Nortec GS User Manual 2

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GS Series

Gas Steam Humidifier

Installation,

User & Maintenance

Guide

IMPORTANT: Read and save this guide for future reference. This guide to be left with equipment owner.

1506222-D

FOR YOUR SAFETY:

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 telephone in your building. Immediately call your gas supplier from a neighbor’s telephone. Follow the gas supplier’s instructions. If you can not reach your gas supplier, call the fire department.

UNIT OPERATING RANGES:

Max. Ambient Temperature 104ºF (40ºC). Min. Ambient Temperature 41ºF (5ºC). Max. Relative Humidity (RH) non-condensing 95% RH. Min. Relative Humidity (RH) non-condensing 5% RH.

WARNING:

Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency, or the gas supplier.

WARNING:

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

IMPORTANT:

Read and save this guide for future reference. This guide to be left with equipment owner.

Table Of Contents

GENERAL 1

- WARNING ................................................1

- DELIVERY ................................................1

- RECEIVING & UNPACKING EQUIPMENT................................1

- GENERAL SPECIFICATIONS ......................................1

- MODEL DESIGNATION .........................................1

MODEL SPECIFICATION 2

GS INDOOR INSTALLATION 3

- LOCATING AND MOUNTING ......................................4

- GAS PIPING ...............................................5

- COMBUSTION AIR REQUIREMENTS ..................................6

- DIRECT VENT GUIDELINES.......................................6

- EXHAUST VENTING ...........................................7

- ADDITIONAL REQUIREMENTS WHEN VENTING THROUGH A SIDEWALL .............11

- ELECTRICAL ..............................................12

- PRIMARY WIRING ...........................................13

- LOW VOLTAGE CONTROL WIRING .................................14

- CONTROL INSTALLATION .......................................15

- PLUMBING ...............................................15

- FILL WATER SUPPLY LINE ......................................15

- DRAIN LINE ...............................................15

- AUX DRAIN PORT ...........................................16

-STEAM LINES AND CONDENSATE LINE ...............................16

GS OUTDOOR INSTALLATION 16

- MOUNTING ...............................................16

-TYPICAL GSTC OUTDOOR INSTALLATION ..............................17

- ROOF CURB DIMENSIONS ......................................18

- GAS PIPING...............................................19

- EXHAUST VENTING ..........................................20

- ELECTRICAL INSTALLATION .....................................20

- FILL WATER SUPPLY LINE ......................................21

- DRAIN LINE ...............................................21

- AUXILIARY DRAIN ...........................................21

- STEAM LINES..............................................22

PRINCIPLE OF OPERATION 22

- COMBUSTION .............................................22

- WATER MANAGEMENT ........................................22

- START UP PROCEDURE .......................................23

- FILLING THE SYSTEM .........................................23

- TESTING THE IGNITION SAFETY SHUT-OFF.............................23

- STARTING THE HUMIDIFIER .....................................24

- TAKING OUT OF OPERATION .....................................24

- INSTALLATION CHECKLIST ......................................25

- SCALE MANAGEMENT .........................................27

- WATER QUALITY ............................................27

- FAULT CONDITIONS ..........................................28

MAINTENANCE 28

- DRAINING THE TANK .........................................28

- MANDATORY MAINTENANCE SCHEDULE ..............................29

- CLEANING THE TANK .........................................30

- SERVICING THE UNIT .........................................31

- SERVICE CHECKS ...........................................31

- COMPONENTS REPLACEMENT....................................32

-Hot Surface Igniter and Flame Sensor Replacement ........................32

-Burner Removal and Installation ...................................32

-Removal and Installation of the Combustion Blower.........................33

-Gas Valve Replacement .......................................33

-Air Switch Replacement .......................................34

-Float Chamber Replacement ....................................34

-Transformer Replacement ......................................35

-Fill Valve Replacement .......................................35

-Drain Pump Replacement ......................................36

-Fill Box Replacement ........................................36

-Removal of the Heat Exchanger ...................................37

- DIP SWITCH SETTINGS ........................................38

- SOFTWARE FLOW CHART ......................................39

- FAULT AND WARNING LIST ......................................60

- EXPLODED VIEW INTERNAL COMPONENTS SPARE PARTS ....................63

- EXPLODED VIEW INDOOR CABINETRY SPARE PARTS.......................66

- EXPLODED VIEW OUTDOOR CABINETRY SPARE PARTS .....................68

- GS QUICK REFERENCE ........................................72

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, or your 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 fail 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:

RECEIVING & 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.

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 with the intended purposes. The manufacturer/ supplier can not be made liable for any damages resulting from improper use.

Gas Steam humidifier equipped with desired

MODEL DESIGNATION

options.

In a bag you will find:

- Manuals.

The unit specification label indicates the model of

gas humidifier according to the following chart:

GS 100 N DV

- Adapter fittings for water connection.

- Steamhose for steam outlet with clamps.

- 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.

PRODUCT LINE

(Gas Steam Humidifier)

TC = Total Controller

c/w KEYPAD

P = Economical

Humidifier size (lbs/hr)

FUEL

= NATURAL GAS

P = PROPANE GAS

DIRECT VENT OPTION

OUTDOOR MODEL

100 200 300 400 500 600

-1-

MODEL SPECIFICATION

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 25 -0.05

PROPANE MAX 140,000 105 -0.35

MIN 50,000 25 -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 25 -0.05

PROPANE MAX 280,000 210 -0.35

MIN 50,000 25 -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 25 -0.05

PROPANE MAX 420,000 315 -0.35

MIN 50,000 25 -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 25 -0.05

PROPANE MAX 560,000 420 -0.35

MIN 50,000 25 -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 25 -0.05

PROPANE MAX 700,000 525 -0.35

MIN 50,000 25 -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 25 -0.05

PROPANE MAX 840,000 630 -0.35

MIN 50,000 25 -0.35

-2-

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 altitude derate information.

FOR U.S. MODELS ONLY

Altitude Derate %

Feet Meters

0-2000 0-610 0

2001-3000 610-915 8

3001-4000 915-1220 12

4001-4500 1220-1370 16

4501-higher 1370-higher Contact Factory

Figure #1

Typical Installation (Indoor)

Steamline

Clean Out Access Door

Exhaust Outlet

Snap on Installation

Steam Outlet

B or BH Venting Type

Control Wiring

Optional Direct Vent

Gas Line Connection

Main Power Disconnect

Shut Off

Fresh Water Fill Line 3/4"min 30-80 psi

Drain

Optional Stand

Service Access Door (Electrical)

Service Access Door (Mechanical)

-3-

Air Gap with Funne

Auxiliary Drain

To Drain

Figure #2

Clearance Requirements

Minimum

36" (91.5 cm)

Left

36" (91.5 cm)

Required only for

GSTC/GSP

500/600

Side Clearance

Minimum

4" (10.2 cm) to vent pipe

Right

30" (76.2 cm)

Optional Stand

Front Clearance

Front

30" (76.2 cm)

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 CAN/CGA B149 Installation 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 #1 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.

· 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 #2.

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.

WARNING: During installation cover the humidifier to prevent any dust or other contaminants from entering the cabinets when activities such as drilling are taking place.

-4-

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 on a roof, a properly

ventilated, temperature controlled, (above freezing), weatherproof enclosure must be used.

DO NOT mount humidifiers on vibrating surface.

Consult factory.

The humidifier shall not be installed directly on

carpeting, tile or other combustible material other than wood flooring.

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 #3.

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.

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 CAN/CGA-B149 Installation Codes in Canada.

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

INCHES W.C.

GAS MIN. MAX.

Natural 4.5 9.0

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.

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.

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 to or greater 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.

NOTES: (See pg 19 for additional Gas Piping information)

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

Propane 9.0 13.0

Figure #3

Gas Connection

Inlet coupling supplied

Shut-off Gas Valve (by others)

Union (by others)

Sediment Trap (by others)

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 it will not interfere with removal of gas valves or 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

-5-

upstream of the gas supply connection to the appliance.

recommended that the supply air line is insulated and

an in line heat is added. Consult factory.

COMBUSTION AIR REQUIREMENTS

Provide for adequate combustion and ventilation air in accordance with Sections 8.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1, or Sections 7.2, 7.3, 7.4 of CAN/CGA B149 Installation Codes, or applicable provisions of the local building codes.

The required free area of supply air opening is:

13 in. sq. (8,387 mm 23 in. sq. (14,839 mm 35 in. Sq. (22,581 mm 47 in. Sq. (30,323 mm 59 in. Sq. (38,064 mm 71 in. Sq. ( 45,806 mm

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.

), for GS 100

), for GS 200

), for GS 300

), for GS 400

), for GS 500

), for GS 600

Attach the air supply line to the manifold using a hose clamp or hose coupling if required. See Figure #4.

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

WARNING: BH Type venting must be used in a direct vent application.

The air intake terminal and the flue gas terminal must end at an outside location. See Figure #5.

Air Piping Insulated (by others)

Hose Coupling (by others)

Air Intake Connection

DIRECT VENT 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 maximum pipe length for the air supply line and exhaust is equivalent to 70’ (21m). The vent pipe diameter must be maintained over the overall length of the vent.

All air piping must be listed type for direct vent application with sealed joints and seams, such as Z flex.

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.

The air supply line must be installed with air supply terminals provided.

At low temperatures, water condensation can form on the outside of the pipe. To prevent this, it is

Figure #5

Direct Vent Side Wall Requirements

Exhaust terminal with opening vertical.

Intake terminal with opening vertical.

4ft-6ft

(1.2 m - 1.83 m)

Keep 6“ (15.2 cm) away from sidewall.

-6-

Location of air intake and flue gas terminal must

comply with all local and national regulations.

EXHAUST VENTING

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.

Category III class must be used in direct vent

applications.

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 CAN/CGA.B149 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 visa 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 gas humidifier may not be used in conjunction with a power venter or draft inducer.

Horizontal Venting Using a Direct Vent Application Using BH Type Only

Wall

BH type vent using double wall vent

with all joints being air and water tight.

