Stulz BNB1000, BNB4000, BNB8000, BNB2000, BNB5000 Installation, Operation & Maintanance Manual

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

(©January, 2008)

MODELS

BNB1000 BNB4000
BNB2000 BNB5000
BNB3000 BNB8000

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

Notice

This document contains information protected by copyright. All rights are reserved. The owner of the equipment for
which this manual is written may photocopy the contents of this manual for internal use only. No part of this docu­ment may be photocopied, reproduced, or translated into another language for use by anyone other than the owner
of the equipment for which this manual is written without the prior written consent of Stulz Air Technology Systems,
Inc. (SATS).

This document contains confidential and proprietary information of Stulz Air Technology Systems, Inc. Distributing or
photocopying this document for external distribution is in direct violation of U.S. copyright laws and is strictly
prohibited without the express written consent of SATS.

Unpublished — rights reserved under the copyright laws of the United States and of other countries.
Other brands and tradenames are trademarks of their respective owners.

Copyright 2007 by Stulz Air Technology Systems, Inc.
Printed in the United States of America.
All rights reserved.

Stulz Air Technology Systems, Inc.
1572 Tilco Drive
Frederick, MD 21704
USA

01/08

(©January, 2008)

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

TABLE OF CONTENTS

1.0 Introduction ....................................... 1-1

1.1 General ...................................................... 1-1

1.2 Safety ........................................................ 1-1

1.2.1 General ...................................................... 1-1

1.2.2 Safety Summary ........................................ 1-1

1.3 Product Warranty ...................................... 1-3

1.4 Specifications ............................................ 1-4

1.5 General Design .......................................... 1-5

1.6 Main Parts ................................................. 1-5

2.0 Installation .........................................2-1

2.1 Receiving the Equipment. .......................... 2-1

2.2 Site Preparation ......................................... 2-1

2.3 Mounting/Placement .................................. 2-2

2.4 Blow Angle Adapter .................................... 2-2

2.5 Supply and Overflow Piping ........................ 2-3

2.6 Main Power/Control Wiring ........................ 2-4

3.0 Trial Operation .................................. 3-1

3.1 Initial Operation .......................................... 3-1

3.1.1 Initial Operation Checklist .......................... 3-1

3.1.2 Procedure For Initial Operation ................... 3-1

3.1.3 Purge the Water Supply Line ..................... 3-1

4.0 Operation .......................................... 4-1

4.1 Precautions ............................................... 4-1

4.2 Operation Procedure and Control ............... 4-1

4.3 Screw For Adjusting Air Volume ................. 4-1

4.4 Steps for Long Term Shutdown................... 4-1

5.4 General Common Repairs/Parts

Replacement ............................................. 5-7

5.4.1 Preparation For Repairs ............................. 5-7

5.4.2 Re-Assembing ........................................... 5-7

5.4.3 Replacing Transducer and Nebulizer

Print Plate ................................................. 5-8

5.4.4 Water Supply Solenoid Valve, Float

Switches and Printed Circuit Board ............ 5-9

6.0 Product Support Group ...................6-1

6.1 Technical Support ...................................... 6-1

6.2 Obtaining Warranty Parts .......................... 6-1

6.3 Obtaining Spare/Replacement Parts .......... 6-1

7.0 Drawings ............................................ 7-1

7.1 Layout Drawing of Humidifier ...................... 7-1

7.2 Electrical Circuit Diagrams ........................ 7-2

List of Figures

Figure 1- Installation of Humidifier .......................... 2-1

Figure 2- Locating the Humidifier ........................... 2-2

Figure 3- Blow Angle Adapter ................................ 2-2

Figure 4- Compression Fitting Section View .......... 2-3

Figure 5- Piping Connection .................................. 2-3

5.0 Maintenance/Repairs ....................... 5-1

5.1 Periodic General Maintenance ................... 5-1

5.1.1 General ...................................................... 5-1

5.2 Maintenance Items and Necessary Tools... 5-2

5.2.1 Air Filter ..................................................... 5-3

5.2.2 Water Tank Interior and Electrical Parts ..... 5-3

5.3 Troubleshooting and Repair ........................ 5-5

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

1.0 INTRODUCTION

1.1 General

Recognized as a world leader, Stulz Air Technology
Systems, Inc. (SATS)
designed and manufactured with the highest quality
craftsmanship using the finest materials available in the
industry. Your ultrasonic humidification system will
provide years of trouble free service if installed and
maintained in accordance with this manual. Damage to
the unit from improper installation, operation or mainte­nance is not covered by the warranty.

This manual contains information for installation,
operation, maintenance, troubleshooting and repair.
STUDY the instructions contained in this manual.
They must be followed to avoid difficulties. Spare parts
are available from SATS to ensure continuous opera­tion. Using substitute parts or bypassing electrical
components in order to continue operation is not
recommended and will VOID THE WARRANTY. Due
to technological advancements, components are
subject to change without notice.

SATS

BNB Series

signed as stand alone direct room humidifiers. Any
use beyond this is deemed to be not intended. SATS
is not liable for any damage resulting from improper
use. The system is designed to be installed indoors
unless otherwise noted on the equipment nameplate.

ultrasonic humidifiers are

Ultrasonic Humidifiers are de-

1.2 Safety

1.2.1 General

Stulz Air Technology Systems, Inc. uses NOTES
along with CAUTION and WARNING symbols
throughout this manual to draw your attention to
important operational and safety information.

A bold text NOTE marks a short message in the
information to alert you to an important detail.

A safety alert symbol accompanies a general
WARNING or CAUTION safety statement.

A safety alert symbol accompanies an electrical
shock hazard WARNING or CAUTION safety state-

ment.

1.2.2 Safety Summary

The following statements are general guidelines
followed by warnings and cautions applicable through­out the manual.

Prior to performing any installation, operation, mainte­nance or troubleshooting procedure read and under­stand all instructions, recommendations and guide­lines contained within this manual.

