



Sloped back to drain



Slope down ½” per 12”



Trapped 2” more than static duct pressure



Traps size ____________



Insulated



Length/Size ____________



90 deg. Elbows qty: ____



45 deg. Elbows qty: ____



Can condensate be trapped anywhere in the steam line? yes ___ no ___

Condensate Lines



Sloped back to drain



Trap is greater than 2” duct static pressure



Size of trap____________

Supply Water Line



Nortec supplied adapter installed on fill valve (½”NPT)



Manual shut off valve and union installed



Verified pressure (30 – 80 psig)



Water source of 10 l/min (2.6 gpm)



Leak tested



½” dia. At max 4ft of the unit

Table 7: GS Inspection Check List

39 | GS Series Installation

Drain Lines



Air gap located within 3ft of the unit



Minimum drain line size of 1” in dia.



Downward slope



Tundish (funnel) installed to provide air gap



Temperature rating of piping



Hose connections tightened



Auxiliary drain piped with shut off valve to tundish

Water Quality



Well water



City water



Softened water



RO/DI water



Conductivity:_______mhmos



Hardness: _______GPG



Silica____ppm



Chlorides:_______ppm



pH:_______

NOTE: Failure due to chloride corrosion is not covered under Nortec’s standard warranty if chloride concentration is allowed to reach elevated levels in the tank. Consult factory for more information.

Electrical Installation



Comply with local regulations



Proper supply voltage (must match rating plate) and breaker size



Electrical disconnect switch close to humidifier



Cables properly affixed



Low voltage wiring & control signal(s) wired to correct terminals



Humidifier configured for correct control signal(s)

Type Of Controls Installed / Location Wiring / Setting



High Limit ______________________________



Air Proving _____________________________



Modulation Control ________________________



On/Off Control ___________________________



Controls by Nortec ________________________



Controls by Others ________________________

GS Series Installation | 40

Scale Management

General

The gas humidifier will periodically “blowdown” water from the tank to reduce the concentration of total

dissolved solids that accumulate during long term operation. Gas Humidifiers are shipped factory set with a blowdown of 25%. This setting ensures that scale build-up will be minimized for all water conditions.

Once the water conditions are known, the blowdown rate can be adjusted by software (GSTC models) or by using dip switches on the logic control board (GSP models).

Another effective means of controlling the amount of scale in the tank is with the use of the Full Tank Blowdown (FTBD) built into the software. When this feature is activated, the drain pump will be energized to drain the entire contents of the tank and then the tank will be refilled with fresh water, thus keeping the amount of total dissolved solids to a minimum. The feature can be programmed in the software to occur after a specific amount of operating time and can also be triggered by a signal sent to the humidifier from a building management system.

Water Quality

Due to the wide range of water conditions found throughout North America it is important that the blowdown is set according to the local water conditions. By water conditions we are referring to the hardness of the water supplied to the humidifier. The hardness is measured in grains per gallon. It is also important to test for silica content. Silicates may cause foaming and contribute to scale buildup in the humidifier tank and float chamber.

Figure 30: Site Water Test Kit P/N 1507214

If you are unaware of the hardness or silica content of your water supply, there are many “do it yourself” kits which can be purchased, or there are several companies that will perform the tests for a reasonable price. You can even contact your municipality for your water condition or order the NORTEC water test kit.

NOTE: Water quality conditions resulting in component failures are not covered under NORTEC’s standard warranty.

Silica Test: Measured in ppm (parts per million) Follow the directions with the kit. A high reading will decrease the performance of your system. The recommended operating range for silica is 0 ppm to 14 ppm. Note: A high silica content along with a high hardness content may increase the service intervals of the system. Consult the factory if this condition exists at the site.

41 | GS Series Installation

Technology

Water /

Type

Water Cond.

Range

Hardness

Range

Silica Range

Alkaline

Range

Chlor.

Range

Gas-fired

Micromhos

GPG

PPM

Potable

0-1500

0-12

0-14

6.5-7.5

0-40

Treated

0-100

0-1

7-7.5

0-40

Hardness: Measured in gpg (grains per gallon). Follow the instructions on each individually wrapped test strip and use the colour chart provided. The recommended operating range for hardness is 0 gpg to 12 gpg. Note: High hardness along with high silica may increase the service intervals of the system. Consult the factory if this condition exists at the site.

pH: Follow the directions on the test strip bottle. The recommended operating range for pH is 6.5 to 7.5 on the colour scale. Consult the factory if outside these parameters.

Chlorides: Measured in ppm (parts per million). Follow the directions on the test strip bottle. The recommended level for chlorides is not to exceed 40 ppm.

High levels of chlorides will attack stainless steel. Consult the factory for additional information if your water contains high levels of chlorides.

Conductivity: Measured in micromhos. Follow the directions for the conductivity pen found inside the box. Multiply the digital reading by 1.5. The recommended operating range for conductivity is 0 - 1500 micromhos. Consult the factory is you measure outside these parameters.

Table 8: Water Quality Ranges

Nortec recommends performing a semi-annual water analysis to ensure optimal performance.

The humidifier is intended to operate on cold potable tap water.

DO NOT use a hot water source to supply the humidifier. Minerals will adhere more easily to surfaces and the fill valve's small flow regulating orifice could become plugged.

Consider using a water softener. Longer operating times between tank cleaning will be reached on softened water.

Reverse osmosis (RO) water can provide very long times before cleaning is required since it is cleaner than softened water. Deionized (DI) water may be used with all models. Consult your Nortec representative for quote on a water treatment system.

Safety Instructions

Refer to pages 1 and 2 of this guide, as well as all other marked safety instructions.

GS Series Installation | 42

Fault Conditions

General

This appliance is equipped with a self diagnostic ignition module which identifies a fault code when it occurs. Refer to the fault & warning list.

GSTC Models

Faults are indicated with a fault message on the display of GSTC models. Recovery from lockout requires resetting of the humidifier. This can be achieved by momentarily shutting off the power switch then turning it back on, or by pressing the reset button on the logic control board mounted inside the electrical cabinet.

A history of all faults is stored in memory of the software and can be viewed through the service level on the display. Refer to the keypad display menu structure at the end of the manual.

GSP Models

Faults are indicated on GSP models with a fault code on the small display screen attached to the logic control board. The display can be viewed by removing the front electrical door. Check the display for the fault code before shutting off power to the unit. Resetting the humidifier clears the fault. This can be achieved by shutting off the power switch, then turning it back on, or by pressing the reset button on the logic control board. A list of all fault codes and the type of fault they represent is located near the back of the manual.

43 | GS Series Installation

Maintenance

General

To ensure proper performance and long operating life of the GS humidifier, it is recommended that the appliance and installation be inspected at least once a year by a qualified service person. A proper maintenance schedule should be followed. Since the amount and type of maintenance required is generally as a result of how much the humidifier operates, all GS humidifiers monitor the amount of steam produced over time and will indicate when service is required. All units come factory set with a service interval of 500 hours. This service interval can be adjusted through software (GSTC models) or by dip switch settings (GSP models) on the logic control board.

All maintenance work must be performed by experienced and trained personnel.

Periodic cleaning of the screens in the vent terminal (where applicable) is recommended.

NOTE: Use only NORTEC original parts to replace damaged or defective components. Failure to do so may cause improper operation of the humidifier and will void warranty.

Draining the Tank

During extended periods of inactivity such as off season or periods of very low demand, it is advisable to drain the water from the tank. On all models this is accomplished by switching the unit to “Drain”.

Do not remove the front clean out port on the tank until the unit has completely drained. On GS 300-600 units do not remove the top clean out ports on the tank unless the water has cooled or the unit has completely drained.

Ensure that power is switched on again during periods of demand.

The GSTC model of the Gas Steam humidifier includes a pre-cleaning sequence feature. When activated (through the keypad), the unit will flush the humidifier, refill with cold water, and flush again reducing the scale accumulated at the bottom of the tank.

GS Series Installation | 44

Parts

30-days

after

initial

start-up

Mid

End of

Season

(2000

hours)

What needs to be done?

Regular Maintenance

Preventive Maintenance

Hot Surface Ignitor

Check for continuity.

Replace hot surface igniter and flame sensor with replacement kit.

Flame Sensor

Check that Flame Sensor is straight.

Clean sensor with fine steel wool.

Gas Burner

Remove from the unit and clean with compressed air from outside matting.

NOTE: It is recommended to replace the burner gasket each time a burner is removed.

Drain Lines

Switch to drain and make sure water flows freely.

Tank X X

Adjust blow down time when required. Check that scale has not accumulated above 2".

Drill out tank nipples when required to ensure nipples are not blocked with scale.

Clean tank when required.

Clean tank.

Magnesium Anode

Check for severe corrosion or scale build up on anode. Replace or scrape off scale if necessary.

Float Chamber

X X X

Ensure floats move freely.

Clean scale from float chamber and hose connecting to it.

Fill Lines

X X X

Adjust blow down time when required. Check that scale has not accumulated above 2".

Drain Lines

X X X

Clean tank when required.

Gas Venting

X X X

Inspect for leaks. Ensure terminal cap is clear and any condensation produced flows to condensate traps. Flue temp should be between 350-400ºF.

Direct Vent

X X

Inspect for leaks. Ensure intake terminal is clear.

H/L Stack Sensor

X X X

Visual check that sensor is intact, wired and attached to the exhaust.

Table 9: Mandatory Maintenance Schedule

45 | GS Series Installation

Warning: Water and scale may be hot enough to cause burns. Turn off humidifier and allow it to cool before cleaning.

Warning: Do not clean the magnesium anode using any chemicals – the anode can react with acids to create flammable hydrogen gas.