Reference local and/or national codes

before installation of the vent

Condensate tee and trap must

be installed. Take the condensate

to a floor drain or a condensate pump

Exhaust venting outlet

Steam Outlet

Hangers straps

Condensate Tee

Trap

Figure #6

3” Min

Direct vent Inlet

2ftMin

Exhaust venting must be min.4 ft, max.6 ft in distance apart from the fresh air intake for direct venting

Terminations supplied with unit

Note: These are

BH type double wall with double wall connectors required.

uidelines only. Follow the local and/or national codes inyour respective area.

-7-

Figure #7

Vertical Venting Application Using B or BH Venting

UL Listed Cap Required

Flashing

B or BH type vent using double wall vent with double wall connectors is required. Reference local and/or national codes before installation of the vent.

Horizontal run

1/4"rise per ft

4" minimum air space required

Exhaust venting

outlet

Steam Outlet

Side Wall Venting Application Using BH Type Only

Wall

BH type vent using double wall vent with all joints being air and water tight. Reference local and/ or national codes before installing vent

Trap

3” Min.

Condensate tee and trap must be installed. Take the condensate to a floor drain or a condensate pump.

Figure # 8

Hangers Straps

Condensate tee required

2 FT Min

B type double wall vent with double wall connectors required for category I appliances. Limitations on horizontal distance when venting with B vent

BH type double wall vent with double wall connectors required and all joints are to be air and water tight. BH vent is a category III appliances

Nortec vent terminal

Exhaust venting outlet

Steam Outlet

Note: These are guidelines only, follow the local and/or national codes in your respective area.

Condensate

Te e

Trap

2 ft Min.

3” Min.

Condensate tee and trap must be installed. Take the condensate to a floor drain or a condensate pump.

BH type double wall vent with double wall connectors is required for category III appliances

-8-

Exhaust venting

Steam Outlet

Co-venting Application Using B Vent Only

B type double wall vent with double wall connectors is required for category I, serving two or more gas appliances.

outlet

Condensate Te e

Figure # 9

UL Listed Cap Required

Condensate tee and trap must be installed. Take the condensate to a floor drain or a condensate pump.

Trap

Note: These are guidelines only. Follow local and/ or national codes in your respective area.

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.

WARNING: Provide a screen or barrier to prevent personal injury in areas where personnel may come into contact with hot vent pipes.

A drip “T” or flue box condensate port 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.

Category I gas appliance uses B type venting. Follow local and/or national codes for venting installation.

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 a unlined masonry or concrete chimney.

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.

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

-9 -

Vent pipe must be secured with hangers or pipe

straps

All horizontal runs must be adequately supported

with hangers or straps to prevent sagging.

Installation as a Category I Appliance

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 & #9)

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

or B-W.

Recommended B-Venting Manufacturers

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 can not 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 CAN/CGA.B149 standards.

An approved venting manufacturers termination

cap for the stack outlet must be used.

The maximum flue temperature is 400 degrees F.

Normal operating range is 360 to 380 degrees F.

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 CAN/CGA.B149 standards.

1. Simpson Dura-Vent

2. Selkirk Canada Corporation

3. American Metal Products

4. Metal-Fab Inc.

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.

· 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 manufacturers instructions for proper clearances to combustibles.

Figure #10

Exhaust Connection

Female to Femal Adapter (by others)

-10-

This appliance should not be connected to a

chimney flue servicing a separate appliance designed to burn solid fuel. Never connect this humidifier to a chimney servicing a fireplace.

This venting category cannot be used in direct

vent applications.

Installation as a Category III Appliance

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. See Figure # 6,#7 & #8.

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

A minimum equivalent vent length of 7 feet must

be connected to the humidifier. Vent lengths must not exceed 100’ (30 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.

Diret vent applications, length of vent should not

exceed 70” in equivalent length.

ADDITIONAL REQUIREMENTS WHEN VENTING THROUGH A SIDEWALL

This venting must be used in all direct vent

applications.

This category installation may not be common

vented with any other natural draft gas appliance or power assist appliance. The humidifier cannot share a chimney flue servicing an appliance designed to burn solid fuel.

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

All joints must be sealed using high temperature RTV silicone.

BH Vent Manufacturers

1. Flex-L International

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 the 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

2. Fas-N Seal

3. Heat-Fab Inc.

4. Z Flex

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.

Locate the vent terminal at least seven feet above grade when it is adjacent to public walkways.

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.

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.

-11-

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 direct vent option.

ELECTRICAL

PRIMARY WIRING

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.

All work concerning the electrical installation

must be performed by qualified personnel.

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.

The humidifier should only be connected to

primary power (mains 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. Power requirement must be 120V or 208-240 Vac, 15A separately fused circuit, single phase. 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. See Figure #1.

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 by-laws.

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.

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 via dip switch settings on the logic control board.

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.

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.

-12-

208-240V1

VOLTAGE

(ACTUAL)

600V/3ph

PRIMARY

Neutral

phase line voltage wiring to unit

(BY OTHERS)

Ground Wire

Ground

Stepdown

Transformer

600V/208V

by others

Note:

- 600V/3 Phase Supply.

- 600V/1ph betweenany twohot leg.

- 347V/1ph betweenhot andneutral.

Dedicated

Circuit

Breaker

Disconnect

Ground Leg

2 Pole Terminal Block

460V/3ph

380V/3ph

208V/3ph

Neutral

Ground Wire

Ground

Stepdown

Transformer

460V/208V

by others

Note:

- 460V/3 Phase Supply.

- 460V/1ph betweenany twohot leg.

- 277V/1ph betweenhot andneutral.

Ground Wire

Ground

Note:

- 380V/3 Phase Supply.

- 380V/1 phasebetween twohot legs.

- 220V/1 phasebetween hotand neutral.

Ground Wire

Ground

Dedicated

Circuit

Breaker

Note:

- 208V/3 Phase Supply.

- 208V/1 phasebetween twohot legs.

- 120V/1 phasebetween hotand neutral.

Disconnect

Dedicated

Circuit

Breaker

Disconnect

Dedicated

Circuit

Breaker

Disconnect

Ground Leg

2 Pole Terminal Block

Ground Leg

2 Pole Terminal Block

Ground Leg

3 Pole Terminal Block

120V/1ph

Neutral

Ground

Note:

- 120V/ 1phase Supply.

- 120V/1phase betweenhot andneutral.

- 240V/1phase betweentwo 120V/1phsupply.

Ground

Stepup

Transformer

120V/240V

min. 2kVa

by others

Note:

- 120V/ 1phase Supply.

- 120V/1phase betweenhot andneutral.

- 240V/1phase betweentwo 120V/1phsupply.

Ground Wire

Dedicated

Circuit

Breaker

Disconnect

Ground Wire

Dedicated

Circuit

Breaker

Disconnect

NOTE: VoltageAt TerminalBlockMust Be InAccordance With Spec. Label. All Wirin

ToBe InAccordance With ExistingNationalAndLocal Electrical Codes.

-13-

Ground Leg

3 Pole Terminal Block

N T

Ground Leg

3 Pole Terminal Block

GS SERIES

EXTERNAL CONTROLS WIRING CONNECTIONS

LOW VOLTAGE TERMINAL STRIP

NOTE: This is a wiring diagram only. For specific wiring instructions, it is necessary to refer

to the wiring diagram which is supplied with each unit.

WARNING: Failure to wire the controller in accordance with the wiring diagram that was supplied with the unit could permanently damage the GSTC/GSP board. Such errors will void the unit warranty.

Security Loop

EXTERNAL

INTERNAL

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.

generic

Modulation Input Signal “A"

Modulation Input Signal “B”

10 Vdc output

enable (24 Vac)

Full Tank Blow Down (FTBD)

Safety Interrupt (24 Vac)

COM

Humidifier “ON”

N.O.

1211

Humidifier “ACTIVE”

COM

N.O.

COM

Humidifier “SERVICE”

N.O.

Humidifier “FAULT”

COM

N.C.

EXTERNAL

1815

INTERNAL

Low Voltage Terminal Strip

1 & 2: Wire all on/off controls and safeties between these two terminals. If not used, jumper1&2forthe

unit to operate.

4: Modulating input to humidifier “A”.

5: Modulating input to humidifier “B”.

6: 10 Vdc output.

8: When 24 Vac input received, the unit will initialize a full tank blowdown.

9: Safety interrupt (24 Vac).

10 & 11: Remote indication connection for humidifier “on” status indication.

12 & 13: Remote indication connection for humidifier “active” status.

14 & 15: Remote indication connection for service required indication.

16 & 17 & 18: Remote indication connection for fault indication.

-14-

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 grille. 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.

PLUMBING

NOTE: All water supply and drain line

connections should be installed in accordance with local plumbing codes.

FILL WATER SUPPLY LINE

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.

Figure # 11

Plumbing Connections

1/2” NPT Water Supply (by Nortec)

3/4” O.D. Drain (Hose clamp by Nortec)

1/2” NPT Female Auxiliary Drain

Union (by others)

Check Valve (by others, if required)

Manual Shut-off (by others)

Union (by others)

Manual Shut-of (by others)

Funnel with Air Gap (by others)

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.

-15-

DRAIN LINE

The humidifier is equipped with a ¾”O.D. Unthread ed 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 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 7-8 gal/min (18-20 l/min).

AUX DRAIN PORT

Figure #12

Steam Line Connection

Steam Line

Snap on Insulation

Hose cuffs & clamps supplied

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 #11).

· The auxiliary drain port is used with the standard freeze protection. Install a shut off valve on this line and pipe to the drain funnel (see Figure #11). 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 #12 for connection details.

For steam line installation between the humidifier and distribution system, consult the distribution system installation manual. Steam Distributor Installation Manual - Form #XX-231 and SAM-e Short Absorption Manifold - Form #XX-249.

GS 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 CAN/CGA B149 Installation codes in Canada. NORTEC can not accept responsibility for installation code violations.

MOUNTING

Typical rooftop installations are shown in Figure #13 & #14.

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 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.

-16-

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 #15 for clearance details.