WARNING

High voltage is used in the operation of this
equipment. Death on contact may result if
personnel fail to observe safety precautions.

CAUTION

This unit must be installed according to local
and national electric codes.

CAUTION

All maintenance and/or repairs must be per­formed by a qualified technician. All personnel
working on or near equipment should be familiar
with hazards associated with electrical mainte­nance.

CAUTION

Always turn off the main power and unplug the
unit before beginning work on the equipment.

A bold text CAUTION safety alert appears with
information that is important for protecting your
equipment and performance. Be especially careful to
read and follow all cautions that apply to your applica­tion.

A bold text WARNING safety alert appears with
information that is important for protecting you from
harm and the equipment from damage. Pay very close
attention to all warnings that apply to your application.

(©January, 2008)

NOTE

Wiring terminations may become loose during
transit of the equipment therefore; verify all wir­ing terminations are secure prior to operation.

NOTE

Do not attempt to make repairs without the
proper tools.

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

NOTE

SATS offers no warranty protection on
humidifcation systems using controls that are
not provided by SATS.

CAUTION

It is essential that De-ionized (DI) or Reverse
Osmosis (RO) water be used as the supply
water source to maintain full warranty cover­age. The use of untreated water will VOID THE
WARRANTY.

CAUTION

Use only non-corrosive stainless steel or poly
tubing rated for use with DI water to supply the
humidifier.

CAUTION

Never block the mist outlet or the opening of
the air inlet. The humidifier may be filled with
the condensed mist and electrical shorts may
result.

CAUTION

Never attempt to remove the mist guide cover
and/or the mist blow tubes while the humidifier
is operating, or electrical shorts may result.

CAUTION

If there is a risk of supply water freezing, pipe
insulation should be provided.

CAUTION

Never apply power when the humidifier is
overturned or upside down. Damage to the
ultrasonic nebulizer unit or transducer may
result.

CAUTION

Never drop the humidifier or apply hard shock
to it. It may damage internal parts.

CAUTION

CAUTION

Observe the unit for water leakage. A short
circuit could occur if the humidifier is splashed
with water while operating.

Ultrasonic Humidifier- Model BNB3000

Drain the water in the tank for sanitary rea­sons when humidifier is turned is off for more
than 3 days.

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

1.3 Product Warranty

SATS offers a standard two year limited warranty as stated below:



2-Year Standard Limited Warranty:

Stulz Air Technology Systems, Inc., warrants to the original buyer of its products that the goods
are free from defects in material and workmanship. Stulz Air Technology Systems, Inc.’s
obligation under this warranty is to repair or replace, at its option, free of charge to the customer,
any part or parts which are determined by Stulz Air Technology Systems Inc. to be defective
for a period of 24 months from date of shipment when a completed start-up form has been
submitted to Stulz Air Technology Systems, Inc. within 90 days from shipment. In the event
that a completed start-up form is not received by Stulz Air Technology Systems, Inc. within 90
days from shipment, the company’s obligation will be for a period of 12 months from date of
shipment. Parts repaired or replaced under this warranty are shipped FOB Factory, and
warranted for the balance of the original warranty period or for 90 days from the date of
installation, whichever is greater.

Stulz Air Technology Systems, Inc.’s warranty does not cover failures caused by improper
installation, abuse, misuse, misapplication, improper or lack of maintenance, negligence,
accident, normal deterioration (including wear and tear), or the use of improper parts or improper
repair.

Purchaser’s remedies are limited to replacement or repair of non-conforming materials in
accordance with the written warranty. This warranty does not include costs for transportation,
costs for removal or reinstallation of equipment or labor for repairs or replacement made in the
field.

If any sample was shown to the buyer, such sample was used merely to illustrate the general
type and quality of the product, and not to represent that the equipment would necessarily
conform to the sample.

This is the only warranty given by the seller, and such warranty is only given to buyers for
commercial or industrial purposes. This warranty is not enforceable until the invoice(s) is paid
in full.

THE FOREGOING SHALL CONSTITUTE SATS’S ENTIRE LIABILITY AND YOUR EXCLUSIVE
REMEDY. IN NO EVENT SHALL SATS BE LIABLE FOR ANY DIRECT, INDIRECT, SPECIAL,
INCIDENTAL, CONSEQUENTIAL, OR EXEMPLARY DAMAGES, INCLUDING LOST PROFITS
(EVEN IF ADVISED OF THE POSSIBILITY THEREOF) ARISING IN ANY WAY OUT OF THE
INSTALLATION, USE OR MAINTENANCE OF THE EQUIPMENT. THIS WARRANTY IS IN
LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.





Conditions for Maintaining Warranty Coverage:

1) De-ionized (DI) or Reverse Osmosis (RO) water is used as the supply water for the humidifier.

2) SATS provided controls are used with the humidification system.

3) Input voltage to the humidifier does not exceed 51VAC.

(©January, 2008)



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1.4 Specifications

Type Ultrasonic Humidifier BNB

Model BNB1000 BNB2000 BNB3000 BNB4000 BNB5000 BNB8000

Nebulizing capacity (lb/h) 2.2 4.4 6.6 8.8 11.0 17.6

Nos. of Ultrasonic nebulizer unit 2 4 6 8 10 16

Power source Single-phase 48VAC; 50/60Hz

Rated power consumption (W) 100 180 250 340 430 670

Weight (lb) 15.4 19.8 24.3 30.9 35.3 50.7

Electrical Characteristics

Allowable voltage range Within ±10% on primary side of transformer; 51VAC (max.) on secondary side.

Insulation resistance 100 M.Ohms or more (excluding solid-state components).

Dielectric voltage withstand Operational when 1500VAC is applied for 1 minute (excluding solid-state components).

Operating conditions

Ambient working conditions 34 to 122°F; 90%RH or less.

Water supply quality DI or RO water. Water conductance <20 microsiemens purity.