Cleaning the Steel Tank

General

It is recommended that the tank be cleaned at least once every season to maintain optimum operation. It may be necessary to increase the frequency of cleaning or increase the blowdown setting in areas of hard water or prolonged annual usage (see the Blowdown Setting section of this manual).

Cleaning of the humidifier is mandatory and must be performed on a regular basis.

To reduce cleaning time, use the pre-cleaning sequence on the GSTC model to help evacuate mineral debris from the unit. Check the controller operation to activate this feature.

The combustion chamber walls are usually self cleaning. The mineral buildup flakes off, due to the expansion and contraction and violent boiling action during on/off cycles, and settles to the bottom of the tank. The combustion end block will have scale build up, as will the heat transfer tubes. These surfaces must be cleaned at regular intervals.

Frontal port cleaning will be done through the front door of the unit. Remove cabinet door on the left of the LCD display using a Philips screwdriver. Remove the side tank port opening, by removing the 3/16 nuts (½” key or socket is needed). When removed, check the magnesium anode on the inside of the clean out port for severe corrosion or scale build up. Replace or clean the anode as necessary. Do not use chemicals to clean the anode, scrape off scale only.

Additional clean out ports are available on the top of the 300/400 and 500/600 lb/h tanks. To access these ports, remove the top cabinet panel using a Phillips screwdriver. Remove the top clean out ports my removing the nuts.

Removal of the heat exchanger(s) is not necessary to clean the inside of the tank.

Scoop out loose scale with a small shovel such as those used for gardening. Once loose scale is removed, use a scraper such as a plastic windshield scraper to remove scale adhering to the tank or heat exchanger walls. DO NOT use a metal scraper that will scratch the stainless steel surfaces of the tank. Once all large pieces of scale have been removed, vacuum the tank out with a shop vacuum, fill part way with water, and flush remaining sediment from the tank through the drain.

Due to the presence of polymer gaskets around the heat exchanger, do not use any harsh cleaning chemicals. Please consult NORTEC prior to using any chemicals. Once the lid has been replaced, fill the unit with water and examine for leaks.

Inspect the drain and fill lines assembly for scale build-up and if necessary remove them from the humidifier for cleaning. If the blowdown assembly becomes blocked, scale build-up in the tank will be accelerated and damage to the humidifier could result. The drain pump may be opened and cleaned. Consult NORTEC for proper procedure.

GS Series Installation | 46

Warning:

Disconnect power before servicing this appliance.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and

dangerous operation.

Reassemble the drain and blowdown if they were removed. Re-install tank top and side lids making sure tank cover gasket is intact. Do not over tighten hold down nuts. If using a torque wrench do not exceed 50 in/lb (5 ft/lb). Re-seal all cabinet lids.

Cleaning the float chamber is accomplished by removing the hold down screws to access the floats and using a small brush to gently clean the scale from the floats and chamber. Ensure that floats are back in place and o-ring is properly seated before tightening screws on float chamber. Special attention must be used when removing or re-installing the float chamber.

The switch board must be replaced into the same position as before cleaning and the tie -wrap must be used to hold the float chamber in position.

Figure 31: Cleaning Tank Access

Servicing the Unit

General

The combustion chamber, heat exchanger and flue baffles are all fabricated from stainless steel and do not require internal cleaning. Should the main burner fail to light, or flame is not detected during the first trial for ignition period, the gas valve is de-energized and the control goes through an interpurge delay before another ignition attempt. The control will attempt two additional ignition trials before going into lockout. The valve relay will be deenergized immediately, and the combustion blower will be turned off.

47 | GS Series Installation

Service Checks

Combustion Blower

The combustion air blower motors are permanently lubricated and do not require lubrication. Clean out any dust that has accumulated in the blower housing using an air gun.

Burner

The combustion air blower motors are permanently lubricated and do not require lubrication. Clean out any dust that has accumulated in the blower housing using an air gun.

Flame Sensor

Flame current is the current which passes through the flame from the sensor to ground. The ignition module must detect a minimum flame current of 0.7 microamps or a flame proving lockout will occur. To measure flame current, connect a DC micrometer to the FC- FC+ terminals on the module. Meter should read 0.7 uA or higher. If meter reads below “0” on scale, meter leads are reversed. Disconnect power and reconnect meter leads for proper polarity. NOTE: Proper polarity of supply voltage to the unit is necessary for flame sensing to occur. Oxidation on flame sensing rod can reduce measured current. The oxidation can be cleaned from the sensing rod using steel wool or an emery cloth.

Igniter Check

If the igniter is suspected of being defective then the following test may be carried out;

Ensure that the power and gas is switched off before servicing.

To test the igniter, disconnect the igniter leads from their terminal connections.

Using a multimeter set the Ohm’s scale and place one of the meter leads on one of the igniter wire ends and

the other meter lead on the end of the other igniter wire.

Gas Valve Setting

The gas valves used in the GS Series humidifier are negative-pressure-regulated valves. The valve setting listed on the product rating plate is shown relative to atmosphere – this setting will always remain constant.

The valves come preset from the factory for the correct gas type. If an adjustment is required, use the following steps:

Remove the screw from the pressure port marked “out” on the back side of the gas valve.

Connect a hose from a digital manometer (or an inclined manometer capable of reading below 0.1”w.c.) to the “out” pressure port.

Activate the humidifier and measure the gas valve pressure once the valve is energized and a flame is established in the combustion chamber. Verify this pressure to the pressure listed on the unit specification label.

If the pressure needs adjusting, remove the locking cap on the top of the gas valve.

Below the locking cap is an adjustment screw. Increase the pressure by turning the adjustment screw clockwise, decrease by turning counter-clockwise.

NOTE: The pressure will fluctuate slightly as the unit operates, especially with very sensitive measuring devices. Use the mean pressure value as the set pressure.

Once the pressure has been adjusted, replace the locking cap.

Replace the screw in the “out” pressure port and tighten firmly.

GS Series Installation | 48

Figure 32: Flame Sensor and Igniter Assembly

Figure 33: Burner Assembly

Component Replacement

Consult factory prior to the replacement of any component.

All service work must be performed by experienced and trained personnel.

Only use original NORTEC spare parts to replace defective components. Damage caused by non-approved parts is not covered under NORTEC’s standard warranty.

Hot surface igniter and flame sensor replacement

Shut off electrical power and gas supply to the humidifier.

Remove the right side service access door.

Disconnect all wiring to the igniter and flame sensor.

Unscrew the fixing nuts for the igniter and flame sensor. Carefully remove the igniter and flame sensor.

Reverse the sequence above to install the new igniter and flame sensor. Always install a new gasket when replacing the flame sensor and igniter.

CAUTION: The silicon carbide igniter is breakable. Handle with great care to avoid damage.

Burner Removal and Installation

Shut off electrical power and gas supply to the humidifier.

Remove the right side service access door.

Disconnect all wiring to the combustion blower, gas valve, air proving switch, igniter and flame sensor (note the connector assignment).

Undo the union on the flexible gas hose and disconnect the gas hose from the gas valve.

Undo the 4 nuts on the blower outlet and remove blower, leaving the gas valve/air inlet assembly and the fan-board mounting bracket (if present) mounted to the blower.

Undo the 4 large nuts that secure the burner mounting plate to the face of the heat exchanger and carefully remove the burner assembly. Handle the burner only by the metal surfaces. Do not grip the ceramic matting as grease, dust or dirt can affect the performance of the burner.

Reverse the sequence above to re-install the burner after cleaning or, if necessary, replace with a new burner. Inspect and replace any gaskets that may be damaged. Tighten the 4 brass nuts of burner mounting plate to a torque of 95 in-lb.

Leak test the gas train before re-commissioning the humidifier.

49 | GS Series Installation

Figure 34: Combustion Blower Replacement

Figure 35: Gas Valve Replacement

Removal and Installation Of The Combustion Blower

Shut off electrical power and gas supply to the humidifier.

Remove the right side service access door.

Disconnect all wiring to the combustion blower, gas valve and air proving switch (note the connector assignment).

Undo the coupling on the flexible gas hose and disconnect the gas hose from the gas valve.

Undo the 2 screws that mount the gas valve/air inlet assembly to the blower and remove the assembly.

Undo the 2 screws of the fan-board mounting bracket (if present) and remove bracket, leaving electronic board and igniter jump start module(s) attached.

Undo the 4 nuts on the blower outlet and remove blower.

Reverse the sequence above to install the new combustion blower. Inspect and replace any gaskets that may be damaged. When mounting the gas valve/air inlet assembly to the combustion blower, ensure that the cork gasket is properly oriented or gas flow through the valve will be impeded.

Leak test the gas train before re-commissioning the humidifier.

Gas Valve Replacement

Shut off electrical power and gas supply to the humidifier.

Remove the right side service access door.

Disconnect all wiring to the gas valve and air proving switch (note the connector assignment).

Undo the coupling on the flexible gas hose and disconnect the gas hose from the gas valve.

Remove the hoses from the air proving switch (note the connection layout).

Undo the 2 screws that mount the gas valve/air inlet assembly to the blower and remove the assembly.

Undo the 4 screws and remove the gas pipe connection from the inlet of the gas pressure regulating valve.

Undo the 3 screws that hold the air inlet venturi to the gas valve. Remove the rubber grommet and brass orifice mounted in the outlet of the gas valve.

GS Series Installation | 50

Figure 36: Air Switch Replacement

Figure 37: Float Chamber Replacement

Undo the 3 screws of the pressure switch support bracket and remove the assembly from the gas valve.