Figure # 13

GSTC Outdoor Typical Installation Rooftop

Electrical Disconnect (By others)

Roof Curb (By others)

BH Vent (By Nortec)

Drain Lines

Funnel With Air Gap

AHU

Insulated Steam Line (By others)

Gas Line with Manual Shut-off (By others)

Water Supply

Manual Shut-off

Roof Curb (By others)

BH Vent (By Nortec)

Electrical Disconnect (By others)

Figure # 14

GS Outdoor Typical Installation Rooftop

Insulated Steam Line (By others)

Gas Line with Manual Shut-off

-17-

Figure # 15

GSTC Outdoor Clearance

Model Front Left Right Back

GSTC Outdoor 100 30" (76cm ) 0 40" (101.6 c m) 6" (15.25 c m) GSTC Outdoor 200 30" (76cm ) 0 40" (101.6 c m) 6" (15.25 c m) GSTC Outdoor 300 30" (76cm ) 30" (76cm ) 40" (101.6 c m) 6" (15.25 c m) GSTC Outdoor 400 30" (76cm ) 30" (76cm ) 40" (101.6 c m) 6" (15.25 c m) GSTC Outdoor 500 30" (76cm ) 30" (76cm ) 40" (101.6 c m) 6" (15.25 c m) GSTC Outdoor 600 30" (76cm ) 30" (76cm ) 40" (101.6 c m) 6" (15.25 c m)

Minimum Required Clearances

TOP

Left

FRONT

RIGHT

3 3/4”

(9.5cm)

ELECTRICAL SIDE

Figure # 16

Roof Curb Dimensions

Model Dimension A Curb Height Shipping We ight Operating Weight

GSTC Outdoor 100 8.63" (27.91cm ) 15" (38.1cm) Min. 400 lbs (181 k g) 556 lbs (252 kg) GSTC Outdoor 200 15.06" (38.25cm ) 15" (38.1cm) Min. 500 lbs (227 kg) 744 lbs (338 kg) GSTC Outdoor 300 30.63" (77.8cm ) 15" (38.1c m) Min. 700 lbs (318 kg) 1185 lbs (539 k g) GSTC Outdoor 400 30.63" (77.8cm ) 15" (38.1c m) Min. 745 lbs (339 kg) 1210 lbs (550 k g) GSTC Outdoor 500 46.25" (117.5cm ) 15" (38.1cm) Min. 800 lbs (363 kg) 1505 lbs (684 kg) GSTC Outdoor 600 46.25" (117.5cm ) 15" (38.1cm) Min. 844 lbs (384 kg) 1525 lbs (693 kg)

Roof Curb by Others

SECTION A-A

MAX.

34 1/8”

(86.6cm)

3/4”

(1.90cm)

11/16”

(1.8cm)

Pipe Chase

Lifting Hooks

BURNER SIDE

6.0”

(15.24cm)

ROOF

PIPE CHASE

5.0”

(12.7cm)

BASE FRAME ELEMENT

CURB

-18-

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 #16 .

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.

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 #17 for details.

Nortec recommends that each Gas Fired

Humidifier has it’s own regulator installed in line to the unit. Th 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 #18

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

Figure #17

Gas Piping

Inlet coupling supplied

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 CAN/CGA-B149 Installation Codes in Canada.

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

Shut-off Gas Valv (by others)

Union (by others)

Sediment Trap (by others)

-19-

(By

)

Figure #18 GasPiping

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.

system can be damaged is by the failure of both devices.

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 #19 for venting components.

Figure #19

Exhaust - Outdoor Units

Rain Cap

All Venting provide by Nortec

Extension Pipe

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 #20 for details.

Figure #20

Electrical Box

Disconnect box (By others)

Storm Collar

Primary wiring

others

-20-

FILL WATER SUPPLY LINE

Each unit is supplied with a ½” NPT male

connection to the fill valve. Refer to Figure #21 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.

Figure #21

Fill Water Connection

1/2” NPT Connection

Figure #22

Drain Connection

AUXILIARY DRAIN

Pipe Chase

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.

Check Valve (If required)

Drain Line Connection

Manual Shut-Off Valve (By others)

· 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 (provide an air gap).

· GS Outdoor units standard with freeze protection 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. See Figure #22. 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 200°F temperatures.

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

Internal drain water tempering will ensure a maximum of 140°F (60°C) during normal

operation.

-21-

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 #23.

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 Form #XX-231 and SAM-e Short Absorption Manifold Form #XX-249).

Figure #23

Steam Connection

BH Venting Supplied

Cuff hose and clamps provide

PRINCIPLES OF 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, then the hot surface ignitor 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 ignitor. 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.

Steam line (Insulation recommended)

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.

-22-

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)

START UP PROCEDURE

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 thehumidifier 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

Remove any demand signal to the unit

Figure #24

Plumbing Connections

Presure Equalizer

Float Chamber

START-UP CHECKLIST

Fill Chamber

Vacuum Break

Main Fill to System

Dual Fill Valve

Drain Outlet

Internal Trap

Drain Pump

Aux. Drain

· 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

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

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 on pages 25 & 26 before commissioning the unit.

-23-

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

At the completion of the float test, the humidifier

will begin the combustion sequence and each burner will ignite in sequence

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, then turn the power back on

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

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:

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

· 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

-24-

GS INSPECTION CHECK LIST

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_______

-25-

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

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 covred under Nortec’s standard warranty. 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________________________

-26-

Close the shut-off valve in the water supply line

Isolate the humidifier from the electrical power

supply at the main disconnect switch

SCALE MANAGEMENT

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.

Figure #25

Site Water Test Kit P/N 1507214

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.

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.

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.

· 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 25 ppm.

NOTE: Failure due to chloride corrosion is not covred under Nortec’s standard warranty. Consult factory for more information.

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

-27-

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.

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

Tech

nology

Gas-

Fired

Water

Type

Potable 0-1500 0-12 0-14 6.5-7.5 0-25

Treated 0-100 0-1 0-1 7-7.5 0-25

NORTEC recommends performing a semi-annual

Water Cond.

Range

Microm

hos

Hard

ness

Range

GPG PPM pH PPM

Silica

Range

Alkalin.

Range

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 front cover and page 1 of this guide.

FAULT CONDITIONS

Chlor.

Range

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.

MAINTENANCE

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.

This appliance is equipped with a self diagnostic ignition module which identifies a fault code when it occurs. Refer to the fault & warning list on pg 60.

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.

-28-

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.

connecting to hit.

sensor with replacement kit.

WHAT NEEDS TO BE DONE?

END OF

REGULAR MAI NTENANCE PREVENTIVE MAINTENANCE

SEASON

- Replace hot surface ignitor and flame

air from outside matting.

- Clean sensor with fine steel wool.

- Check that Flame Sensor is s traight.

- Remove from the unit and clean with compressed

X - Check for c ontinuity.

gasket each time a burner is removed.

NOTE: It is recommended to replace the burner

- Drill out tank nipples when required to

- Adjust blow down time when required. Check that

ensure nipples are not blocked with scale.

scale has not ac cumulated above 2".

- Clean scale from float chamber and hose

float chamber.

- Clean tank when required. - Clean tank.

- Inspec t for leaks at the drain pump, fill cup and

- Inspec t for leaks. Ens ure terminal cap is clear and

traps. Flue temp should be between 350-400ºF.

any condensation produced flows to condensate

attached t o the exhaust.

- Visual c heck that sens or is intact, wired and

MANDATORY M AINTENANCE SCHEDULE

MID

XTank

start-up

30 DAYS

after i nitial

PARTS

Fill Lines X X X - Inspec t for leaks.

Hot Surface

Flame Sensor

Ignitor

Gas Burner

Drain Lines X - Switch to drain and make s ure water flows freely.

Float Chamber X X X - Ensure floats move freely.

Drain Lines XX X

Gas Ve nting XX X

Direct V ent X X - Inspec t for leaks. Ensure intake t erminal is c lear.

H/L Stack Se nsor XX X

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.

CLEANING THE STEEL TANK

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.

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

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.

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.

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 (5ft/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.

Figure #26

Cleaning Tank Access

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 the3/16nuts (½” key or socket is needed).

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

Torque: 50 in-LB (5.7 NM)

-30-

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.

SERVICING THE UNIT

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.

Caution: Disconnect power before servicing this

appliance.

Caution: Label all wires prior to disconnection

when servicing controls. Wiring errors can cause improper and dangerous operation.

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 de-energized immediately, and the combustion blower will be turned off.

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

Igniter Check

If the igniter is suspected of being defective then

the following test may be carried out;

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

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

3. 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:

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

The burners are made of ceramic fabric material and operate in the infrared mode. Depending on the environment, the burner(s) may require removal of lint or grease-laden dust periodically. This may be achieved by removing the burner and applying pressurized air to the external surface of the material. Refer to the Servicing Section related to burner removal.

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 an 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.

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

3. 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.

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

5. 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.

-31-

6. Once the pressure has been adjusted, replace

the locking cap.

gasket when replacing the flame sensor and igniter.

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

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

1. Shut off electrical power and gas supply to the humidifier.

2. Remove the right side service access door.

3. Disconnect all wiring to the igniter and flame

sensor.

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

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

Burner Removal and Installation

1. Shut off electrical power and gas supply to the humidifier.

2. Remove the right side service access door.

3. Disconnect all wiring to the combustion

blower, gas valve, air proving switch, igniter and flame sensor (note the connector assignment).

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

5. 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.

6. 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.

5. Reverse the sequence above to install the new igniter and flame sensor. Always install a new

Figure #27

Flame Sensor and Ignitor Assembly

7. Reverse the sequence above to re-install the burner after cleaning or, if necessary, replace

Figure #28

Burner Assembly

Hold Burner only on metal pipe

Ceramic Matting DO NOT TOUCH!

-32-

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.

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

Removal and Installation of the Combustion Blower

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.

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

Gas Valve Replacement

1. Shut off electrical power and gas supply to the humidifier.

2. Remove the right side service access door.

3. Disconnect all wiring to the combustion

blower, gas valve and air proving switch (note the connector assignment).