Water supply pressure 30 to 75 psi

Water supply temperature 40°F to 104°F

Parts to be provided by user

Humidistat, DI or RO supply water, Water supply valve, Water supply tubing (1/4” stainless steel or poly tubing rated
for DI water, Transformer, Power source and wiring to Transformer (Wire type: 16AWG minimum rated 125V, 176°F).

Notes: 1) Calcium, magnesium or other agents that may be contained in the supply water are atomized into the

air together with the mist and may form white powders after the water has evaporated. To avoid this,
always use DI or RO supply water.

2) The nebulizing capacity of the transducer in the ultrasonic nebulizer unit decreases gradually with
use. It should usually be exchanged after about 10,000 to 15,000 hours of operation, (depending on
water quality and suitable voltage), although the unit may continue to run as long as it’s effective
capacity meets the particular requirements.

3) To ensure full warranty coverage, the input voltage to the humidifier must not exceed 51VAC. If the
voltage on the secondary side of the transformer exceeds 51VAC, damage to the transducers and
print plates will result.

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1.5 General Design

The

BNB

Ultrasonic humidifier directly atomizes water producing a fine mist and is equipped with a fan to deliver
the mist into a room. It is possible to adjust the atomization to maintain room conditions by changing the air
volume.

A complete system consists of the humidifier to produce mist and a transformer (optionally provided by SATS), to
supply power to the humidifier. The humidifier incorporates ultrasonic nebulizer unit(s) to produce ultrasonic waves,
a fan to send out the mist, and an automatic water supply mechanism to maintain the supply water at a constant
level. When conducting routine maintenance, it is important to clean the air filter and water tank because it
significantly affects the humidifying capacity and life of the ultrasonic nebulizers.

1.6 Main Parts

1.6.1 Ultrasonic Nebulizer Unit

Modular sub-assembly located in the bottom of the
water tank incorporating a plate with amplifying circuitry
and a transducer. The transducer oscillates at a high
frequency, producing ultrasonic waves in the water.

1.6.2 Solenoid Valve and Float Switch

(Automatic water supply mechanism)
For maximum atomization, it is essential that the water

level in the tank be constantly maintained. Water level
suitable for atomizing is maintained by means of a
solenoid valve and float switch. When the water level in
the tank falls below the designed level, the float switch
contact turns ON and the solenoid valve opens to
supply water to the tank. When the correct water level
is attained, the float switch contact turns OFF, closing
the solenoid valve.

1.6.3 Relay Board and Float Switch

(Automatic low water shutdown mechanism)

Operating the humidifier when the water level in the tank
is below the top of the transducers will damage the
transducers and the circuitry in the ultrasonic nebulizer
unit. A float switch and a relay are used to prevent the
humidifier from “dry” running. If the water in the tank falls
below a safe level for any reason, the float switch
contact turns off shutting off the relay thus, cutting off
the power supply to the unit.

1.6.4 Fan

Blows the mist produced from the humidifier into the
conditioned space.

1.6.5 Air Filter

Filter for removing coarse dust from the air and prevent
the humidifier water tank and interior from becoming
dirty.

1.6.6 Control Board

Contains relays and protective circuit devices used to
control the operation of the unit.

1.6.7 Screw for Adjusting Air Volume

A screw on the side of the humidifier connected to the
air volume plate is used to adjust the atomization in
accordance with the desired room conditions.

1.6.8 Water Supply Valve

(To be provided by user)
This valve should be installed upstream from the

humidifier for service and maintenance. The valve must
be rated for use with DI water.

1.6.9 Water Supply Tubing

(To be provided by user)
This connects the water supply to the water supply

compression fitting. The tubing must be rated for use
with DI water.

(©January, 2008)

1.6.10 Conductivity Sensor (Optional)

A probe installed in the water supply piping for monitor­ing water quality.

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2.0 INSTALLATION

2.1 Receiving the Equipment

Your Ultrasonic humidifier has been tested and inspected prior to shipment. To ensure that your equipment has
been received in excellent condition, make a visual inspection of the equipment immediately upon delivery. Care­fully remove the shipping container and all protective packaging. Open the box and thoroughly inspect the unit for
any signs of transit-incurred damage. If there is shipping damage, it must be noted on the freight carrier's delivery
forms BEFORE signing for the equipment. Any freight claims MUST be done through the freight carrier. SATS
ships all equipment FOB factory. SATS is not liable for any equipment damage while in transit. SATS can assist in
the claim filing process with the freight carrier. Should any such damage be present, notify the SATS Product
Support Group prior to attempting any repairs. Refer to Section 6.0 of this manual for instructions.

Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies to the
appropriate authority.

Contents of Package:

1. Humidifier

2. Main Power Cable (2-conductor or 4-conductor with connector; 79" long).

3. Control Cable (4-conductor with connector; 79" long).

4. Installation, Operation and Maintenance manual.

Avoid dropping or jarring the unit to prevent damage to the internal parts. The unit should always be stored in a dry
location prior to installation.

A Data Package has been sent with your unit. It contains this manual, system drawings, applicable MSDS’s and
other applicable instructions based on the configuration and options of your unit. The data package has been
placed in your unit in a clear plastic envelope. These documents need to be kept with the unit for future reference.

2.2 Site Preparation

SATS

ultrasonic humidifiers are designed with easy service access in mind. Install the unit in a secure location
where it cannot be tampered with and the power switch cannot be inadvertently turned off. Allow access to the
unit for routine operation, servicing and for necessary maintenance. Position the humidifier in such a way that the
unit can be easily removed for future maintenance and inspection. Refer to the installation drawing provided with
your unit for the dimensions of the humidifier.

NOTE

Working clearance requirements need to be
established prior to mounting the unit. Refer
to local and national electrical codes.

When selecting the installation location,
attention should be paid to the air flow in the
room so that the atomized mist can be
uniformly diffused throughout the room. When
it is installed above the air conditioner, ensure
mist isn’t attracted toward the bottom of the
humidifier. If any obstacle exists in front of the
atomized mist outlet, the mist will be con­densed on the obstacle to form water drop­lets.