Reverse the sequence above to install the new gas pressure regulating valve. Inspect and replace any gaskets that may be damaged. When mounting the gas valve/air inlet assembly to the combustion blower, ensure that the cork gasket is properly oriented or gas flow through the valve will be impeded.

Leak test the gas train before re-commissioning the humidifier.

Air Switch Replacement

Shut off electrical power to the appliance.

Remove right side service panel.

Remove wiring connections to switch.

Remove pressure hose(s) from switch noting proper location.

Remove screws (2) holding the switch.

Reverse above procedure to re-install.

Float Chamber Replacement

Drain the contents of the tank and then shut off electrical power and water supply to the humidifier.

Remove the left front service access door.

Remove the cable connection to the float board.

Remove the hose clamps on the float chamber and remove all hoses (note the correct hose assignment).

Squeeze both sides of the mounting bracket to release it from the slots in the support bracket behind the float chamber.

Reverse the above sequence to install the new module.

Leak test all water connections before re-commissioning the humidifier.

51 | GS Series Installation

Figure 38: Ignition Module Assembly

Figure 39: Transformer Assembly

Ignition Module Replacement

Shut off electrical power to the humidifier.

Remove the front electrical access door.

Disconnect all wiring connections to the ignition module, labeling as required.

Remove the 2 screws securing the ignition module and remove.

Reverse the above sequence to install the new module.

Transformer Replacement

Shut off electrical power to the appliance.

Remove front access door.

Disconnect wiring connections from transformer leads labeling as required.

Remove screws (2) holding transformer.

Reverse above procedure to re-install.

Fill Valve Replacement

Shut off electrical power and water supply to the humidifier.

Remove the right side service access door.

Remove all wiring connections to the fill valve.

Remove the hose clamps on the fill valve outlets and remove hoses (note the correct hose assignment).

Remove the 2 screws securing the fill valve to the cabinet and remove the valve.

Reverse the above sequence to install the new module. Leak test all water connections before recommissioning the humidifier.

Anode Replacement

Follow the steps in Cleaning the Steel Tank on page 46 to remove the clean-out port.

Lift the corroded anode off the steel rod. Replace with a new anode.

Re-attach the clean-out port.

GS Series Installation | 52

Figure 40: Fill Valve Replacement

Figure 41: Drain Pump Assembly

Figure 42: Fill Box Replacement

Drain Pump Replacement

Drain the unit completely. If the pump is broken use the auxiliary drain out port.

Shut off electrical power to the appliance.

Remove front and right doors.

Remove wiring connections to the pump.

Remove hoses attached to the pump.

Reverse above procedure to re-install.

NOTE: To avoid water spillage (some water will be left on the tank bottom after manual draining) use shop vac to remove left over water.

Fill Box Replacement

Take the humidifier out of operation.

Undo the screw (Phillips screwdriver) and remove the right side panel.

Remove hose clamps on the fill box connections and pull off the hoses.

Undo the two nuts securing the fill box to the face of the tank, then remove the fill box.

Re-installation is carried out in the reverse sequence. Make sure the hoses are correctly secured with the hose clamps.

53 | GS Series Installation

Removal of the Heat Exchanger

Take the humidifier out of operation.

Disconnect the gas supply pipe from the connection on the humidifier and close off the pipe.

Unlock and remove the right side panel(s).

On Direct Vent units only: Remove hoses from air intake manifold and air inlet elbows.

Dismount flue gas pipe at the flue gas outlet connection.

On Direct Vent units only: Dismount air supply pipe at the air supply connection.

Unlock and remove the left and the right top panels.

Free all cable connections to the components (combustion blower, ignition module, air pressure switch, etc.) of the respective heat exchanger.

IMPORTANT: Note the connector assignment.

Undo the coupling of the respective flexible gas pipe and remove the flexible gas pipe.

Dismount the burner with the air blower and the gas pressure regulating valve of the respective heat exchanger.

Unscrew the nuts and remove the flue gas manifold from the tank.

Unscrew the nuts on the heat exchanger and pull out the heat exchanger from the tank.

Re-installation is carried out in the reverse sequence. Replace all seals with new ones.

Figure 43: Heat Exchanger Assembly

GS Series Installation | 54

Request – 50%

Humidify 01/01/09 12:00:00 Security loop: Closed

Main Screen The Total Controller main screen displays general information including the current demand, the status of the humidifier, the status of the security loop, the current date and current time.

Note: If a warning is displayed, press the “?” button to display the troubleshooting information.

CONTROL Man. Cap. : 100% Demand : 50% Limit : 55% Output : 305 lb/hr

Esc

Control Information (Humidistat/BMS Control) Displays the limited manual capacity, the current demand from the controller to the humidifier and the current output.

Note: If the humidifier is set to dual channel, the demand of the high limit humidistat will be displayed next to Limit.

CONTROL Man. Cap. : 100% RH CNT : 35%RH CNT Set-P : 40 RH Limit : 40%RH LIM Set-P : 80 Output : 305 lb/hr

Esc

Control Information (Humidity Sensor Control) Displays the limited manual capacity, the current space relative humidity and the relative humidity set point. The current output of the unit is displayed at the bottom of the screen.

Note: If the humidifier is set to dual channel, the limiting

humidity sensor’s measured RH and the desired set point is

also displayed.

Key Pad

GSTC Total Controller Flow Chart

Total Controller

Upon start up, the LCD display will illuminate, the humidifier will start filling and the software will perform a float chamber level check. After the system test, the humidifier will enter normal operation mode and wait for a demand signal. See troubleshooting section for corrective action if error is detected and displayed during start up.

Note: The displayed parameters depend on the configuration of the GSTC and the operation conditions; the display may vary from the following screenshots.

Information Level

Pressing the right and left arrow keys of the Total Controller displays the current humidifier setting screens. NO changes can be made to the settings at this level. Access the User Level to change the parameters displayed.

55 | GS Series Installation

HUMIDIFIER Model : GSTC 600 Capacity : 600 lb/hr Multi Mode : StandAlone REG Mode : Demand Software V : 1.07

Esc

Humidifier Information Displays humidifier information and settings, including the model name and output, the control signal type and the software version.

Note: The Multi Mode indicates if the humidifier is operating alone (StandAlone) or if is linked to other units (Master or Slave). The REG mode indicates the control type, either humidistat (Demand) or Transducer (RH).

BURNERS Burners : 6 Active : 4 Capacity : 600 lb/hr Total O/P : 305 lb/hr Lead : 1 Disabled : -----X

Esc

Burner Information Displays burner information. The lead burner is the first burner to ignite for the present cycle. If burners are disabled, they will be denoted by an X.

Note: In this view, burner 6 is disabled (denoted by X).

TANK STATUS Fill Valve : Off Drain Pump : Off Float Levl : 5 Run Time : 12 hr Serv. Time : 500hr Serv. Due : 425hr

Esc

Tank Status Displays information about the tank, operating time and service time. The run time is the total operating time. The service time indicates the fixed service interval length. The service due time is the time remaining until service is required.

Note: The service interval can be set in the Service Level.

SENSOR INPUTS Sec. Loop : Closed OT Sensors : Closed Tank Temp : Closed

Esc

Sensor Status The SENSOR INPUTS screen displays the current status of the Security Loop, the Over Temperature Sensors and the Tank Temperature Sensor.

Note: The Security Loop and the Over Temperature Sensors must be Closed for the humidifier to operate.

FEATURES LIST Idle Mode : Idle Drain FTBD : On Time Prop. : On BD rate : 25 Drain Cool : Smart Float Ck : On

Esc

Features Information Displays information of the User Settings including the idle mode, the Full Tank Blow Down status, the Time Proportioning status, the Blow Down rate percentage, the Drain Cool mode and the Float Check status.

Note: See User Defined Settings to change these parameters.

GS Series Installation | 56

Blower RPM B1 RPM 3104 B2 RPM 3190 B3 RPM 3104 B4 RPM 3147 B5 RPM 3104 B6 RPM 3104

Esc

Blower RPM Information The Blower RPM screen displays the current RPM of each blower.

OPERATIONAL HOURS Total : 12 Weighted : 4

Esc

Operational Hours Information Displays the total operation hours and the weighted hours. The weighted hours is calculated based on percentage of the output of the unit.

Note: If the unit operates for 2 hours at 50% output, the resulting weighted hour is 1 hour.

100%

-4 hrs 0 hrs

Demand: 50%

Humidity Demand Trend This screen displays the humidity output over the past 4 hours. The current demand is also displayed numerically at the bottom of the screen.

57 | GS Series Installation

Password 0335

Enter Code

Confirm with Set

Esc Set

Request – 50%

Humidify 01/01/09 12:00:00 Security loop: Closed

Menu ?

Main Menu Service Level User Defined Setting Control Setting Diagnostic Menu

Esc Set

Control Setting Source : Analog REG Mode : Demand MOD Mode : Dual CH Multi Mode : StandAlone CNT Type : 0-10V LIM Type : 0-10V

Esc Set

Source Analog Analog Digital

Esc Set

Control Setting

Source : Analog

Analog

Enter Password Press the “Menu” button from any status screen.

Enter the user level code 0335 using the UP arrow key to change the numbers. The RIGHT arrow key moves to the next digit.

Control Setting The Control Setting menu allows the user to modify humidifier communication settings and limit the maximum capacity.

Source Verify that the control signal matches the control type.

Typically, analog signal are sent from a humidistat and are 0-10VDC or 0-20mA.

Digital signals are sent through a network connection.

Control Setting Source : Analog REG Mode : Demand MOD Mode : Dual CH Multi Mode :StandAlone CNT Type : 0-10V LIM Type : 0-10V

Esc Set

REG Mode Demand Demand On/Off RH (P) RH (PI)

Esc Set

REG Mode : Demand

Demand

REG Mode Corresponds to the type of control used.