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

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

6. 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.

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

8. Reverse the sequence above to install the new combustion blower. Inspect and replace

Figure #29

Combustion Blower Replacement

1. Shut off electrical power and gas supply to the humidifier.

2. Remove the right side service access door.

3. Disconnect all wiring to the gas valve and air

proving switch (note the connector assignment).

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

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

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

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

8. 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.

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

-33-

10. 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.

Figure #30

Gas Valve Replacement

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

Air Switch Replacement

1. Shut off electrical power to the appliance.

5. Remove screws (2) holding the switch.

6. Reverse above procedure to re-install.

Float Chamber Replacement

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

2. Remove the left front service access door.

3. Remove the cable connection to the float

board.

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

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

6. Reverse the above sequence to install the new module.

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

2. Remove right side service panel.

3. Remove wiring connections to switch.

4. Remove pressure hose(s) from switch noting

proper location.

Figure #31

Air Switch Replacement

Figure #32

Float Chamber Replacement

-34-

Ignition Module Replacement

1. Shut off electrical power to the humidifier.

2. Remove the front electrical access door.

3. Disconnect all wiring connections to the

ignition module, labeling as required.

4. Remove the 2 screws securing the ignition module and remove.

5. Reverse the above sequence to install the new module.

Figure #33

Ignition Module Assembly

Figure #34

Transformer Assembly

Fill Valve Replacement

1. Shut off electrical power and water supply to the humidifier.

2. Remove the right side service access door.

Transformer Replacement

1. Shut off electrical power to the appliance.

2. Remove front access door.

3. Disconnect wiring connections from

transformer leads labeling as required.

4. Remove screws (2) holding transformer.

5. Reverse above procedure to re-install.

3. Remove all wiring connections to the fill valve.

4. Remove the hose clamps on the fill valve

outlets and remove hoses (note the correct hose assignment).

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

6. Reverse the above sequence to install the new module.

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

Figure #35

Fill Valve Replacement

-35-

Drain Pump Replacement

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

2. Shut off electrical power to the appliance.

3. Remove front and right doors.

4. Remove wiring connections to the pump.

5. Remove hoses attached to the pump.

6. 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.

Figure #36

Drain Pump Assembly

Fill Box Replacement

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

-36-

Removal of Heat Exchanger

1.1. Take the humidifier out of operation.

2.2. Disconnect the gas supply pipe from the

connection on the humidifier and close off the pipe.

3.3. Unlock and remove the right side panel(s).

4.4. On Direct Vent units only: Remove hoses

from air intake manifold and air inlet elbows.

5.5. Dismount flue gas pipe at the flue gas outlet connection.

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

7.7. Unlock and remove the left and the right top panels.

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

Figure #38

Heat Exchange Assembly

IMPORTANT: Note the connector assignment.

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

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

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

12. 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.

-37-

-38-

3 DAY DRAIN

3 DAY DRAIN FUNCTION SW3/7

Function Disabled OFF

Function Enabled (Factory set) ON

KEEP WARM

3 DAY DRAIN FUNCTION SW5/7

Function Enabled ON

Function Disabled (Factory set) - 3 day drain OFF

MAINTENANCE (GSP)

MAINTENANCE INTERVAL (GSP) SW3/8

500 hour (Factory set) OFF

1000 hour ON

ANALOG CHANNEL 1

Input Range SW1/1 SW4/1 SW 4/2

0-10V input OFF OFF OFF

0-5V input OFF ON OFF

2-10V input OFF OFF ON

1-5V input OFF ON ON

0-20mA input ON OFF OFF

0-10mA input ON ON OFF

4-20mA input ON OFF ON

2-10mA input ON ON ON

ANALOG CHANNEL 2

Input Range SW1/2 SW4/3 SW 4/4

0-10V input OFF OFF OFF

0-5V input OFF ON OFF

2-10V input OFF OFF ON

1-5V input OFF ON ON

0-20mA input ON OFF OFF

0-10mA input ON ON OFF

4-20mA input ON OFF ON

2-10mA input ON ON ON

-39-

INPUT CHANNEL

DUAL CHANNEL FUNCTION SW4/5

One Channel Input OFF

Dual Channel Inputs ON

TIME PROPORTIONING

TIME PROPORTIONING SW4/7

Disabled (Factory set) OFF

Enabled ON

BLOWDOWN (GSP)

BLOWDOWN SW5/1 SW 5/2 SW5/3

5% ON OFF OFF

10% OFF ON OFF

15% ON ON OFF

20% OFF OFF ON

25% (Factory set) ON OFF ON

30% OFF ON ON

35% ON ON ON

MAINTENANCE SHUTDOWN

MAINTENANCE SHUTDOWN FUNCTION SW5/4

Unit will shutdown 72 hours after service time expired, by gen

erating an error.

Unit will display warning but continues to operate. (Factory set) ON

FULL TANK BLOWDOWN

FULL TANK BLOWDOWN FUNCTION SW5/8

Disabled OFF

Enabled (Factory set) ON

-40-

OFF

NORTEC TC CONTROLLER

Menu Structure

INTRODUCTORY SCREEN

NORTEC GSTC-400

VERSION X.XX

SYSTEM LOCKOUT

09.05.02 9:30

MAIN MENU

SYSTEM STATUS

SERVICE LEVEL

USER SETTINGS

USE THE UP/DOWN ARROWS TO MOVE THE POINTER TO SELECT A MENU ITEM.

TO OPEN THE SELECTION, PRESS THE ENTER BUTTON.

NOTES:

Go To: System Status - page 22

Service Level - page 24 User Setting - page 26

Keypad Display Menu Structure GENERAL

-41-

MAIN MENU

SYSTEM STATUS

USER SETTINGS

SYSTEM STATUS 1 of 2

ENTER

STATUS: LOCKOUT

DEMAND CHANNEL 1 0%

DEMAND CHANNEL 2 0%

CAPACITY LIMIT 0%

1. DISPLAY TOGGLES BETWEEN LOCKOUT, ACTIVE, AND STANDBY, DEPENDING ON SYSTEM DEMAND

2. ONLY VIEWED IF UNIT IS CONFIGURED FOR DUAL CHANNEL.

SYSTEM DEMAND XXX%

BURNERS ACTIVE X/X

OUTPUT/BURNER XXXLB

TOTAL OUTPUT XXXLB

WATER LEVEL: X

FILL VALVE ON

DRAIN VALVE OFF

DRAIN COOLING: SMART

SYSTEM STATUS

1. DISPLAY WILL SHOW NUMBER OF BURNERS AND DISPLAYS THE NUMBER OF ACTIVE BURNERS.

2. DISPLAYS THE OUTPUT PER

BURNER IN POUNDS PER HOUR OR KG/HR.

3. DISPLAY OF TOTAL SYSTEM OUTPUT IN LBS/HR [KG/HR]

1. DEPENDING ON WATER LEVEL, WILL DISPLAY 0 - 5.

2. TOGGLES BETWEEN ON, OFF, AND PULSED.

3. TOGGLES BETWEEN ON AND OFF

4. DISPLAYS USER SETTING, ON, OFF, OR SMART

-42-

Keypad Display Menu Structure System Status 1 of 2

MAIN MENU

SYSTEM STATUS

SERVICE LEVEL

USER SETTINGS

SYSTEM STATUS 2 of 2

SYSTEM STATUS

ENTER

SERVICE INTERVAL

XXX HOURS

REMAINING XXX HOURS

START DATE: MM:DD:YY

SECURITY LOOP [0/1]

SAFETY SENSORS [0/1]

TANK SENSORS [0/1]

1. DISPLAYS THE USER SELECTABLE MAINTENANCE INTERVAL

2. DISPLAYS THE TIME LEFT BEFORE MAINTENANCE IS DUE

3. DISPLAYS THE START DATE OF THE CURRENT SERVICE INTERVAL

1. DISPLAYS STATUS OF THE SECURITY LOOP (O = OPEN I = CLOSED)

2. DISPLAYS STATUS OF THE SAFETY SENSORS

3DAYDRAIN ON

KEEP WARM OFF

BLOWDOWN RATE 25%

FT BLOWDOWN ON

LOOP BACK

Keypad Display Menu Structure System Status 2 of 2

3. DISPLAYS STATUS OF THE TANK SENSOR

1. DISPLAYS IF FEATURE IS SELECTED

2. DISPLAYS IF FEATURE IS

SELECTED

3. DISPLAYS PRESENT BLOWDOWN RATE

4. DISPLAYS IF FEATURE IS SELECTED.

-43-

SERVICE LEVEL 1 of 2

MAIN ME NU

SYSTEM STATUS

SERVICE LEVEL

USER SETTINGS

ENTER

SERVICE INTERVAL SERVICE HISTORY

FAULT H ISTOR Y TANK DR AIN TANK PR E-CLEAN BURNERS

SHORT CYCLE DELAY

SERVICE INTERVAL SERVICE HISTORY

FAULT H ISTOR Y TANK DR AIN TANK PR E-CLEAN BURNERS

SHORT CYCLE DELAY

SERVICE INTERVAL SERVICE HISTORY

FAULT H ISTOR Y TANK DR AIN TANK PR E-CLEAN BURNERS

SHORT CYCLE DELAY

SERVICE INTERVAL SERVICE HISTORY

FAULT H ISTOR Y TANK DR AIN TANK PR E-CLEAN BURNERS

SHORT CYCLE DELAY

SERVICE LEVEL

SERVICE INTERVAL

XXX HOURS

1. VERTICALARROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING.

1. DISPLAYS THE LAST 10 SERVICE

SERVICE HISTORY X/Y

STEAM HOURS XXXX

(DATE/TIME)

FAULT H ISTOR Y X/Y

(TYPE OF FAULT)

(DATE/TIME)

THIS WILL DRAIN CONTENTS OF TANK

PERIODS

2. DISPLAYS THE NUMBER OF STEAM

HOURS WHEN SERVICE WAS

PERFORMED

3. DISPLAYS THE DATE THE SERVICE WAS PERFORMED

1. DISPLAYS THE LAST 54

FAULT S

2. GIVES A DESCRIPTION OF THE FAULT TYPE

3. DISPLAYS THE DATE THE FAULT OCCURRED.

SERVICE INTERVAL

XXX HOURS

CLEAR REMAINDER?