Figure 1- Installation of Humidifier

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The humidifier must be installed horizontally and level. Prepare hanging bolts for ceiling or brackets for wall (see
Figure 1). The distance from the humidifier to the ceiling should be a minimum of 18” and the distance to the wall
3” or more. For the installation mounting base dimensions, see “Layout Drawing of Humidifier” on page 7-1.

Figure 2- Locating the Humidifier

3.0" Min.

18.0" Min.

Support
Bracket

Ceiling

12'

Humidifier Path

16'

Smoke

Detector

Air

Diffuser

NOTE

Humidity control can only be achieved in a sealed room or if the room has vapor barriers installed. It is
recommended that walls, ceilings and floors be sealed to prevent migration of humidity.

2.3 Mounting/Placement

SATS ultrasonic humidifiers are designed for mounting to a flat surface. Ensure the base is capable of supporting the
weight of the unit. Weight estimates can be found on the installation drawing provided with your unit. Secure the
unit with fasteners (field supplied by others), so that it will not move during operation. Ensure the front edge of the
humidifier is not hanging over the edge of the support bracket.

2.4 Blow Angle Adapter

The blow angle adapter is provided to adjust air flow from the fan and direct mist out horizontally. During initial
operation, adjust the blow angle adapter according to Figure 3 to direct blown mist away from the ceiling and
towards the room.

Figure 3- Blow Angle Adapter

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2.5 Supply and Overflow Piping

The humidifier will require a field installed water supply line and overflow line. Refer to the piping diagram provided with
your unit for details. For the water supply, use DI or RO water. The water supply to the humidifier cannot be taken
directly from the public water service pipe. Untreated supply water will cause a problem in the room where “white
powder” is produced after evaporation from calcium or magnesium dissolved in the water. In cases where water
quality, especially “residue from evaporation”, “pH”, “total hardness” and “water conductivity” exceeds or is outside
the range of standard, routine maintenance intervals for keeping normal operation will be shorter than usual. Also,
the operating life of the transducers and print plates will be significantly reduced.

CAUTION

It is essential that DI or RO water be used as the supply water source to maintain warranty coverage. The use
of untreated water will VOID THE WARRANTY.

NOTE

The water supply piping must be non-corrosive stainless steel or poly tubing rated for use with de-ionized water

Prepare the water supply piping. The water supply piping should be equipped with a water supply valve, (user
provided), at a place as close as possible to the humidifier. The valve must be rated for use with DI water. After the
water supply valve is installed, flushing should be done by supplying water, (see Section 3.0, “Trial Operation”).
This is a necessary step to prevent chips and oil in the piping from entering the humidifier.

Connect the water supply piping to the humidifier by means of a 1/4” stainless steel or poly tubing, (user pro­vided). A compression fitting is provided on the side of the humidifier (see Figure 4). Use two adjustable wrenches
to tighten the connection on the humidifier. (Tightening torque: approximately 90 in/lbs).

Figure 4- Compression Fitting Section View

Figure 5- Piping Connections

Install an isolation valve in the supply water line for maintenance purposes.

If there is a risk that the water supply piping could freeze, wrap the piping with insulating material.

Overflow piping must be provided from the water tank for safety should any failure or problem occur. The overflow
pipe stub, approximately 5/8” outside diameter, should be connected with tubing so that overflowing water can be
directed into a drain pan or an appropriate place such as building drain. The overflow tubing must be sloped
downward and away from the unit and the end should not be plugged.

The drain plug in the bottom of the water tank should not be removed unless an optional “drain down” solenoid
is supplied.

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BNB Ultrasonic Humidifier Installation, Operation & Maintenance Manual

2.6 Main Power And Control Wiring

For wiring, refer to the electrical drawing supplied with your unit to determine the total number of
interconnecting conductors required for your system and for the proper wire terminations.

For internal wiring of the humidifier, see the “Electrical Circuit Diagrams” on page 7-2.

NOTE

Wiring terminations may become loose during transit of the equipment therefore, verify all wiring terminations
are secure prior to operation.

Verify that the main power supply coincides with the voltage, phase and frequency information specified on the
system nameplate. The nameplate also provides the full load amps (FLA), the current that the unit will draw under
full design load, the minimum circuit ampacity (MCA) for wire sizing, and the maximum fuse size (MFS) for circuit
protection. The power source must be provided with a circuit breaker for safety. Ensure a ground is connected to
the unit. The humidifier is rated to operate with an input of 48VAC/single phase. To maintain warranty coverage,
never allow the humidifier input voltage to exceed 51 volts as damage will occur to the transducers and print
plates.

WARNING

On SATS supplied control boxes, the 48 volt “Hot” wire will not be connected when the unit ships. Depending
on the incoming power supply voltage, the taps on the secondary side of the transformer may be a higher
voltage than labeled. It is important that the taps be checked with a voltmeter to ensure the voltage is within
the proper range. Select the secondary transformer tap that is the closest to 48 volts and connect the “Hot”
wire. Never exceed 51 volts as damage will occur to the transducers and print plates.

CAUTION

It is important to note that if the control transformer is supplied with the equipment by SATS, it is sized and
selected based upon the expected load for the unit. Do not connect any additional loads to the control
transformer. Connecting additional loads to the factory supplied control transformer may result in overloading
of the transformer which will cause the transformer circuit breaker to trip.

2.6.1 Humidistat

The humidistat may be optionally provided by SATS. It should be installed at a well ventilated place where changes
in room humidity can be accurately sensed. If customer provided, the humidistat must be a normally open dry
contact type which closes when the relative humidity drops to a user selected setpoint. Refer to the electrical
drawing for the voltage and current rating requirements for the contact. When one humidistat is used to control
multiple humidifiers, relays should be provided so each humidifier has an independant contact.