Demand: Modulating control (Humidistat or BMS) signal range usually 0-10VDC or 0-20mA.

On/Off : On/Off space controllers.

RH(P) and RH(PI): Humidity sensors, generally signals between 2-10VDC and 4-20mA.

Control Setting Source : Analog REG Mode : Demand MOD Mode : Single CH Multi Mode : StandAlone CNT Type : 0-10V LIM Type : 0-10V

Set Set

MOD Mode Single CH Single CH Dual CH

Set Set

MOD Mode : Dual CH

Dual CH

MOD Mode Configures the humidifier to operate with a Single Channel (control only) or Dual Channel (control and high limit).

Note: In Dual Channel MOD Mode, a second Limiting control signal is required.

User Level

Control Settings

GS Series Installation | 58

Control Setting REG Mode : Demand MOD Mode : Single CH Multi Mode :StandAlone CNT Type : 0-10V LIM Type : 0-10V Short CD : On

Set Set

Multi Mode StandAlone StandAlone Master Slave

Set Set

StandAlone

Multi Mode : StandAlone

Multi Mode Sets the humidifier to either independent operation (StandAlone) or linked operation (Master or Slave).

Note: If Master or Slave is selected see Multi Unit Op. Range Settings, displayed after the Manual Capacity.

Control Setting MOD Mode : Dual CH Multi Mode : StandAlone CNT Type : 0-10 V LIM Type : 0-10 V Short CD : On Short CD T : 300

Esc Set

CNT Type 0-10 V 0-5 V 1-5 V 0-10V 2-10 V 0-16 V

3.2-16 V 0-20 mA 4-20 mA

Esc Set

0-10 V

CNT Type : 0-10V

CNT Type Configures the voltage or amperage range of the control signal. Verify that the signal matches the controller (humidistat, transducer or network connection).

Control Setting Multi Mode : StandAlone CNT Type : 0-10V LIM Type : 0-10 V Short CD : On Short CD T : 300 Time Prop. : On

Esc Set

LIM Type 0-10 V 0-5 V 1-5 V 0-10V 2-10 V 0-16 V

3.2-16 V 0-20 mA 4-20 mA

Esc Set

0-10 V

LIM Type : 0-10V

LIM Type Configures the voltage or amperage range of the high limit control signal. Verify that the signal matches the high limit controller.

Control Setting CNT Type : 0-10V Lim Type : 0-10V Short CD : Off Short CD T : 300 Time Prop : On Manual Cap. : 100

Esc Set

Short Cycle Delay Off Off On

Esc Set

Short CD : On

Short Cycle Delay Prevents short cycling or frequent turning on and off of humidifier. When turned On, unit continues to operate for set period of time after demand is met.

Note: When Short CD is turned On, time must be specified. See Short CD T.

Control Setting LIM Type : 0-10V Short CD : Off Short CD T : 300 Time Prop : On Manual Cap. : 100 ModBus Settings

Esc Set

Short Cycle Delay Tm 300 s 300s

Esc Set

Short CD T : 300

Short Cycle Delay Time Time humidifier stays on after demand is satisfied.

Note: Short CD has to be turned On. See above.

59 | GS Series Installation

Control Setting LIM Type : 0-10 V Short CD : On Short CD T : 300 Time Prop. : On Manual Cap. : 100 ModBus Settings

Esc Set

Time Proportioning On Off On

Esc Set

Time Prop. : On

Time Proportioning Allows the humidifier to modulate at low demand.

Control Setting Multi Mode : StandAlone CNT Type : 0-10 V Short CD : Off Time Prop. : On Manual Cap. : 100 ModBus Settings

Esc Set

Manual Capacity 100% 100%

Esc Set

Manual Cap. : 100

Manual Capacity Allows the user to manually set the maximum output of the humidifier.

Control Set Point 40% RH

40% RH

Menu Set

CNT Set-P : 40%

40% RH

RH Settings CNT Set-P : 40% RH CNT Band : 15% RH CNT Itime : 5 min LIM Set-P : 80% RH LIM Band : 15% RH LIM Damp : 5 s RH Alerts : On RH High : 75% RH RH Low : 33% RH

Menu Set

CNT Set-P : 40%

RH Settings

Only present if RH Alerts is set to On

Only present if MOD Mode is set to Dual CH

RH Settings

The RH Settings submenu is used to adjust setpoint, the proportional band, and the integral time if REG Mode is set to RH (P) or RH (PI) and the humidifier is connected to humidity sensors. Access the RH Settings submenu by pressing the menu key while RH Settings is highlighted in the Control Settings menu.

CNT Set-P

Sets the humidity setpoint value. The humidifier will attempt to maintain this humidity level in the space where the control transducer is installed.

GS Series Installation | 60

Control Band 15% RH

15% RH

Menu Set

CNT Band : 15% RH

15% RH

Limit Set Point 80% RH

80% RH

Menu Set

LIM Set-P : 80%

80% RH

Limit Band 15% RH

15% RH

Menu Set

LIM Band : 15% RH

15% RH

Limit Damping 5 s

5 s

Menu Set

LIM Damp : 15% RH

5 s

Control Integral Time 5 min

5 min

Menu Set

CNT Itime : 5 min

5 min

CNT Band

CNT Band should not normally be changed. The CNT Band setting adjusts the band within which the humidifier will modulate between 0 and 100% output. (Default = 15%)

Int Time

Int Time should not normally be changed. Int Time adjusts the frequency at which the controller corrects for proportional control error. It is only displayed if REG Mode is set to RH (PI)

LIM Set-P

Sets the duct high limit setpoint value. As RH in the duct approaches the high limit the output of the humidifier will be throttled back to prevent wetting the duct. (Default = 80%)

LIM Band

Should not normally be changed. The LIM Band setting adjusts the band within which the humidifier will throttle down the humidifier output from 100 to 0%. (Default = 15%)

Limit Damping

Sets the number of seconds the sensed RH must exceed the limit band before output is throttled down. (Default = 5 s)

61 | GS Series Installation

RH Alerts On On Off

Menu Set

RH Alerts : On

RH High 75% RH

75% RH

Menu Set

RH High : 75%

75% RH

RH Low 33% RH

33% RH

Menu Set

RH Low : 33% RH

33% RH

RH Alerts

Sets whether the humidifier will display warnings when humidity rises above or falls below configured limits. (Default = Off)

RH High

Sets the RH level above which the humidity must rise before a warning is generated. Warning is only generated if RH Alerts is set to on.

RH Low

Sets the RH level below which the humidity must fall before a warning is generated . Warning is only generated if RH Alerts is set to on.

GS Series Installation | 62

Control Setting Short CD : Off Short CD T : 300 Time Prop. : On Manual Cap. : 100 Multi Unit Op. Range ModBus Settings

Esc Set

Multi Unit Op. Range

Multi Unit Op. Range Consult GSTC Networking 2-10 Units Installation and Wiring Diagram Instructions for configuration details.

Multi Unit Op. Range Full Out. :100 Zero Out. : 0

Esc Set

Full Out. : 100

Full Out.

100 %

Esc Set

Multi Unit Op. Range Full Out. :100 Zero Out. : 0

Esc Set

Zero Out. : 0

Zero Out.

0 %

Esc Set

Control Settings - Multi Unit Operation Range

63 | GS Series Installation

Control Setting LIM Type : 0-10V Short CD : Off Short CD T : 300 Time Prop. : On Manual Cap. : 100 ModBus Settings

Esc Set

Modbus Settings Parity : None1 Addr : 1 Timeout : 300 Rem Disabl : On

Esc Set

Modbus Settings

Parity :None1

Parity

None1 None1 None2 Odd Even

Esc Set

None1

Modbus Settings Parity : None1 Addr : 1 Timeout : 300 Rem Disabl : On

Esc Set

Addr : 1

Addr

Esc Set

ModBus Settings for network communication to BMS.

Parity Error check for network communication.

Address Modbus Address

Timeout Time to ModBus timeout in the absence of a digital demand signal.

Remote Disable Allows unit to be disabled remotely through the network.

Modbus Settings Parity : None1 Addr : 1 Timeout : 300 Rem Disabl : On

Esc Set

Timeout : 300

Timeout

300 s

Esc Set

Modbus Settings Parity : None1 Addr : 1 Timeout : 300 Rem Disabl : Off

Esc Set

Rem Disabl : On

Rem Disable

Off Off On

Esc Set

Control Settings - Modbus Settings

GS Series Installation | 64

Password 0335

Enter Code

Confirm with Set

Esc Set

Request – 50%

Humidify 01/01/09 12:00:00 Security loop: Closed

Menu ?

Main Menu Service Level User Defined Settings Control Setting Diagnostic Menu

Esc Set

User Defined Setting Drain Cool : Smart BD rate : 25 FTBD : On FTBD Time : 23:30 FTBD Hours : 100 Idle Mode : Idle Drain

Esc Set

Drain Cool Smart Off On Smart

Esc Set

User Defined Setting

Drain Cool : Smart

Smart

Enter Password

Press the “Menu” button from any

status screen.

Enter the user level code 0335 using the UP arrow key to change the numbers. The RIGHT arrow key moves to the next digit.

User Defined Settings Allows the user to configure humidifier operation parameters.

Drain Cool Configure drain tempering. Set to Smart for efficient drain water cooling.

User Defined Setting Drain Cool : Smart BD rate : 25 FTBD : On FTBD Time : 23:30 FTBD Hours : 100 Idle Mode : Idle Drain

Esc Set

Blowdown Rate 25 % 25%

Esc Set

BD rate : 25

Blowdown Rate The blowdown rate adjusts the amount of water that is drained each hour. The percentage relates to the tank volume.