SERVICE INTERVAL

XXX HOURS

CLEAR REMAINDER?

THIS WILL DRAIN CONTENTS OF TANK

CONTINUE?

1. PRESSING ENTER STARTS THE TANK DRAIN PROCEEDURE

2. USE UP DOWN ARROWS TO CHANGE HOURS

3. PRESSING ENTER CLEARS THE REMINDER

SERVICE (HR)

CHANGE VALUE XXX

-44-

Keypad Display Menu Structure Service Level 1 of 2

MAIN MENU

SYSTEM STATUS

SERVICE LEVEL

USER SETTINGS

ENTER

SERVICE LEVEL 2 of 2

SERVICE LEVEL

SERVICE INTERVAL SERVICE HISTORY

FAULT H ISTORY TANK DRAIN TANK PRE-CLEAN BURNERS

SHORT CYCLE DELAY

1. VERTICAL ARROW INDICATES ADDITIONAL

THIS WILL DRAIN CONTENTS OF TANK

SELECTIONS AVAILABLE BY SCROLLING.

THIS WILL DRAIN CONTENTS OF TANK

CONTINUE?

1. PRESSING ENTER STARTS THE TANK DRAIN PROCEDURE

SERVICE INTERVAL SERVICE HISTORY

FAULT H ISTORY TANK DRAIN TANK PRE-CLEAN BURNERS

SHORT CYCLE DELAY

SERVICE INTERVAL SERVICE HISTORY

FAULT H ISTORY TANK DRAIN TANK PRE-CLEAN BURNERS

SHORT CYCLE DELAY

END

BURNER 1: ENABLED BURNER 2: ENABLED BURNER 3: ENABLED BURNER 4: ENABLED BURNER 5: ENABLED BURNER 6: ENABLED

SHORT CYCLE DELAY

SECONDS XX

BURNER 1: ENABLED BURNER 2: ENABLED BURNER 3: ENABLED BURNER 4: ENABLED BURNER 5: ENABLED BURNER 6: ENABLED

SHORT CYCLE DELAY

CHANGE VALUE XX

BURNER 1

ENABLED

DISABLED

Keypad Display Menu Structure Service Level 2 of 2

-45-

USER SETTINGS 1 of 3

0335

CHANGE TIME

XX:XX

MAIN MENU

SYSTEM STATUS

SERVICE LEVEL

USER SETTINGS

DATE/TIME/UNITS

ENTER

LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

1. VERTICAL ARROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING.

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

USER SETTINGS

TIME HH:MM

DATE MM.DD.YY

UNITS: LB/HR

SELECT LANGUAGE ENGLISH FRENCH GERMAN

0335

SELECT LANGUAGE ENGLISH FRENCH GERMAN

CHANGE DATE

MM.DD.YY

SELECT UNITS

LB/HR

KG/HR

PRESS ENTER TO SELECT UNITS

PRESS ENTER TO SELECT LANGUAGE

-46-

Keypad Display Menu Structure UserSetting1of3

MAIN MENU

SYSTEM STATUS

SERVICE LEVEL

USER SETTINGS

ENTER

USER SETTINGS 2 of 3

USER SETTINGS

PAGE 1

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT CALIBRATE

USER SETTINGS

1. VERTICAL ARROW INDICATES

FTBD HOURS XXX FTBD HOUR XX BLOWDOWN RATE XX% FLOAT CHECK HH:MM FILL CORRCTN XX% DRAIN CORRCTN XX% DRAIN COOL: SMART

ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING.

0335

FTBD HOURS

CHANGE HOURS? XXX

FTBD HOUR

CHANGE HOUR? XX

BLOWDOWN RATE

CHANGE VALUE XX%

STEAM OUTPUT

FLOAT CHECK

CHANGE VALUE HH:MM

FILL CORRCTN

CHANGE VALUE XXX%

Keypad Display Menu Structure UserSetting2of3

-47-

0335

DRAIN CORRCTN

CHANGE VALUE XXX%

DRAIN COOL ON OFF SMART

USER SETTINGS 3 of 3

USER SETTINGS

MAIN MENU

SYSTEM STATUS

SERVICE LEVEL

USER SETTINGS

ENTER

DATE/TIME/UNITS

LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT CALIBRATE

DATE/TIME/UNITS

LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT CALIBRATE

DATE/TIME/UNITS

LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT CALIBRATE

END

CONTROL TYPE

CONTROL INPUT

1. VERTICAL ARROW INDICATES ADDITIONAL SELECTIONS AVAILABLE BY SCROLLING.

TRANSDUCER INPUT

SET MAXIMUM CAPACITY XXX%

CALIBRATE SIGNAL?

0335

CONTROL TYPE

CONTROL INPUT

TRANSDUCER INPUT

SET MAXIMUM CAPACITY XXX%

CALIBRATE SIGNAL

CALIBRATE 4957

PRESS ENTER TO SELECT CONTROL TYPE

USE UP/DOWN ARROWS TO SET MAXIMUM CAPACITY

PRESS ENTER TO CALIBRATE SIGNAL

-48-

Keypad Display Menu Structure UserSetting3of3

NORTEC TC CONTROLLER

INTRODUCTORY SCREEN

NORTEC GSTC-400

VERSION X.XX

SYSTEM LOCKOUT

User Settings: (password protected)

This section allows the user to set parameters specific to their requirements. For further details see specific section below.

Diagnostics: (safety loop protected)

Allows the user to activate and monitor various system operations.

06.07.03 9:30

Product name

NORTEC GSTC (100-600)

Version

The display will indicate the revision level of the

control software

System

Depending on system activity, the display will

toggle between LOCKOUT, ACTIVE or STANDBY.

Date/Time

The actual date and time will be displayed.

MAIN MENU

The main menu lists the available sub menus where system adjustments can be made. Some of the menus are password and jumper protected to

Service checklist: (not available for first release)

Troubleshooting: (not available for first release)

SYSTEM STATUS SERVICE LEVEL USER SETTINGS DIAGNOSTICS

block access by unauthorized personnel.

System status

Displays various system parameters as the user scrolls through the lists. For further details see specific section below.

Service Level: (password protected)

This section is specific to all service related activity. For further details see specific section below.

-49-

SYSTEM STATUS

SCREEN 1:

Output/Burner:

This field will display the actual output of steam

generated by each burner (kg/hr or lbs/hr).

STATUS: LOCKOUT

DEMAND CHANNEL 1 0%

DEMAND CHANNEL 2 0%

CAPACITY LIMIT 0%

Status:

Displays the present status of the system. Depending on system activity at the time, the field could display: lockout (security loop open), active (unit generating steam) or standby (security loop closed but no modulation demand signal).

Demand channel 1:

This field will display the modulation demand input on that channel.

Demand channel 2:

Field only visible if the unit is configured for dual modulation. This field will display the modulation demand input on that channel.

Capacity limit:

This field displays the user adjusted capacity limit set for the humidifier.

Total output:

This field will display the total system steam output

(kg/hr or lbs/hr).

SCREEN 3:

WATER LEVEL: X FILL VALVE ON DRAIN VALVE OFF DRAIN COOLING: SMART

Water level:

This field displays the present water level detected

by the float system.

Fill valve:

This field displays status of fill valve, on, off, or

pulsed.

Drain valve:

This field displays status of drain pump, on or off.

Drain cooling:

SCREEN 2:

SYSTEM DEMAND XXX% BURNERS ACTIVE X/X OUTPUT/BURNER XXXLB TOTAL OUTPUT XXXLB

System demand:

This field displays the total system demand as a percentage.

Burners active:

This field displays the number of active burners and the number of available burners.

This field displays the user (or factory default)

setting.

OFF: fill will not activate when drain is activated.

ON: fill will activate whenever the drain activates.

SMART: fill will activate only when drain water is

hot.

-50-

SCREEN 4:

closed the display will indicate “1”. Closed indicates that the tank temperature is above 160ºF (70ºC).

SERVICE INTERVAL

XXX HOURS REMAINING XXX HOURS START DATE: MM:DD:YY

Service interval:

This field displays the user (or factory default) setting for the humidifiers service reminder in steam hours.

Remaining:

This field displays the amount of time (steam hours) remaining before the next service is to be performed.

Start Date:

This field displays the date this service interval began.

SCREEN 5:

This input is used for the “keep warm” feature and

for activating the fill valve during blowdown cycles.

SCREEN 6:

3 DAY DRAIN 1 KEEP WARM 0 BLOWDOWN RATE XX%

FT BLOWDOWN 1

3 day drain

This field indicates if the feature has been selected

(0 = no, 1 = yes).

Keep warm

This field indicates if the feature has been selected

(0 = no, 1 = yes).

Blowdown rate:

This field displays the selected blowdown rate.

SECURITY LOOP [0/1] SAFETY SENSORS [0/1] TANK SENSORS [0/1]

Security loop:

This field displays the status of the security loop (terminals 1 and 2 on LV terminal strip). If it is open the display will indicate “O”, if it is closed the display will indicate “I”.

Safety sensors:

This field displays the status of the safety sensors* input. If it is open the display will indicate “0”, if it is closed the display will indicate “1”.

*There are two safety sensors on the GSTC. One for tank over temperature and one for stack over temperature. Both sensors are wired in series.

Full tank blowdown

This field indicates if the feature has been selected

(0 = no, 1 = yes).

Tank sensor

This field displays the status of the tank sensor input. If it is open the display will indicate “0”, if it is

-51-

SERVICE LEVEL

SERVICE INTERVAL SERVICE HISTORY FAULT HISTORY TANK DRAIN TANK PRE-CLEAN BURNERS SHORT CYCLE DELAY

The service level area is where service related tasks are performed. Below is a description of each field and what can be performed in them. When a parameter requires a change, press the two arrow keys and enter the password (0335). As long as you remain in this section, you will not need to enter the password more than once.