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3.0 TRIAL OPERATION

3.1 Initial Operation

3.1.1 Initial Operation Checklist

For new installations, ensure the unit is ready to operate by going through the following checklist prior to start-up:

1. The humidifier is installed horizontally and level.

2. No obstacle is within 15 feet in front of the atomizing direction.

3. The electrical wiring is correctly connected.

4. De-ionized or reverse osmosis water supply is used.

5. The water supply piping and overflow piping are correctly connected and secured.

6. All parts are correctly installed.

After the above items are checked, the trial operation may begin.

3.1.2 Procedure for Initial Operation

1. Open the water supply valve allowing water to flow to the unit.

2. Set the humidistat to a desired humidity level.

3. Turn the main power source switch (circuit breaker) to ON.

4. If the humidistat is ON, power is supplied to the humidifier, the water supply is started and when
the required water level is reached, atomizing starts.

5. If the operation does not start, increase the set point of the humidistat.

After operation is started, check the following items on a regular basis:

Atomizing is visible through all the mist blow tubes.

Check the humidifier parts, overflow pipe and other piping for signs of leaking water.

By operating the ON/OFF contact of the humidistat, ensure that it is interconnected properly and
controls operation of the humidifier.

Check to see that the mist diffusion is good and that objects in the room or any obstacle is not directly
exposed to the mist.

After the above items are checked and if no trouble is found, the trial operation is completed.

A screw for adjusting air volume to the mist guide tubes is provided on the side of the humidifier. It is set to
“MAX” at the time of shipment. Normally it is not necessary to change this setting. If it is desired to change
the atomization including mist diffusion or if coarse particles are observed due to voltage fluctuation, the
screw should be adjusted. When the screw is changed from “MAX” to “MIN” the decrease in effective
nebulizing capacity is about 20%.

3.1.3 Purge the Water Line

The first time the unit is operated, metal shavings or debris that may form during the installation process will be
flushed through the supply water piping. After performing the steps in Section 3.1.2 above, follow the steps below
to purge the water line:

Set the main switch of the power source to OFF for safety.

Close the water supply valve.

Remove the water tank drain plug and drain the tank. After draining, securely install the plug.

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4.0 OPERATION

4.1 Precautions

The screw provided on the side of the humidifier for adjusting air volume should not be loosened except when
adjustment is necessary.

Do not remove the air filter at the bottom of the humidifier during operation.

Do not block the outlet of the mist blow tubes. It could cause a failure when the mist flow is reversed.

Drain the water from the water tank for sanitary reasons if the unit is turned off for more than 3 days.

4.2 Operation Procedure and Control

1. Open the water supply valve and supply water to the unit.

2. Check the setting of the humidistat and set it to a desired humidity level.

3. Turn on the main power switch (circuit breaker), suppying power to the humidifier.

4. When power is supplied to the humidifier, water flows into the unit. When the required water level is reached,
atomizing starts.

5. During operation, stopping and restarting of the humidifier is controlled by means of the signal from the humi­distat.

6. The water level in the water tank is maintained by means of the float switch and solenoid valve.

4.3 Screw for Adjusting Air Volume

The screw for adjusting air volume provided on the side of the humidifier is set to “MAX” at the time of shipment
and normally it is not necessary to change it.

If it is desired to change the atomization including mist diffusion or if the mist contains coarse particles due to
supply voltage fluctuation, the screw should be adjusted. To adjust the screw, loosen it and move it towards the
“MIN” direction and set it at an optimum position while checking the atomizing condition.

When the screw is changed from “MAX” to “MIN” the decrease in effective humidifying capacity is about 20%.

4.4 Steps for Long Term Shutdown

When operation is stopped for a long time (one week or longer), the following steps must be performed. Also, refer
to Section 5.1, “Periodic General Maintenance”.

Set the main switch (circuit breaker), from the power source to OFF.

Close the water supply valve.

Drain the water tank.

Check and clean the water tank interior and air filter.

For restarting operation after a long-term shutdown, see the previous Section 4-2, “Operation Procedure and
Control”.

(©January, 2008)

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5.0 MAINTENANCE/REPAIRS

5.1 Periodic General Maintenance

Systematic, preventive maintenance of the humidifier is recommended for optimum system performance. Routine
periodic maintenance should include, but is not limited to the following:

Tightening electrical connections.

Cleaning, inspecting the unit’s components visually.

Checking the level of water and ensuring no leaks are present.

A system should be established to record any problems, defects or deficiencies noted by operators and discov­ered during maintenance inspections, together with the actions taken. For assistance, contact the SATS Product
Support Group. Ensure adherence to all safety precautions while performing any type of maintenance.

5.1.1 General

Before the maintenance inspection and repairs are done, be sure to set the power supply circuit breaker (main
switch) to OFF and close the water supply valve.

WARNING

Turn off power to the unit unless you are performing tests that require power. With power and controls
energized, the unit could begin operating automatically at any time.

CAUTION

The transducer is a very delicate part. When the water tank interior is cleaned, special care must be taken to
ensure the transducer is not scratched on the surface with a screwdriver, etc.

Do not supply power to the ultrasonic nebulizer units while the transducer lead wires (yellow and orange) are
removed.

Proper tools must be used. Excessive tightening or insufficient tightening may cause failure.

When performing maintenance or repairs, care must be taken to ensure small parts such as screws will not
be lost.

Care must be taken avoid injury by sharp edges of the sheet metal, etc.

Solid scaffolding must be provided for working in high places.

Testing insulation resistance and dielectric withstand voltage should be avoided because the humidifier incor­porates sensitive electronic parts.

When parts are replaced, genuine SATS parts must be used. Contact SATS Product Support Group for
assistance.

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5.2 Maintenance Items and Necessary Tools

Item Cycle Description Necessary Tools

Routine Maintenance

Check water tank
interior, mist blow tubes
and electrical parts.

Replacing transducer.

Replacing nebulizer print
plate.

Replacing water supply
solenoid valve.

Replacing float switches.

About once a week depending
on the extent of contamination.
The interval should be short­ened if environmental condi­tions are particurlarly dusty

Once a month or as required
if environment is dusty or
water suppy quality is poor.

Replacing Parts

After about 10,000 to 15,000
hours of operation.