Note: Current setting: 25% of the tank each hour.

User Defined Setting Drain Cool : Smart BD rate : 25 FTBD : Off FTBD Time : 23:30 FTBD Hours : 100 Idle Mode : Idle Drain

Esc Set

Full Tank Blowdown On Off On

Esc Set

FTBD : On

Full Tank Blow Down The tank can be set to drain completely at a set time of day after a set interval of weighted hours.

Note: See FTBD Time to set time of day and FTBD Hours to set interval.

User Defined Settings

65 | GS Series Installation

User Defined Setting BD rate : 25 FTBD : On FTBD Time : 23:30 FTBD Hours : 100 Idle Mode : Idle Drain Idle Drain : 72

Esc Set

FTBD Time Hour : 23 Minute : 30

Esc Set

FTBD Time : 23:30

Hour : 23

Full Tank Blow Down Time Set the desired time of day to completely drain the tank and refill.

Note: Since the FTBD interrupts humidifier operation, it is recommended to set time outside peak operation time.

User Defined Setting FTBD : On FTBD Time : 23:30 FTBD Hours : 100 Idle Mode : Idle Drain Idle Drain : 72 Fill Corr : 100

Esc Set

FTBD Hours

100 h

Esc Set

FTBD Hours : 100

Full Tank Blow Down Interval Set the desired weighted time interval between FTBDs.

Idle Mode Idle Drain Idle Only Idle Drain Keep Warm

Esc Set

Idle Drain

User Defined Setting FTBD Time : 23:30 FTBD Hours : 100 Idle Mode : Idle Drain Idle Drain : 72 Fill Corr : 100 Drain Corr : 100

Esc Set

Idle Mode : Idle Drain

Idle Mode Configures humidifier operation when there is no call for humidity.

Idle Only: Humidifier is on standby.

Idle Drain: Humidifier drains after specified idling time (see Idle Drain).

Keep Warm: Water in tank is kept between 140-160ºF (60 -70ºC)

User Defined Setting Idle Mode : Idle Drain Idle Drain : 72 Fill Corr. : 100 Drain Corr. : 100 Float Ck : 23:30 Date : 01/01/09

Esc Set

Fill Correction 100 % 100 %

Esc Set

Fill Corr : 100

Fill Correction Adjust the fill on and fill off times. Values above 100% will increase the fill on time and values below 100% decrease fill on time.

User Defined Setting Idle Drain : 72 Fill Corr. : 100 Drain Corr. : 100 Float Ck : 23:30 Date : 01/01/09 Time : 12:00:00

Esc Set

Drain Correction 100 % 100 %

Esc Set

Drain Corr : 100

Drain Correction Used to compensate for variation in drain pump flow rates. The drain correction adjusts the actual drain duration by drain time. Increasing drain correction increases drain duration and decreasing correction decreases drain time.

GS Series Installation | 66

User Defined Setting Fill Corr. : 100 Drain Corr. : 100 Float Ck : 23:30 Date : 01/01/09 Time : 12:00:00 Unit Steam : lb/hr

Esc Set

Float Check Hour : 23 Minutes : 30 Status : On

Esc Set

Float Ck : 23:30

Hour : 23

Float Check Set the time of day the humidifier performs a test of the float chamber levels. The test can be turned On or Off.

Note: The Float Check does not interrupt humidifier operation and can be set at any time of day.

User Defined Setting Drain Corr. : 100 Float Ck : 23:30 Date : 01/01/09 Time : 12:00:00 Unit Steam : lb/hr Language : English

Esc Set

Date Day : 1 Month : 1 Year : 9

Esc Set

Date : 01/01/09

Day : 1

Date Set the current date displayed on the main screen. The date is factory set.

User Defined Setting Float Ck : 23:30 Date : 01/01/09 Time : 12:00:00 Unit Steam : lb/hr Language : English Contrast : 3

Esc Set

Time Hour : 12 Minute : 0

Esc Set

Time : 12:00:00

Hour : 12

Time Set the current time displayed on the main screen. The time is set at the factory.

67 | GS Series Installation

User Defined Setting Float Ck : 23:30 Date : 01/01/09 Time : 12:00:00 Unit Steam : lb/hr Language : English Contrast : 3

Esc Set

Unit Steam

lb/hr kg/hr lb/hr

Esc Set

Unit Steam : lb/hr

lb/hr

Unit Steam Set the units of the steam output. Can be set to either pounds per hour or kilograms per hour.

User Defined Setting Float Ck : 23:30 Date : 01/01/09 Time : 12:00:00 Unit Steam : lb/hr Language : English Contrast : 3

Esc Set

Language

English English French German Dutch

Esc Set

Language : English

English

Language

Set the Total Controller’s displayed

language.

User Defined Setting Float Ck : 23:30 Date : 01/01/09 Time : 12:00:00 Unit Steam : lb/hr Language : English Contrast : 3

Esc Set

Contrast

Esc Set

Contrast : 3

Contrast

Set the Total Controller’s LCD

display contrast.

GS Series Installation | 68

Password 0335

Enter Code

Confirm with Set

Esc Set

Request – 50%

Humidify 01/01/09 12:00:00 Security loop: Closed

Menu ?

Main Menu Service Level User Defined Settings Control Setting Diagnostic Menu

Esc Set

Service Level Burner Disable Service Tm : 500 Tank Drain Tank PreClean Reset Error History Reset Serv. Reminder

Esc Set

Burner Disable 1 Burner : Enabled 2 Burner : Enabled 3 Burner : Enabled 4 Burner : Enabled 5 Burner : Enabled 6 Burner : Disabled

Esc Set

Service Level

Burner Disable

1 Burner : Enabled

1 Burner Enabled Disabled Enabled

Esc Set

Enabled

Service Level The service level allows access to software controlled service tools and access to service time intervals and reminders.

Burner Disable Allows the user to disable and enable burners. Disabled burners are displayed in the information level. Burners can only be disabled when the security loop is open.

Service Level Burner Disable Service Tm : 500 Tank Drain Tank PreClean Reset Error History Reset Serv. Reminder

Esc Set

Service Reminder

500 h

Esc Set

Service Tm :500

Service Tm Set time interval of the service reminder.

Note: Do not modify. Interval set from factory.

Service Level

69 | GS Series Installation

Service Level Burner Disable Service Tm : 500 Tank Drain Tank PreClean Reset Error History Reset Serv. Reminder

Esc Set

Interrupt Operation

and Drain Tank

No Yes

Tank Drain

Manual Drain

19m 45s

Stop

Tank Drain Initiate software controlled complete drain of the tank.

Service Level Burner Disable Service Tm : 500 Tank Drain Tank PreClean Reset Error History Reset Serv. Reminder

Esc Set

Interrupt Operation?

(This operation can take > 1hr)

No Yes

Tank PreClean

PreClean

Drain 1 5m 0s

Stop

Tank Pre-clean Initiate pre-clean of the tank before major servicing. During pre-clean, the tank is drained, refilled and then drained a second time.

Service Level Burner Disable Service Tm : 500 Tank Drain Tank PreClean Reset Error History Reset Serv. Reminder

Esc Set

Reset Error History Are you sure?

No Yes

Reset Error History

Reset Error History Resets error history.

Service Level Burner Disable Service Tm : 500 Tank Drain Tank PreClean Reset Error History Reset Serv. Reminder

Esc Set

Reset Serv. Reminder are you sure?

No Yes

Reset Serv. Reminder

Reset Serv. Reminder Resets service reminder.

Note: Service reminder should only be reset after servicing.

GS Series Installation | 70

Password 0335

Enter Code

Confirm with Set

Esc Set

Request – 50%

Humidify 01/01/09 12:00:00 Security loop: Closed

Menu ?

Main Menu Service Level User Defined Settings Control Setting Diagnostic Menu

Esc Set

Diagnostics Menu Fault History Service History Remote Test

Esc Set

Fault History

12.01.01 12:00 RMW

12.01.01 12:00 DCF

Esc ?

Diagnostics Menu

Fault History

12.01.01 12:00 RMW

RMW: RH LIMIT WARNING The RH input

is lower than 3%.

Esc

RMW: System Response

Operation is

interrupted until an

input higher than 3%

is received.

Esc ?

RMW: System Response

Operation is

interrupted until an

input higher than 3%

is received.

Esc ?

RMW: Troubleshooting

Check connection

between sensor and

unit.

Esc ?

RMW: Troubleshooting

Check that sensor

is function.

Esc ?

RMW: Troubleshooting

Ensure controls are

located such that

they provide

accurate readings.

Esc ?

RMW: Troubleshooting

Consult Factory

Esc ?

Faulty History Fault history reads as the following: MM/DD/YY HOUR:MINUTE Error Code Press the “?” for an explanation of the error code and access to the troubleshooting guide. Use the UP and DOWN arrow keys to navigate through the explanations and corrective action required.

Diagnostic Menu

Allows the user to read through the fault history, the service history and perform a test of the remote fault indicator.

Diagnostic Menu

71 | GS Series Installation

Diagnostics Menu Fault History Service History Remote Test

Esc Set

Service History

12.01.01 0000 Serv

Esc ?

Service History Display service history according to date and time.

Diagnostics Menu Fault History Service History Remote Test

Esc Set

Remote Test

Remote Test Steam Relay

Off

Esc Set

Remote Test Steam Relay

Esc Set

Remote Test Service Relay

Off

Esc Set

Remote Test Service

Esc Set

Remote Test Error Relay

Off

Esc Set

Remote Test Service

Esc Set

Remote Test Allows the user to test manually the remote fault indication. Three relays are available:

• Steam Production

• Service Needed

• Humidifier Error

GS Series Installation | 72

GSTC Warning Displayed

Description of Warning

Corrective action by unit

Troubleshooting

IMW-X:IGNITION FAIL

The Ignition module identified has failed to ignite within the allotted time (4 minutes).