SERVICE INTERVAL SERVICE HISTORY

FAULT HISTORY TANK DRAIN TANK PRE-CLEAN

BURNERS SHORT CYCLE DELAY

MAINTENANCE TIME XXX HOURS

MAINTENANCE DUE XXX HOURS

SERVICE INTERVAL

XXX HOURS

CLEAR REMAINDER?

Service interval

In this area the customer can set a service interval for humidifier MAINTENANCE.

MAINTENANCE TIME

XXX HOURS

This field displays the user selected MAINTENANCE time. To change the time selected enter the user code and adjust the time in SET MAINT. TIME (0-3000 hours, 0 = disabled).

MAINTENANCE DUE

XXX HOURS

This field displays the time remaining until the next service interval. To reset the MAINTENANCE due time, enter the user code and select CLEAR REMINDER?

SERVICE INTERVAL SERVICE HISTORY

FAULT HISTORY TANK DRAIN TANK PRE-CLEAN

BURNERS

SHORT CYCLE DELAY

SERVICE HISTORY X/Y

STEAM HOURS XXXX

(DATE/TIME)

Service history

In this area the customer can view the history of service maintenance performed on the humidifier.

SERVICE HISTORY X/Y

The service history stores the last 10 service periods.

X = service occurrence, where 1 is the most recent.

-52-

Y = total number of recorded services (up to 10 maximum).

STEAM HOURS XXX

(DATE/TIME)

This field displays the steam hours and the date and time when the specific service (X) was performed.

SERVICE INTERVAL SERVICE HISTORY

FAULT HISTORY TANK DRAIN TANK PRE-CLEAN

BURNERS SHORT CYCLE DELAY

FAULT HISTORY X/Y

(TYPE OF FAULT)

(DATE/TIME)

Fault history

In this area the customer can view the history of recorded faults for the humidifier.

FAULT HISTORY X/Y

The fault history stores the last 54 system faults.

X = fault occurrence, where 1 is the most recent.

Y = total number of recorded faults (up to 54 maximum).

(type of fault) and (date/time)

A description of the fault type is displayed along with a date and time stamp when the fault occurred.

SERVICE INTERVAL SERVICE HISTORY

FAULT HISTORY TANK DRAIN TANK PRE-CLEAN

BURNERS SHORT CYCLE DELAY

THIS WILL DRAIN CONTENTS OF TANK

CONTINUE?

Tank Drain

The tank drain feature, when activated, will activate the drain valve for a fixed period of time (depending on unit

size).

To drain the tank press enter when CONTINUE is selected. During the tank drain cycle the display will indicate

the tank is draining and the amount of time remaining on the cycle. To interrupt the cycle the unit must be switched off then on. Must enter service password to activate this function.

-53-

Tank Pre-Clean

The tank pre-clean feature when activated will activate the drain valve for a fixed period of time (depending on unit size). The fill valve will then activate, filling the tank partially with cold water. At the completion of the fill cycle the tank will once again drain.

This will help to flush out any accumulated minerals as well as cool the tank for the service personnel.

To pre-clean the tank press enter when CONTINUE is selected. During the tank pre-clean cycle the display will indicate the tank is draining and the amount of time remaining on the cycle. To interrupt the cycle the unit must be switched off then on. Must enter service password to activate this function.

Burners

This field allows the user to enable and disable individual burners for service reasons. Depending on the GSTC model, only the number of burners installed will be displayed

SERVICE INTERVAL SERVICE HISTORY

FAULT HISTORY TANK DRAIN TANK PRE-CLEAN

BURNERS

SHORT CYCLE DELAY

BURNER 1: ENABLED BURNER 2: ENABLED BURNER 3: ENABLED BURNER 4: ENABLED BURNER 5: ENABLED BURNER 6: ENABLED

BURNER 1

ENABLED

DISABLED

After entering the user code (0335) the individual burner can be highlighted. Once ENTER is pressed, the burner can be enabled or disabled.

Short Cycle Delay

The short cycle delay feature can be used to reduce the amount of ON/OFF cycles during operation. The feature will cause a delay between cycles by forcing the system to wait a pre set period (seconds) before responding to a demand signal.

SERVICE INTERVAL

SERVICE HISTORY

FAULT HISTORY TANK DRAIN TANK PRE-CLEAN

BURNERS SHORT CYCLE DELAY

SHORT CYCLE DELAY

SECONDS XX

SHORT CYCLE DELAY

CHANGE VALUE XX

The delay can be set from 1 to 1000 seconds. The default shall be 1 second since any larger value can result in a less dynamic response of the system as a whole. This feature should only be used once a short cycle condition has been identified.

-54-

User Settings

DATE/TIME/UNITS

LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE

CAPACITY LIMIT

CALIBRATE

When a parameter requires a change, press the two arrow keys and enter the password (0335). As long as you

remain in this section, you will not need to enter the password more than once.

Date / Time Units

This field is used for modifying the Date, time and the units of measurement. The date and time are important

parameters when features such as full tank blowdown are enabled.

CHANGE TIME

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

0335

TIME HH:MM

DATE MM.DD.YY

UNITS: LB/HR

0335

XX:XX

CHANGE DATE

MM.DD.YY

SELECT UNITS

LB/HR

KG/HR

Time (of day)

To set the time of day, highlight the selection then enter the user code (0335). Press enter. Use the UP/DOWN

arrows to adjust the hours (24 hour format). Pressing enter saves the setting and indexes the display to minutes. Use the UP/DOWN arrows to adjust the minutes. Pressing enter saves the setting and returns the user to the previous menu.

Date

To set the date, highlight the selection then enter the user code (0335). Press enter. Use the UP/DOWN arrows to

select the month. Pressing enter saves the setting and indexes the display to number of the month. Use the UP/DOWN arrows to adjust the number. Pressing enter saves the setting and indexes the display to year. Use the UP/DOWN arrows to adjust the year. Pressing enter saves the setting and returns the user to the previous menu.

Units

Here the user can select the unit of steam production rate. To set the units, highlight the selection then enter the

user code (0335). Press enter. Use the UP/DOWN arrows to select the units (LB/HR or KG/HR). Pressing enter saves the setting and returns the user to the previous menu.

-55-

Language Controls

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE

SELECT LANGUAGE ENGLISH FRENCH GERMAN

CAPACITY LIMIT CALIBRATE

This field allows the user to select the menu language of choice (English, French, German)

Here the user can select the language of choice for the menu displays. To set the language, highlight the selection then enter the user code (0335). Press enter. Use the UP/DOWN arrows to select the choice (English, French, German). Pressing enter saves the setting and returns the user to the previous menu.

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

NOTE: ONLY ENGLISH AVAILABLE AS OF 05/03

FTBD HOURS XXX FTBD HOUR XX BLOWDOWN RATE XX% FLOAT CHECK HH:MM FILL CORRCTN XX% DRAIN CORRCTN XX% DRAIN COOL: SMART

0335

FTBD HOURS

CHANGE HOURS? XXX

Water Management

This section allows the user to set time based parameters and adjust water control parameters.

FTBD Hours

This section allows the user to set the frequency of full tank blowdowns (FTBD). FTBD’s drains and re-fills the entire contents of the humidifier after a preset accumulated operating time. Run time is measured in steam hours (weighted run time hours), and can be adjusted from 0 hours (feature off) to 400 hours in 25 hour increments.

Once the FTBD time has expired, the controller will wait until the FTBD hour to initiate the cycle. This prevents random drains at times when they would be inconvenient.

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

FTBD HOURS XXX FTBD HOUR XX BLOWDOWN RATE XX% FLOAT CHECK HH:MM FILL CORRCTN XX% DRAIN CORRCTN XX% DRAIN COOL: ON

0335

FTBD HOUR

CHANGE HOUR? XXX

-56-

FTBD Hour

Works in conjunction with FTBD hours.

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

Here the user sets the time of day (24 hour format) when they want the FTBD to execute. The time can be set to

trigger the cycle during off hours, when the humidity requirements are minimal.

The time is adjusted in one-hour increments.

FTBD HOURS XXX FTBD HOUR XX BLOWDOWN RATE XX% FLOAT CHECK HH:MM FILL CORRCTN XX% DRAIN CORRCTN XX% DRAIN COOL: ON

0335

BLOWDOWN RATE CHANGE VALUE XX% STEAM OUTPUT

Blowdown Rate

This parameter adjusts the frequency of blowdown cycles.

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

FTBD HOURS XXX FTBD HOUR XX BLOWDOWN RATE XX% FLOAT CHECK HH:MM FILL CORRCTN XX% DRAIN CORRCTN XX% DRAIN COOL: ON

FLOAT CHECK CHANGE VALUE HH:MM

0335

Depending on water quality, the blowdown rate can be adjusted from 5% to 50%. The percentage is based on the

steam production rate i.e. a 10% BD rate will drain 10 kg. of water for every 100 kg. of steam produced.

The higher the mineral content of the water the higher the BD rate should be set.

Float Check

This parameter sets the time of day the controller will force a float check.

Float checks are important to ensure the water level detection system is operating correctly. The float check also

tests the fill and drain system and will report any problems detected.

To set the time of day, highlight the selection then enter the user code (0335). Press enter. Use the UP/DOWN

DATE/TIME/UNITS

LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

FTBD HOURS XXX FTBD HOUR XX BLOWDOWN RATE XX% FLOAT CHECK HH:MM FILL CORRCTN XX% DRAIN CORRCTN XX% DRAIN COOL: ON

0335

DRAIN COOL: ON OFF SMART

- 57-

Fill CORRCTN (correction)

Used for adjusting the fill rate. Adjustments to be made under factory direction only.

Drain CORRCTN (correction)

Used for adjusting the drain rate. Adjustments to be made under factory direction only.

Drain Cool

The customer can select the type of drain water tempering they require (depending on local plumbing codes)

The customer can select ON, OFF, or SMART.