If damaged or upon failure.
Also recommended when
replacing transducer

If damaged or upon failure.

Sect. 5.2.1 on
page 5-3

Sect. 5.2.2 on
page 5-3

Sect. 5.4.3 on
page 5-8

Sect. 5.4.4 on
page 5-9

NoneAir filter cleaning.

Adjustable wrenches (2)

Phillips screwdriver

7/32” Nut driver

Soft cleaning cloth

Small brush

Diagonal wire cutter

Replacing printed circuit
board.

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5.2.1 Air Filter

1) Stop the humidifier.

2) Loosen and remove the filter case mounting screws (2 Pcs.)
at the lower front of the humidifier. Photo 1

3) Pull out the filter case, remove the stopper
and remove the filter.

4) Wash the filter media with clean water.

5) Lightly shake off excess water and dry it well in the shade.

6) When the filter is dried, put it back in the filter case, install
the stopper and install the filter case in the humidifier.

7) If the filter is seriously clogged and cannot be cleaned by
washing with water, or if it is seriously deteriorated, it should be
replaced with a new one.

Photo 2

5.2.2 Water Tank Interior and Electrical Parts

1) Stop the humidifier, set the power supply circuit breaker (main
switch) to OFF and close the water supply valve.

2) Remove the plug from the drain pipe and drain the water tank.
After draining, re-install the plug securely.

3) Remove the the water supply piping. Be sure to use two
wrenches to prevent the body of the compression fitting on the
humidifier from turning. Photo 3

4) Loosen and remove the four mist guide cover mounting
screws (4 Pcs. knurled), on the side of the humidifier. Photo 4

5) Loosen the screws (1 Pc. or 2 Pcs.), at the front of the
humidifier and remove the mist guide cover.

6) Loosen and remove the two air flow guide (water tank cover)
mounting screws. Remove the air flow guide and the check
water tank interior for contamination. Photo 5

7) Remove the screws (4 Pcs.) holding the electrical access
cover. Photo 6

8) Remove the electrical access cover, inspect the interior and
check the following points:

No water leakage from the solenoid valve joint.

No discoloration, deformation or deterioration of printed
circuit board.

No damage to electrical wires or cables.

No abnormality of parts.

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9) Loosen and remove the float panel mounting screw (1 Pc.).
Lift the float panel and check for contamination of the float
switches. Photo 7

Note

Be careful not to splash water onto the electrical parts.

10) If no defects are found through the above inspection, re­assemble by reversing the above procedure.

Note

When assembling, be careful not to pinch the wires be­tween the sheet metal.

11) If the water tank interior and float switches are contaminated,
clean them using the following procedure. If any defects are
found with the electrical parts, take necessary steps referring to
Sect. 5.4 “Common Repairs/Parts Replacement” on page 5-7.

12) Clean the surface of the transducers, etc. in the water tank
by wiping with soft, oil free cleaning cloth. Photo 8

Note

Be careful not to scratch the surface of transducer.

13) Lift the float panel. Wipe and clean the water tank interior
and clean the float switches with a small brush.

Note

Be careful not to remove the float portion from the stem.

14) Remove the mist guide tubes from the air flow guide (water
tank cover) removed in step 6. Photo 9

15) Clean the mist blow tubes with clean water.

Note

It is essential that the mist outlet and its surrounding area
are free from foreign material.

Note

Be careful not to damage the rubber ring portion of the
mist outlet.

16) Re-assemble by reversing the above procedure.

Note

When re-assembling, be careful not to pinch the wires
between the sheet metal.

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5.3 Troubleshooting and Repair

Should any failure occur, make the necessary repairs referring to the following table. As a rule, power must be
turned off when troubleshooting is performed but if it is absolutely necessary to troubleshoot when power is
supplied, special attention must be paid to avoid electric shock and short-circuiting.

1) First the humidifier and its surrounding area should be checked.

Failure Cause Checking Remedy

No mist is
generated.

Amount of mist is
too low.

Power supply
system

Water supply system Water supply valve is

Other

Power supply system

Water supply control
system

Other

Power source switch
(circuit breaker) turned off.

No power supply to the
transformer.

Faulty transformer.

closed.

Thermo protector switch
(TP) tripped due to
overheating.

Supply voltage is low.

Operating water level is
high and overflowing.

Humidifier is not level.

‡Air filter clogging.

volume is loosened.

Visually check switch
position.

Measure the voltage at
transformer input termi­nals.

Measure the voltage at
transformer input and
output terminals.

Check opening/closing of
the valve.

Check if ambient tempera­ture and water temperature
are within specified range.

Check voltage at transformer
input and output terminals.

Visually check. See 3) on next

Visually check. Correct.

Pull out the filter and
visually check.

Check the screw for
adjusting air volume.

Turn switch on.

Supply power.

Replace the
transformer.

Open the valve

Correct.

Correct the
voltage.

page.

Clean the filter.

Adjust.Screw for adjusting air

Mist supply is
coarse.

Power supply system

2) If the cause can not be located through the above checking, remove the mist guide cover
and air flow guide and check the interior of the water tank.

Failure Cause Checking Remedy

No mist is
generated.

Amount of mist is
too low.

Remarks:

The causes of failures marked ‡ can be prevented through periodic maintenance/inspection. See Section 5.1, “Periodic
General Maintenance”.

5-5

‡ Dust and foreign material are accumulated in
the water tank.

‡ Dust and foreign material are accumulated in
the water tank.

‡ Scale deposited on transducer surface.

Supply voltage is high. Check voltage at trans-

former input and output
terminals.

Clean the interior of the water
tank.

Visually check the
interior of the
water tank.

Clean interior of water tank and
replace the transducer.

ir Technology Systems, Inc.

Fine tune the mist
quality with the
voltage and/or air
volume adjusting
screws.

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3) If the cause cannot be located through the above checking, parts may faulty. Check the
interior of the humidifier.

Failure Cause Checking Remedy

No mist is
generated.