The unit will index to next available burner in the sequence.

(1) Check sight port of problematic burner. Watch for hot igniter (glowing red) followed by a flame. (2) If igniter not hot, check for voltage. Check wiring. Replace igniter if necessary. (3) If igniter is hot but no flame, ensure gas supply connected. Check for 24V at gas valve. (4) If flame visible, check flame sensor wiring. Check L1 not wired to N. Consult Factory.

APW-X:AP OPEN WARN

The air proving switch identified has opened while the unit was operating.

Unit will interrupt operation and retry three times.

After a third try a fault is generated.

(1) Ensure pressure tubes are secure. Check wiring to A/P switch and to driver board. (2) Ensure blower is operating. if not, check wiring and power to blower. Check blower relay. (3) Perform blower diagnostic test to ensure A/P switch remains closed during operation. (4) Check for suction In pressure tubes. If switch does not close it may be defective. Consult Factory.

AOW-X:AP OPEN WARN

The air proving switch identified did not close during blower start-up.

Unit will interrupt operation and retry three times.

After a third try a fault is generated.

(1) Ensure pressure tubes are secure. Check wiring to A/P switch and to driver board. (2) Ensure blower is operating. If not, check wiring and power to blower. Check blower relay. (3) Perform blower diagnostic test to ensure A/P switch remains closed during operation. (4) Check for suction In pressure tubes. If switch does not close it may be defective. Consult Factory.

BHW-X:BLOWER RPM HIGH

The indicated blower has an RPM higher than the lead blower by more than the allowable tolerance.

The unit will keep monitoring blower RPM and display this warning if RPM remains high.

(1) Ensure pressure tubes are secure. Check wiring to A/P switch and to driver board. (2) Ensure blower is operating. If not check wiring and

power to blower. Check blower relay. (3) Perform blower diagnostic test to ensure A/P switch remains closed during operation. (4) Check for suction In pressure tubes. If switch does not close it may be defective. Consult Factory.

BLW-X:BLOWER RPM LOW

The indicated blower has an RPM lower than the lead blower by more than the allowable tolerance.

The unit will keep monitoring blower RPM and display this warning if RPM remains low.

(1) Ensure blower in question is securely connected and is receiving correct voltage. (2) Verify blower control wiring connection. Check blower diagnostic test for abnormalities. (3) Ensure no restriction on blower. Ensure no blockage of blower inlet. (4) Blower speed may decrease due to wear. Safe to operate but output may be reduced. Order new blower.

HMW: MAINT. WARNING

The preset service interval time has expired.

The unit will continue to run for 200 hours before a fault is generated.

(1) Service unit. Consult maintenance guide in the Nortec manual. (2) Reset service interval time after maintenance has been completed.

Troubleshooting

Table 10: GSTC Warning Troubleshooting

73 | GS Series Installation

FTW:FILL WARNING

The fill valve has been active for an extended length of time and the water level is still zero

Fill valve remains activated. Warning will change to fault if float level remains at zero.

(1) Ensure water line is open and that adequate water supply and pressure is available. (2) Check wiring to float board and fill valve. Check strainer on fill valve inlet. (3) Check that drain valve, auxiliary drain valve or manual drain switch are not activated. (4) Check fill valve using diagnostic output test. Consult Factory.

RHW:RH HIGH WARNING

The measured RH is above the RH High alarm setting.

The humidifier will remain idle until the measured RH drops below setpoint.

(1) Check that RH high setting is correct for the application. (2) Check sensor location (too close to steam distributor or other sources that affect measurement). (3) System may be oversized. Lower manual capacity of the unit. (4) Consult Factory.

RLW:RH LOW WARNING

The measured RH is

below the “RH Low”

alarm setting.

The humidifier should be operating unless in standby or lockout mode.

(1) Check that RH low setting is correct for the application. (2) Check sensor location (too close to door, window, or other sources that affect measurement). (3) Humidifier may be in lockout or standby. Check security loop. Check that all burners operational. (4) System may be undersized. Check manual capacity setting. Consult factory.

RMW:RH LIMIT WARNING

The RH input is lower than 3%.

Operation is interrupted until an input higher than 3% is received.

(1) Check connection between sensor and unit. (2) Check that sensor is functional. (3) Ensure controls are located such that they provide accurate readings. (4) Consult factory.

NSW:NO SIGNAL WARNING

No communication is detected from Master unit. (This unit is set up as slave)

Operation is interrupted until signal is received.

(1) Verify that one unit is configured as master. (2) Check connection between master and slave. (3) Consult factory.

RDW: REMOTE DISABLED

The unit has been remotely disabled through modbus communication or Nortec Online.

Operation is interrupted until unit is re-enabled via modbus or software.

(1) Enable unit through building management system (BMS) or Nortec Online. (2) If unit cannot be enabled remotely, try enabling unit under software Modbus Settings. (3) Consult factory.

NBW: NO BURNERS AVAIL

All burners have been disabled via software. No burners are available for operation.

The unit will not be able to respond to a demand until 1 or more burners are enabled.

GS Series Installation | 74

GSTC Fault Displayed

Description of Warning

Corrective action by unit

Troubleshooting

(screen)

IMF:NO BURNERS AVAIL

All burners have produced an ignition module failure. No burners are available to produce steam.

Unit is unsafe to operate with this fault. Investigate the problem before restarting unit.

(1) Ensure gas supply is connected and open. Verify gas supply pressure matches specification label. (2) Check that igniters get hot/glow during ignition sequence, followed by a flame. Check wiring/voltage (3) If igniter hot but no flame, check for 24V at gas valve. (4) If flame visible, check flame sensor wiring. Verify L1 not wired to N. Consult factory.

AOF-X:AP FAIL FAULT

The air proving switch identified did not close during blower start-up after 3 attempts.

Unit is unsafe to operate with this fault. Investigate the problem before restarting unit.

(1) Ensure pressure tubes are secure. Check wiring to A/P switch and to driver board. (2) Ensure blower is operating. If not, check wiring and power to blower. Check blower relay. (3) Perform blower diagnostic test to ensure A/P switch closes and opens during operation. (4) Check for suction In pressure tubes. If switch does not close it may be defective. Consult factory.

ACF-X:AP CLOSED

The air proving switch identified was closed while the blowers were inactive.

Unit will remain in fault mode until condition is corrected or unit is reset.

(1) Ensure pressure tubes are secure. Check wiring to A/P switch and to driver board. (2) Check for over/under pressure in room. Verify proper vent installation. Check termination for wind. (3) Perform blower diagnostic test to ensure A/P switch closes and opens during operation. (4) Potential faulty air proving switch. Contact factory.

BNFX:BLOWER NOT OP

The indicated blower is not operating or registered an RPM below 500 RPM while being energized.

Unit is unsafe to operate with this fault. Investigate the problem before restarting unit.

(1) Check electrical connections. Ensure feedback and power cables are connected to blower and PCB. (2) If blower not operating, ensure blower relay is operating. Check output from PCB. (3) If blower is operating, feedback signal could be missing. (4) Perform blower diagnostic test to verify controller is receiving signal. Consult factory.

GVF-X:GAS VALVE FAIL

The indicated gas valve was energized out of sequence or when not expected to be energized.

Unit is unsafe to operate with this fault. Investigate the problem before restarting unit.

(1) Ensure electronics are connected according to the wiring diagram. (2) Check connections to all ignition modules and gas valves. Ensure adequate supply voltage. (3) Consult factory.

FTF:FILL FAULT

The fill valve has been active for an extended time without reaching level 1.

Unit will not operate without proper water level. Investigate the problem before restarting unit.

Table 11: GSTC Fault Troubleshooting

75 | GS Series Installation

FCF:FILL CHECK FAULT

The fill valve has been active for an extended time without increasing a float level

Unit will not operate without accurate float level reading. Investigate before restarting unit.

DCF: DRAIN CHECK

Drain Pump activated for extended period without changing float level

Unit needs to drain for optimal performance

(1) Back pressure from drain lines can slow draining of unit. (2) Drain Pump could be obstructed. Clean Drain pump. Check that the drain Pump is powered. (3) Ensure Float Level Sensor connected and that levels change on fill.

FIF: FLOAT INCONSIST.

On startup the unit registers that the float levels do not increase logically from 1 to 5

Unit cannot operate without accurate float level reading

(1) Float level sensor is malfunctioning (2) Inspect all hoses. Inspect all. connections. Consult factory.

FLF: FLOAT LEVEL

More than one float level is registering at the same time

Unit cannot operate without accurate float level readings.

(1) Float level sensor Is malfunctioning. Inspect all connections. (2) Ensure that hoses are properly connected and unobstructed. (3) Ensure correct hose from fill valve is connected to chamber. Consult factory.

KWF: KEEP WARM FAULT

Keep Warm activated but tank temperature has not increased within time allotted

Unit cannot operate in such condition.

(1) Check connection to tank temperature Sensor. Check to ensure no more than One burner is disabled. (2) Check tank to See if hot (caution). Check electrical Signal to sensor. (3) Tank temperature Sensor may be Defective. Consult factory.

OTF: OVER TEMP FAULT

The exhaust or tank Safety sensor has exceeded the safety limit

Unit cannot operate in such condition

(1) Check unit float system. Unit may not be operating with the correct water levels. (2) Ensure that exhaust line is open and free of obstructions. (3) Consult factory.