ON – whenever the drain valve is activated through software, the fill valve will automatically activate. This is the factory default setting, but is the most wasteful of water since it will activate even if the drain water is cool.

OFF – The drain water is never tempered. This can be used where plumbing codes permit. Some process waters are very expensive, so the customer may choose to temper the drain water through other means.

SMART – The humidifier has a tank sensor that communicates the water temperature to the controller. If the water is hot during drain cycles the fill valve will be activated. This is the most “water smart” of the settings.

DATE/TIME/UNITS LANGUAGE CONTROLS

WATER MANAGEMENT CONTROL TYPE CAPACITY LIMIT

CALIBRATE

CONTROL TYPE CONTROL INPUT TRANSDUCER INPUT

0335

CONTROL TYPE CONTROL INPUT TRANSDUCER INPUT

Control Input

This section is used for configuring the controller for a controller input or a transducer input.

To select control input, highlight the selection then enter the user code (0335). Press enter. Use the UP/DOWN arrows to select control input.

The controllers dip switches then determine the type (0-10 Vdc, 0-20 mA, etc.) of control signal to process.

-58-

Transducer Input

This section is used to configure the controller for transducer signals

In this section you can adjust the proportional, integral and derivative constants. There is also a PID learn

algorithm which will tune the various PID constants for optimal performance.

Capacity Limit

In this section the customer can adjust the maximum output of the humidifier between 25-100%.

To adjust the maximum capacity, highlight the selection then enter the user code (0335). Press enter. Use the

UP/DOWN arrows to adjust the output between 25 and 100%.

DATE/TIME/UNITS LANGUAGE CONTROLS WATER MANAGEMENT CONTROL TYPE CAPCITY LIMIT CALIBRATE

SET MAXIMUM CAPACITY XXX%

0335

Calibrate

This selection is used to fine-tune the operating range of the controller. Some modulation signals are not precisely

as stated e.g. a 0-10 controller could actually modulate over a 0-11 volt range.

This selection should only be used by factory-trained individuals.

-59-

FAULT LIST

GSTC fault

displayed

FAULT

NO BURNERS

AVAILIBLE

FAULT

AIR PROVING

SWITCHXOPEN

WITH

BLOWERS ACTIVE

FAULT

AIR PROVING

SWITCH X

CLOSED WITH

BLOWERS

INACTIVE

FAULT

BLOWER X

RPM HIGH

FAULT

BLOWER X

RPM LOW

FAULT

BLOWER X

NOT OPERATIONAL

GSP fault code

Description of fault Troubleshooting

displayed

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

AOF-X On startup after 3 tries if the AP switch does

not close within the proving period, this fault

will be generated

ACF-X On initial startup if any of the A/P switches are

closed this fault will be generated.

BHF-X If the blower RPM is above the RPM tolerance

for more than 10 seconds, this fault is

generated and the humidifier stops.

BLF-X If the blower RPM is below the RPM tolerance

for more than 10 seconds, this fault is

generated and the humidifier stops

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

-Check red LED’s on all modules for flashing fault code

-Ensure there is gas supply to the humidifier

-Ensure that the burners have not been disabled in the software

-Consult factory

-Check that blue hoses on the Air Proving switch have not come loose.

-Check that wires on the Air Proving switch are on the N/O contacts

-If available, swap Air Proving switch with another and see if the fault follows the air proving switch, if so, replace switch

-Consult factory

-Ensure that wiring on the air proving switchisontheN/Ocontacts

-Ensure that there is no continuity between the switch with the wires off, if so replace switch

-Ensure that there is not a strong positive pressure in the room holding the switch closed

-Consult factory

-Check wiring to lead blo wer and ensure a good connection.

-Check lead blower for any restrictions by testing it in the diagnostics screen.

-Consult factory

-Check wiring to blower X and ensure a good connection.

-Check blower X for any restrictions by testing it in the diagnostics screen.

-Consult factory

-Ensure there is power to the blower and that all wires are making a proper connection.

-Consult factory

FAULT

ILLEGAL GAS

VALVE

BURNER X

GVF-X If the controller detects that a gas valve has

activated at a time it should not this fault is

Generated.

-60-

-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

-Consult factory

FAULT LIST

FAULT

GAS RE-IGNITION

BURNER X

FAULT

DRAIN NOT

WORKING

DRAIN IS BLOCKED

FAULT

FLOAT CHECK

FAULT

ILLEGAL FLOAT

COMBINATION

FAULT

FILL VAVLE ON

DETECTION

INCONSISTENT

FAULT

KEEP WARM TIME

OUT

TOO LONG TO

HEAT

FAULT

STACK OVER

TEMP.

SWITCH TRIPPED

FAULT

MAINTENANCE

TIME

HAS ELAPSED

FAULT

WATER FILL FAIL

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

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

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.

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.

KWF During a keep warn cycle, if the tank

temperature sensor does not open within a

certain time window, this fault is generated.

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.

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

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.

-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

-Consult factory

-Ensure that pump is being energized

-Check for b lockage in all aspects of the drain system

-Float board defective

-Consult factory

-Ensure the proper operation of the fill valve and drain valve via the diagnostics screen

-Float board is defective

-Consult factory

-Miswired float board

-Defective float board

-Consult factory

-Float board defective

-Contact agent for replacement float board

-Ensure that the tank temperature sensor is connected

-Defective tank temperature switch

-Contact agent for replacement switch.

-Do not operate and consult the factory

-Perform tank cleaning and all other maintenance requirements outlined in the manual.

-Verify water supply is open

-Verify adequate water supply to unit (30-80psi, 10L/min, minimum ½” dia. Line size)

-Verify wire harness and connection between float chamber and I/O board (TB)

-61-

WARNING LIST

GSTC Warning

displayed

WARNING

IGNITION MODULE X

FAIL

WARNING

AIR PROVING SWITCH X

OPEN WITH

BLOWERS ACTIVE

WARNING

AIR PROVING SWITCH X

OPEN WITH

BLOWERS ACTIVE

WARNING

BLOWER X

RPM HIGH

WARNING

BLOWER X

RPM LOW

WARNING

MAINTENANCE TIME

HAS ELAPSED

WARNING

Too LONG TO FILL

WARNING

KEEP WARM ACTIVE

SYSTEM DEMAND

ACTIVATED AT 75%

GSP warning

Description of warning: Troubleshooting

displayed

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.

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.

AOW-X On startup if the AP switch does not close within the proving

period. After 3 tries, a fault will be generated.

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.

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.

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

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.

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).

SEE FAULT LIST

-Warning message

will stop being displayed once tank temperature sensor indicates water is warm

-Keep warm feature can be disabled using dip-switch settings

-62-

-63-

GS Series Internal Components Spare Parts

Number Description Part # GS 100 GS 200 GS 300 GS 400 GS 500 GS 600

101 Cover Plate, Clean-Out Port 2523457 1 1 2 2 3 3

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 ½” npt 1505959 1 1 1 1 1 1

106 P-Trap 2526521

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 1

Dual 2524403 1 2 2 3 3

109 Direct Vent Air Manifold

GS 100 1506140 1

GS 200 1506141 1

GS 300/400 1506142 1 1

GS 500/600 1506143 1 1

110 Heat Exchanger Replacement Kit

Mini 2528422 1

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 1

Dual 1505942 1 2 2 3 3

113 Exhaust Manifold

GS 100 1505875 1

GS 200 1505861 1

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 Auxillary Drain Plug 1507043 1 1 1 1 1 1

116 Auxillary 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 2521137 1 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 6

-64-

GS Series Internal Components Spare Parts - continued

Number Description Part # GS 100 GS 200 GS 300 GS 400 GS 500 GS 600

126 Igniter / flame sensor gasket 1506892 1 2 3 4 5 6

127 Hot Surface Igniter Replacement kit

110-120V Models 2528418 1 2 3 4 5 6

208-240V Models 1507695 1 2 3 4 5 6

128 Flame Sensor Replacement Kit 1507694 1 2 3 4 5 6

Igniter / flame Sensor Replacement Kit

110-120V Models 2528420 1 2 3 4 5 6

208-240V Models 1507712 1 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 1 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 1 2 3 4 5 6

133 Burner / Blower Gasket 1708208 1 2 3 4 5 6

Not

Shown

Bracket, Fan Board Mount 1505899 1 1 2 2 3 3

Not

Fan Board 1505689 1 1 2 2 3 3

Not

Igniter Jump Start Module 1506793 1 2 3 4 5 6

Not

Hose Replacement Kit 1507696 1 1 1 1 1 1

Not

Flexible hose for Direct Vent 1502148 1 2 3 4 5 6

Not

¼” Tube for Air Proving (per inch) 1605227 Order (by foot) as Required

-65-

-66-

GS Series Indoor Cabinetry Spare Parts

Number Description Part # GS 100 GS 200 GS 300 GS 400 GS 500 GS 600

201 Service Door Assembly

Mini 2524439 1

Single 2524440 1

Double 2524441 1 1

Triple 2524458 1 1

202 Fron t Door Assembly 2528421 1 1 1 1 1 1

203 Recessed Handle 2523444 1 1 1 1 2 2

204 Transformer 24/16V 15VA 50/60 hz 1505760 1 1 1 1 1 1

205 Logic Control Board 1505762 1 1 1 1 1 1

206 I/O Board 1504760 1 1 1 1 1 1

207 Primary Transformer

110-120 V Models 1504859 1 1 1 1 1 1

208-240V Models 15067619 1 1 1 1 1 1

Fuse for Primary transformer, 6.25 AMP 1505020 1 1 1 1 1 1

208 Ignition Control Module

110-120V Models 2525914 1 2 3 4 5 6

208-240V Models 1505987 1 2 3 4 5 6

209 Relay Mount Socket 1703250 1 1 1 1 1 1

210 Blower Relay 1453020 1 1 1 1 1 1

Not

Shown

211a LCD Display Assembly 1507741 1 1 1 1 1 1

211b LCD Mounting Bracket 1506951 1 1 1 1 1 1

211c On/Off Drain Switch 1453001 1 1 1 1 1 1

Slotted wire duct 1506041 Order by Length Required

-67-

GS Series Outdoor Cabinetry

Exploded View

-68-

GS Outdoor Spare Parts List

Description Pa rt # GS 100 GS 200 GS 300 GS 400 GS 500 GS 600

1Transformer24/16V15VA 1505760111111 2Transformer208-24Vac250VA 1506719111111

Fuse6.25Ampfor208Vtransformer1505020111111 3aLCDDisplayAssembly 1507741111111 3bLCDMountingBracket 1506951111111 3cOn-Off-DrainSwitch 1453001111111