Water supply
control system

Water supply float
switch (FS1) is faulty.

‡ Water supply float

switch arm sticking.

Drain the water tank,
remove the printed circuit
board terminal (FS1) and
test the continuity of the
float switch.

If there is no continu­ity, replace the switch.

Clean the switch. If
operation is not re­stored, replace switch.

Amount of mist
is too low.

Oscillation control
system.

Other

Water supply
system overflow­ing.

Water supply
solenoid valve is
faulty.

Float switch for low
water level is faulty.

‡ Float switch for low

water level is sticking.

Fan lead wires are
loose or disconnected
from the terminals.

Water supply float
switch is faulty.

‡ Water supply float

switch arm sticking.

No water supply is provided
even if the water tank is
drained and voltage of the
SV terminal on the printed
circuit board is 48VAC.

With the water tank filled
with water, remove the
wire from terminal (FS2)
on the printed wiring
board and check conti­nuity of float switch.

Open the electrical
section and check the
lead wire connecting
terminals.

If the water level in the tank
is up to the overflow pipe,
remove the wire from
terminal (FS1) on the
printed circuit board and
ensure there is no continu­ity on the float switch.

Replace the
solenoid valve.

If no continuity exists,
replace the switch.

Clean the switch. If
operation is not re­stored, replace switch.

Correct.

If there is continuity,
replace the switch.

Clean the switch. If
operation is not re­stored, replace switch.

4) Consumable parts

Failure Cause Checking Remedy

No mist output,
or mist output is
too low.

Remarks:

If the humidifier is operated for a long time with a deteriorated transducer, the nebulizer print plate may fail. The transduc­ers should be replaced using the estimated lifetime of 10,000 to 15,000 hours as the point of reference.

If the cause cannot be located through the above checking, please contact

If the humidification system is supplied with a water conductivity meter control (optional), ensure the meter is operating
properly and that the supply water is within the recommended guidelines for mineral content.

(©January, 2008)

Deterioration of transducer due to
aging.

Water supply
solenoid valve is
faulty.

ir Technology Systems, Inc.

Overflowing occurs even
after power is turned off.

The life is about 10,000 to
15,000 hours of humidifier
operation.

SATS

Product Support Group.

Replace the
solenoid valve.

Replace the transducer.

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5.4 Common Repairs/Parts Replacement

When parts are replaced, the following sections “5.4.1 Prepara­tion for Repairs” and “5.4.2 Re-assembling” must be observed.

5.4.1 Preparation for Repairs (Removal of Water Tank)

1) Stop the humidifier, set the power supply circuit breaker (main
switch) to OFF and close the water supply valve.

2) Remove the drain pipe plug and drain the water tank. After
draining, re-install the plug securely.

3) Remove the connection of the water supply. Be sure to use
two wrenches to prevent the body of the compression fitting on
the humidifier from turning. Photo 10

4) Remove the screw-on connector for the main cord and
operating cord. Photo 11

5) Remove the mist guide cover mounting screws (4 Pcs.
knurled) on the side of the humidifier.

6) Loosen the screws (1 Pc. or 2 Pcs.) on the front of the
humidifier and remove the mist guide cover.

7) Remove the air flow guide (water tank cover) mounting screws
(2 Pcs.) and remove the air flow guide. Photo 12

8) Remove the control box cover mounting screws (4 Pcs.).
Photo 13

9) Remove the control box cover, remove the fan lead wire

bundling band, and remove the lead wire connecting terminals.

Photo 14

10) Loosen the water tank mounting screws (2 Pcs.) at the

lower part on the side of the humidifier. Photo 15

11) Remove the water tank portion. Take the water tank to a

convenient place for working before replacing parts.

5.4.2 Re-assembling

1) Before re-assembling the humidifier, confirm there is no water

leakage by pouring water into the tank.

2) When re-assembling after replacing parts, inspect the interior

and check the following points:

All the screws must be securely tightened.

All the lead wires must be correctly and securely connected.
(Special attention should be paid to the fan lead wires.)

All the plates, boards and relays must be free from discoloration,
deformation and deterioration.

Electrical wires must not be damaged.

3) After re-assembly is completed, supply water and power and

operate the unit. Check to see that normal nebulizing mist is
visible from all the mist blow tubes and that there is no water
leakage.

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5.4.3 Replacing the Transducer and Nebulizer
Print Plate

1) Referring to Section 5.4.1, “Preparation for Repairs” on page

5-7, take the water tank to a convenient place for working.

2) Loosen and remove the water tank back panel mounting

screws (2 Pcs.) and remove the panel portion. Photo 16

3) When replacing the transducer, remove the two transducer

lead wires, (yellow and orange). Photo 17

Note

Grasp the terminals when removing wires. Never pull the
lead wires.

4) Using a 7/32” nut driver, remove the transducer mounting

screws (2 Pcs.) and remove the transducer, spacer and o-ring.
Save the screws to mount the new part. Photo 18

5) Clean the spacer, o-ring groove and o-ring.

6) Assemble the new transducer with the spacer and o-ring and

install them with the saved mounting screws. Photo 19

Notes

Ensure the o-ring is not damaged. If it is damaged, re­place it with a new one.

Carefully align the transducer’s rubber packing in the in­dent in the bottom of the water tank to prevent leakage.

The mounting screws must be evenly tightened. Do not
overtighten.

7) Connect the lead wires to the plate. The colored lead wires

must be inserted as shown on the plate. (Orange wire to ORG,
Yellow wire to YEL)

8) To replace the nebulizer print plate, remove the four wires

connected to the terminals from the plate to be replaced.

9) Using a 7/32” nut driver, remove the plate mounting screws

(2 Pcs.) and remove the plate. Save the screws to mount the
new part. Photo 20

10) Install the new plate together with the silicon sheet provided

using the saved mounting screws.

11) Connect the nebulizer print plate interconnecting wires

(black to H, white to G) and transducer lead wires (orange to
ORG, yellow to YEL)

When the nebulizer print plate is replaced, it is recom­mended that the transducer be replaced also.