HMF: MAINT. FAULT

The humidifier maintenance interval and 72hour window for cleaning has expired.

Unit cannot operate Is such a condition

(1) Unit requires servicing. Consult maintenance guide in the Nortec manual. (2) Service reminder must be cleared after maintenance. Refer to manual.

GS Series Installation | 76

GSP fault code displayed

Description of fault

Troubleshooting

NBF

Once the GS controller detects an ignition module fail, it will index to the next available ignition module. If all ignition modules have failed or there are none available (in the case of a 100 unit) this fault will be generated.

(1) Check red LED’s on all modules for flashing fault code. (2) Ensure there is gas supply to the humidifier. (3) Ensure that the burners have not been disabled in the software. (4) Consult factory.

AOF-X

On startup after 3 tries if the AP switch does not close within the proving period, this fault will be generated

(1) Check that blue hoses on the Air Proving switch have not come loose. (2) Check that wires on the Air Proving switch are on the N/O contacts (3) If available, swap Air Proving switch with another and see if the fault follows the air proving switch, if so, replace switch (4) Consult factory

ACF-X

On initial startup if any of the A/P switches are closed this fault will be generated.

(1) Ensure that wiring on the air proving switch is on the N/O contacts. (2) Ensure that there is no continuity between the switch with the wires off, if so replace switch. (3) Ensure that there is not a strong positive pressure in the room holding the switch closed. (4) Consult factory.

BHF-X

If the blower RPM is above the RPM tolerance for more than 10 seconds, this fault is generated and the humidifier stops.

(1) Check wiring to lead blower and ensure a good connection. (2) Check lead blower for any restrictions by testing it in the diagnostics screen. (3) Consult factory.

BLF-X

If the blower RPM is below the RPM tolerance for more than 10 seconds, this fault is generated and the humidifier stops

(1) Check wiring to blower X and ensure a good connection. (2) Check blower X for any restrictions by testing it in the diagnostics screen. (3) Consult factory.

BNF-X

On startup, if the blower RPM does not exceed 500 RPM within 5 seconds or if during operation, the RPM drops below 500 RPM for more than 5 seconds this fault is generated

(1) Ensure there is power to the blower and that all wires are making a proper connection. (2) Consult factory.

GVF-X

If the controller detects that a gas valve has activated at a time it should not this fault is Generated.

(1) Ensure that the ignition module is not miswired or that the module is not faulty by swapping it with a known good one. If the problem follows the ignition module, replace the module. (2) Consult factory.

GIF-X

Following an ignition module fault if the modules gas valve activates this fault will be generated.

DBF

There are many time windows in the GS software. If, during a drain cycle, the time window for the water level to drop is exceeded, this fault is generated.

(1) Ensure that pump is being energized. (2) Check for blockage in all aspects of the drain system. (3) Float board defective. (4) Consult factory.

Table 12: GSP Fault List

77 | GS Series Installation

FCF

Once every 24 hours (provided the unit is powered and in an operating or standby condition) the controller will test the water level detection circuit. If the test fails this fault is displayed.

(1) Ensure the proper operation of the fill valve and drain valve via the diagnostics screen. (2) Float board is defective. (3) Consult factory.

WLF

If the controller detects two or more float level readings, which are not expected (ex. Switch 1 and 3 ON or switch 1, 2, and 3 ON) this fault will be recorded.

(1) Miswired float board. (2) Defective float board. (3) Consult factory.

FDF

The controller monitors the water level as it fills and drains. It expects to see the levels increase logically (1-2-3-4-5). If the water level increases and jumps a step (1-2-4-5) this fault will be generated. The same holds for water level decreasing.

(1) Float board defective. (2) Contact agent for replacement float board.

KWF

During a keep warn cycle, if the tank temperature sensor does not open within a certain time window, this fault is generated.

(1) Ensure that the tank temperature sensor is connected. (2) Defective tank temperature switch. (3) Contact agent for replacement switch.

OTF

If input TB5, # 4 on the logic board goes low (no 24 Vac detected) this fault will be generated. This could indicate either the tank over temperature switch has opened or the stack over temperature switch has opened.

(1) Do not operate and consult the factory.

HMF

In the user menu the user sets the maintenance time. Once this time expires a warning is displayed. 72 hours later the warning changes to this fault. The maintenance time is measured in weighted operational hours. With switch 5, #4 deactivated, this fault is enabled.

(1) Perform tank cleaning and all other maintenance requirements outlined in the manual.

FTF

Fill time-out fault during fill process. The GS software monitors the changes in water level during filling sequence. If ware level changes do not occur within an expected time interval, this fault will be generated.

(1) Verify water supply is open. (2) Verify adequate water supply to unit (30-80psi, 10L/min, minimum ½” dia. Line size). (3) Verify wire harness and connection between float chamber and I/O board (TB).

GS Series Installation | 78

GSP Warning Displayed

Description of Warning

Troubleshooting

IMW-X

Once the controller activates an ignition module, it will allow 4 minutes for the gas valve to activate. After the trial period, if the gas valve has not activated, a fault will be generated. The module will be locked out and the next burner will be indexed.

SEE FAULT LIST

APW-X

Should the air proving switch open while the unit is operating this warning is generated. The controller shuts down and retries. There are no limits to the amount of times this warning is generated.

SEE FAULT LIST

AOW-X

On startup if the AP switch does not close within the proving period. After 3 tries, a fault will be generated.

SEE FAULT LIST

BHW-X

If a blower RPM is above the RPM tolerance limit this warning is generated. If it is above the RPM tolerance limit for more than 10 seconds a fault will be generated.

SEE FAULT LIST

BLW-X

If a blower RPM is below the RPM tolerance limit this warning is generated. If it is below the RPM tolerance limit for more than 10 seconds a fault will be generated.

SEE FAULT LIST

HMW

In the user menu the user sets the maintenance time. Once this time expires this warning is displayed. The maintenance time is measured in weighted operational hours. With switch 5, #4 activated, this warning will remain until the warning is reset in the user level.

SEE FAULT LIST

UNW-6

Low water level has not been reached within expected time interval during initial fill sequence. Unit will continue filling while warning is displayed. A Water Fill Fail fault will be generated if the low water level is not reached after an additional length of time.

SEE FAULT LIST

UNW-C

Keep warm feature has initiated combustion sequence at 75% output. This occurs when keep warm feature has been activated via dip-switch settings, the system demand is below minimum and the tank temperature sensor is registering cold (open contacts).

(1) Warning message

will stop being displayed once tank temperature sensor indicates water is warm. (2) Keep warm feature can be disabled using dip-switch settings.

Table 13: GSP Warning List

79 | GS Series Installation

Wiring Diagrams & Spare Parts

GS Series Installation | 80

Figure 44: GSTC 100-600 (110-120 VAC) Internal Wiring Diagram

81 | GS Series Installation

Figure 45: GSTC 100-600 (208-240 VAC) Internal Wiring Diagram

GS Series Installation | 82

This Page Intentionally Left Blank

83 | GS Series Installation

Figure 46: GS Series INDOOR Exploded View - Internal Component

GS Series Installation | 84

Description

Part #

GS 100

GS 200

GS 300

GS 400

GS 500

GS 600

101

Clean-Out Door Kit, with Anode, GS/SE, B/B+

2570309

1 1 1 1 1

102

Gasket, Tank Cover Plate

2524361

1 1 2 2 3 3 103

Secondary Safety Switch

1504832

1 1 1 1 1 1 104

Fill Box

2526152

1 1 1 1 1 1 105

Vacuum Break Valve 1/2"npt

1505959

1 1 1 1 1 1 106

P-Trap

2553825

1 1 1 1 1 1 107

Dual Fill Valve 10.0 l/min & 0.35 l/min

1505759

1 1 1 1 1 1 108

Heat Exchanger Gasket

Single

2524405

Dual

2524403

1 2 2 3 3 109

Direct Vent Air Manifold

GS 100

1506140

GS 200

1506141

GS 300/400

1506142

1 1

GS 500/600

1506143

1 1 110

Heat Exchanger Replacement Kit

Mini

2528422

Single

2528423

1 1

Dual

2528424

1 1 2 2 3 111

Stack High Limit Switch

1506745

1 1 1 1 1 1 112

Exhaust Manifold Gasket

Single

1505973

Dual

1505942

1 2 2 3

113

Exhaust Manifold

GS 100

1505875

GS 200

1505861

GS 300/400

1505843

1 1

GS 500/600

1505828

1 1 114

Flexible Gas Hose with fittings

1505960

1 2 3 4 5 6 115

Auxiliary Drain Plug

1507043

1 1 1 1 1 1 116

Auxiliary Drain termination

1506925

1 1 1 1 1 1 117

Drain Pump 24v 60 Hz

1502644

1 1 1 1 1 1 118

Tank Thermal sensor

1506026

1 1 1 1 1 1 119

Float Chamber

1115933

1 1 1 1 1 1 120

Float Chamber Mounting Bracket

1113777

1 1 1 1 1 1 121

Float Board

2511137

1 1 1 1 1

122

Lower Mixing Box

1506749

1 1 1 1 1 1 123

Replacement Burner Ass'y

110 - 120V Models

2528416

1 2 3 4 5 6

208-240V Models

1507669

1 2 3 4 5 6 124

Burner Plate Gasket

1505936

1 2 3 4 5 6 125

Sight Port Replacement kit

2528417

1 2 3 4 5

Table 14: GS Series INFOOR Exploded View - Internal Components

85 | GS Series Installation

Description

Part #

GS 100

GS 200

GS 300

GS 400

GS 500

GS 600

126

Igniter/flame sensor gasket

1506892

2 3 4 5 6

127

Hot Surface Igniter Replacement Kit

110 - 120V Models

2528418

2 3 4 5 6

208-240V Models

1507695

2 3 4 5 6

128

Flame Sensor Replacement Kit

1507694

2 3 4 5 6

Igniter/flame sensor Replacement Kit

110 - 120V Models

2528420

2 3 4 5 6

208-240V Models

1507712

2 3 4 5 6

129

Combustion Blower

110 - 120V Models

2524360

1 2 3 4 5 6

208-240V Models

1502289

1 2 3 4 5 6 130

Air Proving Switch

1504175

2 3 4 5 6

131

Gas Valve Assembly

Natural Gas

1507713

1 2 3 4 5 6

Propane

1507714

1 2 3 4 5 6 132

Elbow Assembly for Air Intake

1504204

2 3 4 5 6

133

Burner/Blower Gasket

1708208

2 3 4 5 6

Not

shown

Bracket, Fan Board Mount

1505899

1 2 2 3 3

Not

shown

Fan Board

1505689

1 2 2 3 3

Not

shown

Igniter Jump Start Module

1506793

2 3 4 5 6

Not

shown

Hose Replacement kit

1507696

1 1 1 1 1

Not

shown

Flexible hose for Direct Vent

1502148

2 3 4 5 6

Not

shown

Rod, Sacrificial Anode, MG 1" x 4"