4LogicControlBoard 1505762111111 5I/OBoard 1504760111111 6IgnitionControlModule 1505987123456 7 Slotted wire duct 1506041 8RelayMountSocket 1703250111111

9BlowerRelay 1453020111111 10Thermostat,On/Off,80F 1508042111111 11ElectricalCabinet 1506989111111 12FrontPanel 1507783111111 13AccessDoor,Electronics 1507801111111 14AccessDoor,Tank 1507800111111 15 Left Panel Mini 1508096 1

Single 1508095 1

Double 1507861 1 1

Triple 1507804 1 1

16 Top Cap Assembly Mini 1508100 1

Single 1508099 1

Double 1507863 1 1

Triple 1507806 1 1 17DisplayBracketHolder 1506950111111 18 Female to Female Coupling 3" Dia. 1508136 1

4" Dia 1508135 1 5" Dia 1507886 1 1

6" dia 1507880 1 1

19 Vent Pipe, 24" Long 3" Dia 1508132 1

4" Dia 1508131 1 5" Dia 1507888 1 1

6" dia 1507882 1 1

20 Chimney Flashing, for 3" vent pipe 1508138 1

for 4" vent pipe 1508137 1 for 5" vent pipe 1507885 1 1 for 6" vent pipe 1508150 1 1

21 Storm Collar, for 3" vent pipe 1508140 1

for 4" vent pipe 1508139 1 for 5" vent pipe 1507890 1 1 for 6" vent pipe 1507884 1 1

22 Vent Pipe, 12" Long 3" Dia 1508134 1

4" Dia 1508133 1 5" Dia 1507884 1 1

6" dia 1507881 1 1

23 Rain Cap Mini 1508130 1

Single 1508129 1

Double 1507889 1 1

Triple 1507883 1 1 24CoolingFan 1507891111111

order by length required

-69-

25 Fan Hood 1507811 1 1 1 1 1 1 26 Cover Plate Top Panel 1508109 1 1 1 1 1 1 27 Gasket, Steamline 100 1508105 1

200/300 1507872 1 1

400/500/600 1507871 1 1 1

28 Cover Plate Steam Line 100 1508106 1

200/300 1507870 1 1

400/500/600 1507810 1 1 1 29 Step-up transformer (120/240V option) 1508167 1 1 1 1 1 1 30 Mounting bracket, step-up transformer 1507759 1 1 1 1 1 1 31 Mid Cross Member Mini 1506958 1

Single 1506978 1

Double 1506983 1 1

Triple 1506972 1 1 32 Gas Line Bracket 1506960 1 1 2 2 2 2 33 Rear Frame Element 1506963 1 1 1 1 1 1 34 Rear Panel 1507785 1 1 1 1 1 1 35 Cross Member Mini 1506957 2

Single 1506979 2

Double 1506981 2 2

Triple 1506971 2 2 36 Mounting bracket, float chamber 1508114 1 1 1 1 1 1 37 Front Frame 1506959 1 1 1 1 1 1 38 Right Panel Mini 1508087 1

Single 1508097 1

Double 1507862 1 1

Triple 1507803 1 1 39 Access Door, Side 1507801 1

1507800 1 2 2 1507860 1 1

40 Base Assembly Mini 1508123 1

Single 1508122 1

Double 1508017 1 1

Triple 1508018 1 1 41 Lifting Lug 1507901 4 4 4 4 4 4 42 Pump House Heater 500 watts 1508039 1 1 2 2 3 3 43 Mounting Bar Pump House Heater, Mini 1508113 2

Single 1508112 2

Double 1508111 2 2

Triple 1508164 2 2 44 Strapping, Pump House Heater 1508110 1 1 2 2 3 3

-70-

Qty

GS100 GS200 GS300/400 GS500/600

Description

LEG, FLOOR STAND, GS/SE, B STYLE

Item

PLATE, CARRIER, FLOOR STAND, GS/SE, B STYLE

BRACE, COMMON, FLOOR STAND, GS/SE, B STYLE

BRACE, FLOOR STAND, GS-SE, B STYLE

BOLT, 3/8-16UNC X 3/4LG

Lock washer, 0.375

14.85in (37.7 cm)

21.15in (53.7 cm)

36.7in (93.3 cm)

GS200, GH2E80

GS300, GS400,

GH2E120, GH2E160

52.35in (133 cm)

GS500, GS600,

GH2E200, GH2E240

109.4cm

43.1in

90.7cm

35.7in

43.1in

109.4cm

76.7cm

30.2in

UNIT SIZE DIMENSION A

GS100, GH2E40

0.5in

1.3cm

Nut, 3/8-16 UNC, SST

A + 2in (5.1 cm)

A - 4.2in (10.6 cm)

06/26/2003

150-7308

GS Stand Assembly Instructions

REV A

DETAIL A

DETAIL B

(SHOWN THE STAND FOR GS300/400)

THE MIDDLE SECTION IS USED ONLY FOR GS300/400 AND GS500/600

ASSEMBLY INSTRUCTIONS

1. UNPACK STAND AND CHECK THAT ALL PIECES ARE PRESENT AND UNDAMAGED.

2. ASSEMBLE STAND TO CONFIGURATION SHOWN ON SHEET 1. HAND TIGHTEN ALL

BOLTS ONLY.

3. HOIST HUMIDIFIER UP ABOVE THE FLOOR A MINIMUM OF 32 IN (812.8 MM).

4. POSITION STAND BELLOW THE LEGS OF THE HUMIDIFIER. ALIGN HUMIDIFIER AND

STAND SO THAT HOLES IN THE HUMIDIFIER BASE ALIGN WITH HOLES IN STAND.

5. LOWER HUMIDIFIER 1/4" ABOVE STAND TO ALIGN WITH NEAREST HOLE.

6. FASTEN STAND TO HUMIDIFIER USING THE BOLTS, LOCKWASHERS AND NUTS

PROVIDED.

7. TIGHTEN NUT AND BOLT PAIRS TO 200 IN-LB ((2.3 Kg-m) OR UNTILL SECURE.

8. LOWER ENTIRE ASSEMBLY TO FLOOR AND ENSURE THAT IT IS STABLE.

9. SHIMMING OF THE FLOOR BELLOW THE LEGS OF THE STANDS MAY BE NECESSARY

TO ENSURE BALANCE OF THE HUMIDIIFER.

10. THE STAND MAY BE PERMENANTLY FASTENED TO THE FLOOR VIA THE HOLES IN

THE LEG SUPPORT PLATES.

FLOOR STAND, ASSEMBLY INSTRUCTIONS, GS/SE

2525888

-71 -

Item GS 100 GS 200 GS 300 GS 400 GS 500 GS 600

Gas Pressure

GS Quick Reference

Natural Gas min "wc/mbar

Natural Gas max "wc/mbar

Propane min

Propane max

Min free air opening in/cm 13/33 23/58 35/89 47/119 59/150 71/180

Input BTU's

Max 140,000 280,000 420,000 560,000 700,000 840,000

Min GSTC 45,000

Direct vent min 60,000

Gas Piping Size in/cm 1/2/1.3 3/4/1.9 1/2.5 1/2.5 1.25/3.2 1.25/3.2

"BH" Vent

"B" Vent

"BH" Exhaust Piping in/cm 3/7.6 4/10.2 5/12.7 5/12.7 6/15.2 6/15.2

Appliance Category

Full Weight In lbs./kg 416/188 588/266 954/432 974/441 1340/607 1360616

XX X XXX

4/10.2 5/12.7 7/17.8 7/17.8 8/20.3 8/20.3

I or III I or III I or III I or III I or III I or III

5/14

9/22

10/23

14/34

Empty Weight In lbs./kg 266/120 354/160 485/217 529/239 659/298 703/318

User level password

Water consumption (25% bd)

Gallons/litres 433/1639 866/3278 1300/4921 1733/6560 2166/8199 2600/9842

Tank Water Volume

Gallons/litres 18/71 29/111 58/221 55/210 84/320 81/309

Fill valve flow rates

To tank: Gallons/litres

To float chamber: Gallons/litres

Supply water pressure

Min. psi/kpa

Max. psi/kpa

Drain rate (includes D.W.C)

Gallons/Litres per minute

Min drain pipe size in/cm

Power supply requirements

1 to 1.5 / 2.5 to 3.8 OD or larger

0335

2.64/10

0.09/0.35

30/206

80/551

5.2/20

120 volts a/c

208-240 volts a/c 1PH

Steam Outlet size in/cm 1.75/4.4 3/7.6 3/7.6 4/10.2 4/10.2 4/10.2

XX X XXX

Transformer Required

-72-

LIMITED WARRANTY

Walter Meier Inc. and/or Walter Meier Ltd. (hereinafter collectively referred to as THE COMPANY), warrant for a period of two years from date of shipment, that THE COMPANY's manufactured and assembled products, not otherwise expressly warranted, are free from defects in material and workmanship. 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 Walter Meier’s 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 retains the right to change the design, specification and performance criteria of its products without notice or obligation.

Walter Meier (Climate USA) Inc.

826 Proctor Avenue, Ogdensburg, New York 13669

Walter Meier (Climate Canada) Ltd.

2740 Fenton Road, Ottawa, Ontario K1T3T7

Tel: 866 NORTEC 1 Fax: 613 822 7964

northamerica.climate@waltermeier.com www.humidity.com

PRINTED IN CANADA

Nortec GS User Manual 2

Specifications and Main Features

Frequently Asked Questions

User Manual