12) Referring to Sect. 5.4.2, “Re-assembling” on page 5-7, re-

assemble by reversing the above procedure.

(©January, 2008)

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5.4.4 Water Supply Solenoid Valve, Float Switches and
Printed Circuit Board

1) Referring to Section “5.4.1, “Preparation for Repairs” on page 5-

7, take the water tank to a convenient place for working.

2) Cut the band bundling the solenoid valve and float switch lead

wire. Photo 21

Note

Be careful not to damage the lead wires.

3) Remove the connecting wires of the parts to be replaced from

the terminals on the printed circuit board.

Note

Grasp the terminals when removing wires. Never pull the
lead wires.

4) Remove the float panel mounting screws and lift the float panel.

Save the screws to mount the new part. Photo 22

5) When the solenoid valve is replaced, remove the pipe fitting

from the inlet side of the solenoid valve. Photo 23

6) Remove the solenoid valve mounting screws.

Photo 24

7) Remove the elbow on the outlet side and install the new

solenoid valve on the outlet side. Be sure to seal the fitting with
teflon tape.

Note

Ensure the elbow is facing the correct direction.

8) Install the new solenoid valve to the float panel and re-install the

pipe fitting.

Note

Ensure the o-ring is not damaged. If it is damaged, replace
it with a new one.

9) To replace the float switch, remove the lock nut on the float

switch and replace the switch with a new one. Photo 25

Note

Since there are two types of float switches, one type for
the water supply and one type for low water level, the type
must be checked when the float switch is replaced.

Type for water supply ............ FS1

Type for low water level .......... FS2

10) To replace the printed circuit board, remove all the lead wires

connected to the board.

11) Slide the printed circuit board out along the guides, remove it

and install a new one. Photo 26

12) Referring to Section 5.4.2, “Re-assembling” on page 5-7,

assemble by reversing the above procedure.

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6.0 PRODUCT SUPPORT GROUP

SATS provides to its customers a Product Support
Group (PSG) which not only provides technical support
and parts but the following additional services, as
requested: performance evaluations, start-up assis­tance and training.

6.1 Technical Support

The SATS Product Support Group (PSG) is dedicated
to the prompt reply and solution to any problem
encountered with a unit. Should a problem develop that
cannot be resolved using this manual, you may
contact PSG at [phone] Monday through
Friday from 8:00 a.m. to 5:00 p.m. EST. If a problem
occurs after business hours, dial the page number
[phone] and follow the steps below:

1. Wait for the dial tone.

2. Dial your telephone number (including area code).

3. Press the pound (#) key.

4. Wait for a busy signal.

5. Hang up the telephone.

One of our service technicians will return your call.
When calling to obtain support, it is vital to have the
following information readily available, (information is
found on unit's nameplate):

• Unit Model Number (BNBXXXX)

• SATS Item Number (123456)

• Unit Serial Number (1234567)

• Description of Problem

6.2 Obtaining Warranty Parts

Warranty inquires are to be made through the Product
Support Group (PSG) at [phone] Monday
through Friday from 8:00 a.m. to 5:00 p.m. EST. A
service technician at
system over the telephone with a field service techni­cian to determine the defect of the part. If it is deter­mined that the part may be defective a replacement
part will be sent UPS ground. If the customer requests
that warranty part(s) be sent by any other method than
UPS ground the customer is responsible for the
shipping charges. If you do not have established credit
with SATS you must provide a freight carrier account
number.

SATS

will troubleshoot the

A written (or faxed) purchase order is required on
warranty parts and must be received prior to 12:00
p.m. for same day shipment. The purchase order must
contain the following items:

• Purchase Order Number

• Date of Order

• SATS Stated Part Price (obtained from PSG)

• Customer Billing Address

• Shipping Address

• Customer's Telephone and Fax Numbers

• Contact Name

• Unit Model No., Serial No. & SATS Item No.

The customer is responsible for the shipping cost
incurred for shipping the defective part(s) back to
SATS. Return of defective part(s) must be within 30
days at which time an evaluation of the part(s) is
conducted and if the part is found to have a manufac­turing defect a credit will be issued.

When returning defective part(s) complete the Return
Material Authorization Tag and the address label
received with the replacement part.

See SATS Standard Warranty located in section one
of this manual.

6.3 Obtaining Spare/Replacement Parts

Spare and replacement parts requests are to be made
through the Product Support Group (PSG) by fax (301)
620-1396, telephone [phone] or E-mail
([e-mail]). Quotes are given for specified
listed parts for a specific unit.

SATS accepts Visa and MasterCard. SATS may
extend credit to its customers; a credit application
must be prepared and approved (this process could
take one week).

A 25% minimum restocking charge will be applied on
returned stocked parts that were sold as spare/
replacement parts. If the returned part is not a stocked
item, a 50% restocking charge may be applied.
Additionally a Return Material Authorization Number is
required when returning parts. To receive credit for
returned repair/replacement parts, the parts must be
returned to SATS within 30 days of the purchase date.
Spare part sales over 30 days old will be considered
final and the parts will remain the sole property of the
ordering party.

(©January, 2008)

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7.0 DRAWINGS

7.1 Layout Drawing of Humidifier

Model BNB1000 BNB2000 BNB3000 BNB4000 BNB5000 BNB8000

Dimension “A” 10.12” 14.49” 18.78” 23.11” 27.44” 40.43”

Dimension “B” 4.21” 8.54” 12.87” 17.20” 21.54” 34.53”

Dimension “L” 11.81” 16.14” 20.47” 24.80” 29.13” 42.13”

Dimension “P” 11.02” 15.34” 19.68” 24.02” 28.35” 41.34”

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7.2 Electrical Circuit Diagrams

BNB1000 to BNB4000

Typical Wiring Diagram

100 VAC

BNB5000 & BNB8000

Typical Wiring Diagram

100 VAC

(©January, 2008)

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(©January, 2008)

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