2570307

1 1 1 1 1

Not

shown

1/4" Tube for air proving (per inch)

1605227

Order (by foot) as required

Table 14: GS Series INFOOR Exploded View - Internal Components - continued

GS Series Installation | 86

This Page Intentionally Left Blank

87 | GS Series Installation

Figure 47: GS Series INDOOR Exploded View - Cabinetry

GS Series Installation | 88

Description

Part #

GS 100

GS 200

GS 300

GS 400

GS 500

GS 600

201

Service Door Assembly

Mini

2524439

Single

2524440

Double

2524441

1 1

Triple

2524458

202

Front Door Assembly

2535268

1 1 1 1 1 1 203

Recessed Handle

2523444

1 1 1 1 1

205

GSTC Processor Board Replacement

2544252

1 1 1 1 1

206

Drive Board

2535504

1 1 1 1 1 1 207

Primary Transformer

110 - 120V Models

2532672

1 1 1 1 1

208-240V Models

2532673

1 1 1 1 1

Fuse for Primary transformer, 6.25 Amp

2523526

1 1 1 1 1 1 208

Ignition Control Module

110 - 120V Models

2525914

1 2 3 4 5

208-240V Models

1505987

1 2 3 4 5 6 209

Relay Mount Socket

1703250

1 1 1 1 1

210

Blower Relay

1453020

1 1 1 1 1

Not

Shown

Slotted wire duct

1506041

order by length required

211

Display Panel w/keypad indoor

2544253

1 1 1 1 1

212

On/Off Drain Switch

1453001

1 1 1 1 1

213

Remote Fault Board

2521279

1 1 1 1 1

Not

Shown

Remote Fault Board Ribbon Cable

2522062

1 1 1 1 1

Table 15: GS Series INDOOR Exploded View - Cabinetry

89 | GS Series Installation

Figure 48: GS Series OUTDOOR Exploded View – Cabinetry

GS Series Installation | 90

Description

Part #

GS 100

GS 200

GS 300

GS 400

GS 500

GS 600

205

GSTC Processor Board Replacement

2544252

1 1 1 1 1

206

Driver board

2535504

1 1 1 1 1

207

Primary Transformer

110 - 120V Models

2532672

1 1 1 1 1

208-240V Models

2532673

1 1 1 1 1

Fuse for Primary transformer, 6.25 Amp

2523526

1 1 1 1 1 1 208

Ignition Control Module

110 - 120V Models

2525914

1 2 3 4 5

208-240V Models

1505987

1 2 3 4 5 6 209

Relay Mount Socket

1703250

1 1 1 1 1

210

Blower Relay

1453020

1 1 1 1 1

213

Remote Fault Board

2521279

1 1 1 1 1

Not

Shown

Remote Fault Board ribbon cable

2522062

1 1 1 1 1

Not

Shown

Slotted wire duct

1506041

order by length required

311

Display Panel w/keypad outdoor

2544255

1 1 1 1 1

212

On-Off-Drain Switch

1453001

1 1 1 1 1 1 313

Thermostat, On/Off, 80F

1508042

1 1 1 1 1

322

Vent Pipe 12" Long

3" Dia

1508134

4" Dia

1508133

5" Dia

1507884

1 1

6" Dia

1507881

323

Rain Cap

Mini

1508130

Single

1508129

Double

1507889

1 1

Triple

1507883

324

Cooling Fan

1507891

1 1 1 1 1

342

Pump House Heater 500 watts

1508039

1 1 2 2 3

Table 16: GS Series OUTDOOR Exploded View - Cabinetry

91 | GS Series Installation

Figure 49: GS Stand Assembly Instructions

GS Series Installation | 92

Item

GS 100

GS 200

GS 300

GS 400

GS 500

GS 600

Gas Pressure

Natural Gas min (in wc/mbar)

4.5/11.2

Natural Gas max (in wc/mbar)

9/22.4

Propane min (in wc/mbar)

9/22.4

Propane max (in wc/mbar)

13/32.3

Min free air opening (in/cm)

13/33

23/58

35/89

47/119

59/150

71/180

Input

Max (BTU)

140,000

280,000

420,000

560,000

700,000

840,000

Min GSTC (BTU)

45,000

Direct vent min (BTU)

60,000

Gas Piping Size (in/cm)

1/2/1.3

3/4/1.9

1/2.5

1.25/3.2

"BH" Vent X X X X X X

"B" Vent X X X X X X

"BH" Exhaust Piping (in/cm)

3/7.6

4/10.2

5/12.7

6/15.2

4/10.2

5/12.7

7/17.8

8/20.3

Appliance Category

I or III

Full Weight In (lbs/kg)

416/188

588/266

954/432

974/441

1340/607

1360/616

Empty Weight In (lbs/kg)

266/120

354/160

485/217

529/239

659/298

703/318

User level password

0335

Water consumption (25% bd)

Gallons/liters per hour

433/1639

866/3278

1300/4921

1733/6560

2166/8199

2600/9842

Tank Water Volume

Gallons/liters

18/71

29/111

58/221

55/210

84/320

81/309

Fill valve flow rates

To tank: Gallons/liters per minute

2.64/10

To float chamber: Gallons/liters per minute

0.09/0.35

Supply water pressure

Min. (psi/kPa)

30/206

Max. (psi/kPa)

80/551

Drain rate (includes D.W.C)

Gallons/Litres per minute

5.2/20

Min drain pipe size (in/cm)

1 to 1.5 / 2.5 to 3.8 OD or larger

Power supply requirements

120 volts a/c

X X X X X

208-240 volts a/c 1PH

X X X X X

Steam Outlet size (in/cm)

1.75/4.4

3/7.6

4/10.2

Table 17: GS Quick Reference

93 | GS Series Installation

Warranty

Nortec Humidity Inc. and/or Nortec Humidity Ltd. (hereinafter collectively referred to as THE COMPANY),

warrant for a period of two years after installation or 30 months from manufacturer’s ship date, whichever date is earlier, that THE COMPANY’s manufactured and assembled products, not otherwise expressly

warranted (with the exception of the media) are free from defects in material and workmanship. The heat exchanger(s) will have an additional warranty that ensures the heat exchanger will be free from defects in materials and workmanship for an additional year, for a total period of 3 years from installation or 40 months from the manufacturer’s ship date, whichever is earlier. No warranty is made against corrosion, deterioration, or suitability of substituted materials used as a result of compliance with government regulations.

THE COMPANY’s obligations and liabilities under this warranty are limited to furnishing replacement parts to the customer, F.O.B. THE COMPANY’s factory, providing the defective part(s) is returned freight prepaid by

the customer. Parts used for repairs are warranted for the balance of the term of the warranty on the original humidifier or 90 days, whichever is longer.

The warranties set forth herein are in lieu of all other warranties expressed or implied by law. No liability whatsoever shall be attached to THE COMPANY until said products have been paid for in full and then said liability shall be limited to the original purchase price for the product. Any further warranty must be in writing, signed by an officer of THE COMPANY.

THE COMPANY’s limited warranty on accessories, not of the companies manufacture, such as controls, humidistats, pumps, etc. is limited to the warranty of the original equipment manufacturer from date of original shipment of humidifier.

THE COMPANY makes no warranty and assumes no liability unless the equipment is installed in strict accordance with a copy of the catalog and installation manual in effect at the date of purchase and by a contractor approved by THE COMPANY to install such equipment.

THE COMPANY makes no warranty and assumes no liability whatsoever for consequential damage or damage resulting directly from misapplication, incorrect sizing or lack of proper maintenance of the equipment.

THE COMPANY makes no warranty and assumes no liability whatsoever for damage resulting from freezing of the humidifier, supply lines, or drain lines.

THE COMPANY retains the right to change the design, specification and performance criteria of its products without notice or obligation.

GS Series Installation | 94

U.S. Patent 5,816,496

Canadian Patent 2,203,332

U.S.A. Nortec Humidity Inc.

826 Proctor Avenue Ogdensburg, NY 13669

CANADA Nortec Humidity Ltd.

2740 Fenton Road Ottawa, Ontario K1T 3T7

TEL: 1.866.NORTEC1 FAX: 613.822.7964

EMAIL: nortec@humidity.com WEBSITE: www.humidity.com

95 | GS Series Installation

Nortec GS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual