Vapac VapaNet Series, LE05, LE30, LE45, LE55 Operation Manual

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Page 1

These instructions contain operating information and should be left with the unit.

Electrode Boiler Units

Installation & Operation Manual

Edition 3.2.2

(For use with Software version 7.1 & subsequent issues)

Installation in countries covered by EC Directives:

This product meets the requirements of the RoHS Directive 2002/95/EEC

This product will meet the requirements of the Low Voltage Safety Directive

Directive

2004/108/

Failure to comply with these instructions may invalidate the manufacturer's warranty or any

certificate/declaration of conformance requested to be supplied with the unit.

EEC when installed in accordance with the instructions contained in this manual.

2006/95/

EEC and the EMC

Page 2

CONTENTS

Important Installation Points .................................................................................................................... 3

1.0 Installation. .................................................................................................................................... 4

1.1 Vapac LE unit dimensions ......................................................................................................... 4

1.1.1 LE weights ............................................................................................................................. 8

1.2 Positioning the steam pipes ...................................................................................................... 8

1.2.1 General .................................................................................................................................. 8

1.2.2 Steam Hose Connection ........................................................................................................ 8

1.3 Plumbing Considerations. ......................................................................................................... 9

1.4 Electrical Connections ............................................................................................................. 10

1.4.1 Important E.M.C. Considerations ....................................................................................... 10

1.4.2 Power Supply Connection ................................................................................................... 11

1.4.2.1 Volt free alarm outputs ........................................................................................................ 11

1.4.2.2 Unit control terminals ........................................................................................................... 11

1.4.3 Electrical Connections ......................................................................................................... 12

1.4.4 Cable Entry Provision .......................................................................................................... 12

1.4.5 Vapac Control Circuit Transformer ...................................................................................... 12

1.4.6 RDU Connection .................................................................................................................. 12

1.5 Cylinder Electrical demand loads ............................................................................................ 14

1.5.1 LExx Units............................................................................................................................ 14

1.5.2 LExxP Units ......................................................................................................................... 17

1.6 Control Circuit Connections .................................................................................................... 19

1.6.1 Control Circuit Wiring ........................................................................................................... 19

1.6.2 Proportional Control ............................................................................................................. 19

1.6.3 Control Signal Selection ...................................................................................................... 19

1.6.4 On/Off Control ..................................................................................................................... 19

1.6.5 Sensing Head ...................................................................................................................... 20

1.6.6 Security Circuit / E.P.O. Shutdown ...................................................................................... 20

1.6.7 Load Shed Option ................................................................................................................ 20

1.6.8 Master/Slave System ........................................................................................................... 21

2.0 Start-Up / Operation .................................................................................................................... 22

2.0.1 Start-up check list ................................................................................................................ 22

2.0.2 Start-Up Instructions ............................................................................................................ 22

2.0.3 Commissioning/Start-Up ...................................................................................................... 22

2.0.4 Features of VAPANET Electode Boiler Unit ........................................................................ 22

2.1 Service Advice......................................................................................................................... 23

2.1.1 Procedure for cylinder Exchange. ....................................................................................... 23

2.1.2 Typical Cylinder / Electrode Layouts ................................................................................... 23

2.2.1 Feed Valve with Strainer ..................................................................................................... 24

2.2.2 Drain Pump .......................................................................................................................... 24

3.0 Location of Indicators and Controls ............................................................................................ 25

3.1 Positioning of Indicators and controls on Vapac ® Vapanet ® LE Units. ............................... 25

3.2 Initial Set-up ............................................................................................................................ 26

3.3 Normal Run / Standby / Start-up – No User Intervention Required ........................................ 27

3.4 Fault / Service Indications – Requiring Operator Intervention. ............................................... 28

3.4.1 To Postpone the Sevice: ..................................................................................................... 28

3.4.2 To Service the unit: .............................................................................................................. 29

3.5 Fascia Label symbols .............................................................................................................. 30

3.6 Other Options .......................................................................................................................... 30

4.0 Trouble-shooting Check List ....................................................................................................... 31

5.0 Wiring diagram ............................................................................................................................ 32

Appendix 1. ............................................................................................................................................ 43

A Guide to Positioning Steam Pipes: ................................................................................................. 43

Appendix 2 ............................................................................................................................................. 45

A Guide to Positioning Multipipes: ..................................................................................................... 45

Page 3

Important Installation Points

The unit must be installed to comply with national regulations and/or codes of practice. A qualified electrician must carry this out.

Ensure at least 1000 mm clear front access to the electrical and steam sections.

Do not locate the cabinet where the ambient temperature around the unit could exceed 35º C; or fall below 5º C e.g., an unventilated roof mounted enclosure – see minimum space / ventilation requirements page 7. * If below 5º C Frost protection kit required.

Do not locate the cabinet where a ladder is required for service access as this could make servicing and cylinder service or exchange hazardous.

Make sure steam line(s) have adequate slope (min 12%) for condensate drainage and use condensate separators if the pipe is lower than the unit.

Provide adequate support to prevent sags developing in flexible steam lines, which can fill with water and create a "trap".

Do not locate vented drain directly under the cabinet.

Important Electrical Connection Items

Control cabling should be run in screened cables and kept separate from any mains carrying cables (see page 10).

Before commissioning the unit, check that all electrical (power) connections - including those at the terminals and contactor are tight.

Check that the transformer primary winding connection is correct for the supply voltage at Vapac terminals A1 & A2.

The Vapac transformer must not be used to power other equipment.

Do not mount the 'LR' unit close to a source of strong electromagnetic emissions, such as a variable speed motor drive, Kva transformer, or 'UPS' unit. A minimum gap of 2 meters must be maintained between the unit and such devices. Larger output devices may require an increased gap distance, depending on the nature of screening / filtration measures fitted to the device.

Use a high-limit humidistat to ensure positive interruption of unit operation when overhumidification is detected (See page 17).

It is important that the control signal connected to terminals 5 & 6 must be referenced to ground at the control PCB – this can be done by linking either terminal 5 or 6 to terminal 7. NB if the controller output is referenced to ground, it is important that the “leg” which is connected to ground at the controller is also connected to ground at the Vapac unit. Grounding the opposite “leg” will cause damage to the controller and/or the Vapac control PCB.

Important Maintenance Items

Only a qualified electrician should carry out maintenance.

The boiler contains hot water, and must be drained before any maintenance is carried out on the steam section. This should be done prior to isolating the power, and removing the front access panel

ESD SENSITIVE DEVICES USED ON PCB. ENSURE ANTI-STATIC PRECAUTIONS ARE TAKEN WHEN REMOVING OR REPLACING PCB’S.

Page 4

Cabinet Size 1.

LE18

–

All

points.

1.0 Installation.

Do’s

Do mount the unit as close to the steam distribution

pipe(s) as possible.

Do mount the unit at a height convenient for reading the

display window.

Do ensure adequate side ventilation (min 80 mm). Do ensure adequate service access to the front of the unit

(min 1000 mm).

Do ensure adequate service access below the unit (min

1000 mm).

Do ensure that the holes in the rear top panel remain

unobstructed to allow a free flow of air see fig 1.

Do use the marking on the side of the carton as a template

to mark the mounting hole positions.

Do remove the cylinder, if necessary, to access the

mounting holes in the back of the steam section.

Do use M6 projecting type wall bolts or equivalent to

mount the unit in position.

Do mount units with RDU’s so that steam pipe discharge is

above head height.

Do leave minimum gap between the top of an RDU and

the ceiling as per table in fig 2.

1.1 Vapac LE unit dimensions

Covering model references:

LE05 – All LE09 – All

6.0265.055.0

Don’ts

Don’t mount the unit close to sources of strong electro-

magnetic emissions e.g. variable speed lift motor drives, kVa transformers etc.

Don’t mount the unit in an unventilated enclosure. Don’t mount in a position requiring ladder access to the

unit.

Don’t mount the unit behind a false ceiling or other

situation where an unusual malfunction (e.g. water leak) would cause damage.

Don’t mount the unit in an area which will be hosed down. Don’t install the unit where the ambient temperature can

exceed 35oC; or fall below 5oC (Unless frost protection kit fitted).

Don’t mount the unit inside a cold-room or other place

where temperature and humidity conditions can cause condensation on electrical components.

Don’t mount the unit where the sound of a contactor

opening/closing and water flow in a pipe would be

unacceptable e.g. libraries, private apartments, etc. Don’t position an RDU to discharge directly over expensive equipment, desks or stored materials

203.0172.0

6.0

Left: Top view of unit showing steam outlet position (35 mm spigot)

Below: Rear view of unit showing wall mounting

Right: View from beneath unit showing the electrical gland plate (approx 120mm x 120mm) with an entry hole (approx 105mm x 90mm)

120.0

140.0

675.0

50.0

74.0444.0

Left: View from beneath unit showing:

‘F’ (Feed) 19mm BSP male connection for connection for flexible hose provided with unit.

‘D’ (Drain) connection for 35 mm pipe.

172.0203.0

285.0

430.0

70.0

204.0

For clearance around the unit for ventilation & access please see page 7

Page 5

Cabinet Size 2.

LE55

All

Covering model references:

LE30 – All LE45 – All

360

165

330

305

186

Steam Outlet 54 mm

Left: Top view of unit showing steam outlet position (54 mm spigot)

Below: Rear view of unit showing wall mounting points.

165

Right: View from beneath unit showing the electrical gland plate (approx 120 mm x 120 mm) with an entry hole (approx 105 mm x 90 mm)

Gland Plate

810

120 X 120

299

520

73555

305

Left: View from beneath unit showing-

‘F’ (Feed) ¾ “ BSP male connection for connection

for flexible hose provided with unit.

‘D’ (Drain) connection for 35 mm pipe.

For clearance around the unit for ventilation and access and for units with RDU’s see page 7

Page 6

Cabinet Size 4.

Covering model references:

LE60 – All LE90 – All LE110 – All

360

610

190

176

346

322

360

Steam Outlets 54 mm

Left: Top view of unit showing steam outlet positions (54 mm spigots)

Below: Rear view of unit showing wall mounting points.

610

990

190

73555

Right: View from beneath unit showing the electrical gland plate (approx 120 mm x 120 mm)

with an entry hole (approx 105 mm x 90 mm)

Gland Plate

120 X 120

810

20.5"(520)

70 850

F F

152

343

505

31.1"(790)

468

Left: View from beneath unit

Gland Plate

120 X 120

237

343

showing-

‘F’ (Feed) ¾ “ BSP male connection for connection for flexible hose provided with unit.

‘D’ (Drain) connection for 35 mm pipe.

For clearance around the unit for ventilation and access see page 7

Page 7

Cabinet Sz 1 with RDU

Cabinet

Clearance around LE Units

LE09 All

LE18 All

LE30 All

LE45/LE55

LE45/55

Dimensions

size 2 with RDU

Dimensions

RDU 30 kg/h A = 602mm B = 205mm

RDU 45 kg/h A = 842mm B = 360mm

L L

Unit L

LE05 All

(No RDU)

LE05 All

(With RDU)

LE09 All

(No RDU)

(With RDU)

(No RDU)

LE18 All

(With RDU)

LE30 All

(No RDU)

(With RDU)

(No RDU)

(With RDU)

LE60 - 110 All (Twin

Cylinder No RDU)

min

85 1000 500 -

85 1000 - 200

85 1000 500 -

85 1000 - 250

85 1000 500 -

85 1000 - 500

85 1000 500 -

100 1000 - 750

85 1000 500 -

200 1000 - 775

85 1000 500 -

min

A minimum clear space of 1 m is required in

front of the unit for maintenance access

Page 8

∅

For guidance on positioning of steam pipes see Appendix 1.

1.1.1 LE weights

The unit dry weight is the delivered unit with no water in unit, the wet weight is the operational weight when the unit is running . The RDU weight must be added to the unit weight if fitted on top of the Electrode Boiler unit.

Vapanet model Dry Kg Wet Kg RDU

Kg LE05 and LE05P 23.5 29 6 LE09 and LE09P 24 31 10 LE18 and LE18P 24.5 36 12 LE30 and LE30P 34 62 14 LE45,LE45P & LE55 34 62 16 LE60 and LE60P 52 106 NA LE90, LE90P & LE110 52 106 NA

1.2 Positioning the steam pipes

1.2.1 General

Steam pipes should be positioned as shown below, allowing a minimum rate of fall back to the unit of

Do ensure radius hose bends are fully supported to

prevent kinks developing when in service.

Do add extra insulation to steam hose for longer

runs (2m-5m) and in cold ambient conditions to avoid excess condensate and reduction in delivered output.

Don'ts

Don't allow steam hose to develop kinks or sags. Don't include horizontal runs or 90o elbows in the

steam line.

Steam Distribution Pipe requirement

Electrode Boiler Unit Model

35mm ∅ Pipe No. 54mm ∅. Pipe No.

Duct Pressure Pa.

LE05(P) LE09(P) LE18(P)

+2000

-600

LE30(P) LE45(P) LE55

LE60(P) LE90(P) LE110

+2000

-600

12% to allow the free flow of condensate back to the unit. If the above fall is not possible, then condensate separators must be fitted as shown in appendix 1. The position of the steam pipe or multipipe in a air-

No Sags!

Flexible Steam Pipe.

conditioning system relative to other items such as bends, filters, heat exchangers, etc., is critical. The steam pipe must not be located closer to such item, than the entrainment distance, and must be decided by the design engineer responsible for the project.

Do's Do obtain project engineer's instruction/drawing for

chosen location of pipe

Flexible Steam Pipe.

Distance to first bend.

Do obtain project engineer's instruction/drawing for

pipe position relative to the top & bottom of the duct (or sides if airflow is vertical.

R min for 35 R min for 54 ∅ Pipe = 500mm

Pipe = 250mm

Do check if alternative slope of Ø35mm pipe has

been specified.

Do use bracket/lug on the end of Ø54mm pipes for

extra support.

VAPAC HUMIDIFIER

1.2.2 Steam Hose Connection

Do's

Do use Vapac steam hose or well insulated copper

pipe.

Do keep steam hose as short as possible (under 2m

for max efficiency).

Do arrange to have a vertical rise immediately over

the unit of 300mm.

Do use the full height available between the unit

and steam pipe to provide maximum slope (min 12-20% for condensate to drain back to the steam cylinder (or down to a condensate

separator). Always provide a continuous slope. Do provide adequate support to prevent sagging a) fit pipe clips every 30-50cm or b) support straight lengths on cable trays

35 or 54 mm copper or stainless steel steam pipe with Insulation.

35mm ∅ Pipe Selection

Duct width

B mm 320-470 470-620 620-770 770-920

920-1070

1070-1200

In-duct Length

L mm

300 450 600 750 900

1050

Flexible pipe coupling to connect Steam pipe to Duct pipe coupling length to allow for line movement and expansion. Coupling clamp with Hose clips each end.

Fig 6

54mm ∅ Pipe Selection

Duct width

B mm

700-950

950-1450

1450+

In-duct Length

L mm

(Kg)

650 (1.8) 900 (2.2)

1400 (3.2)

or in heat resistant plastic pipe.

For guidance on use of Multipipes see Appendix 2.

Page 9

1.3 Plumbing Considerations.

1.3.1 Cold water supply

General

The Vapanet range of electrode boilers is capable of operating with a range of “raw mains” water quality. The water supply should be within the following limits:-

Hardness 50 – 500 ppm Conductivity 80 – 1000µS PH 7.3 – 8.0 Silica 0 Pressure of between 1 - 8 bar.

In addition, if stainless steel electrodes are used the chlorine level must not exceed 170 ppm.

Water Supply rates

1.20 l/min

2.50 l/min

5.00 l/min

Do’s

Do install a stop-valve/Shut-off valve and a strainer close to

the unit.

Do provide a water supply with sufficient pressure and pipe

size to ensure an adequate flow rate to all units connected to the system.

Do use the water connection with nylon nut provided.

LE05 LE09 LE18 LE30 LE45/LE55 LE60 LE90/LE110

LE05P LE09P LE18P LE30P LE45P LE60P LE90P

A B C D F

K L M N

H G S V

Single Cylinder Units 30-55 kg/h

ALL Dimensions in mm

Don'ts

Don’t use a wrench or other tool to tighten the water supply

connection - the nylon nut and rubber washer provided, should only require tightening by hand to effect a seal. If water seepage occurs, undo the nut to wipe the washer clean and re-seat it.

1.3.2 Drain connection

General

Do's Do ensure metal drain and supply water pipework is grounded

electrically close to the unit (a ground/earth stud is positioned on the underside of the cabinet.

Drain capacity per cylinder.

(Max.pump flow rate at Power supply frequency)

Do’s Do use copper or plastic pipe rated for 110 oC. Do arrange to discharge drain water from the unit into a

trapped and vented drain at a position where flash steam rising from the drain line vent will not pose a problem for the Vapac or other equipment.

Do provide adequate fall for the drain pipework to allow free

flow of water drained from each unit.

Do ensure drain line pipe size will accommodate water being

drained at the same time from all the Vapac units which are connected to it.

KEY: -

A Tundish Fill-cup B Steam Cylinder C Feed Drain Manifold D Drain Pump F Feed Solenoid Valve G Water Connection ¾” BSP. H Flexible hose ¾” BSP. K 35∅ Steam Hose coupling and Hose

L 35∅ copper or plastic Drain for 110°C

M Tundish N U-trap side exit. S Optional Strainer V Isolation stop cock

Clips.

Water with supports.

l/min Hz

16.8

17.2

60.

Twin Cylinder units 60-110 kg/h

Fig 7

Page 10

Control Cable / Security Circuit

Important Power Connection Information

Note:

1.4 Electrical Connections

24 V a.c. Control circuit -

9 V a.c. PCB Circuit -

Transformer Primary Circuit And RDU.

230V ac Pump Supply. -

Vapac 24V and 9 V secondary Transformer Primary supply connections: Vapac units are wired to allow connection to alternative site Voltages. Make the following simple checks before connecting the power supply:Move the BROWN connection on the VAPANET transformer primary winding circuit to the position marked with the supply Voltage that is to be connected between VAPANET power terminals A1 and A2. The transformer primary circuit terminal positions are clearly marked:- 200V, 230V, 380, 415 & 440V. If the actual (measured) site voltage is 400v the preferred tapping is 380V. The transformer is fitted below the Drain tray, and is accessible by removing two screws and the cover, which should be slid it towards you.

6.3 A 20 mm (T – Time Lag) fuse (Pt.No. 1080093) mounted on VAPANET Echelon PCB (Pt.No.1150630).

2 A 20 mm (F - Quick blow) fuse (Pt No. 1080099) mounted on the VAPANET Echelon PCB (Pt, No. 1150630).

Two fuses protect the control circuit on Single cylinder units F1 2.0A (slow blow) (Pt. No. 1080095) mounted in fuse-terminal holder protects Primary transformer and RDU unit if fitted. F2 500 mA 20 mm (F - Quick blow) fuse (Pt No. 1080054) mounted in fuse-terminal holder protects Transformer Primary and Pump or both pumps if two pumps are fitted.

The pump or pumps on twin cylinder units are fed from the main transformer via a 230 volt auto winding. The pumps are protected by fuse F1 and F2 above feeding the transformer primary.

1.4.1 Important E.M.C. Considerations

Use a dedicated, earthed metal conduit for both the control signal cable and the security circuit cables along their entire length - they may share the same conduit where practicable. The earth must be made by "metal-to-metal" contact and should be a good RF (Radio Frequency) earth.

The control and security circuit connections should be run in screened cable with the screen grounded at the VAPANET end (onto the electrical section back panel). The screen should be maintained as close as possible to the cable ends and any tail between the screen and the earth point must be kept short (50 mm maximum).

Control Cable / Security Circuit Conduit Entry Arrangement

Electrical section metalwork

All metal surfaces which come into contact with each other, must be free of paint, grease, dirt, etc., thereby ensuring a good low impedance R.F. (Radio Frequency) path to ground.

Metal conduit

Cables to control terminals

Outer insulation

Screening Arrangement

Tail to be kept short (less than 50mm)

Screen left intact

Earthed back panel

Page 11

1.4.2 Power Supply Connection

The unit requires the following connections as shown in the diagram below

1.4.2.1 Volt free alarm outputs

The unit has connections for volt free alarm outputs these are on the three double terminals next to the main power input terminals. The top terminals are for unit volt free fault alarm as follows:

The bottom terminals are for unit volt free run signal as follows:

542 common for fault alarm 543 Normally closed when no fault 544 Normally open when no fault

545 Common for run signal 546 Normally closed when unit is in standby or

fault (not running)

547 Normally open when unit is in standby or fault

(not running)

If the unit is part of a master slave system or network, the run & fault outputs can be selected (via keypad & display) as either network (system) or unit only. This is selectable at Service Engineers Level, in the Engineering Menu, in the window “Fault/Run Scope”. The default is “network”. It is possible to get both alarm & Run indication in all units: Single cylinder units will give this indication if the service interval has expired; Twin Cylinder & Networked units will give this indication if the service interval has expired or if the master cylinder is operating and any slave cylinder (or cylinders) are in fault.

1.4.2.2 Unit control terminals

For unit control and network termination see section

1.6 the terminal layout is shown here.

Page 12

Notes:

FOR FULL EL

ECTRO

MAGNETIC COMPATIBILITY A NEUTRAL CONNECTION IS REQUIRED FOR ALL PROPORTIONAL

1.4.3 Electrical Connections

The wiring to the Vapac should be done by a qualified electrician. The external overcurrent protection and wiring should comply with the appropriate Regulations and Codes of Practice

Important: Make sure the connection to the primary Voltage winding of the Vapac transformer matches the supply Voltage which is to be connected between Vapac terminals A1 & A2.If the actual (measured) site voltage is

400v the preferred tapping is 380V

A fused disconnect/isolator or MCB should be used to disconnect the supply from all electrodes simultaneously.

This must be sized to suit the total maximum phase/line current of the unit and should be located adjacent to the Vapac cabinet or within easy reach and readily accessible.

In Vapac VAPANET units terminals A1, A2 and A3 are for the power supply connections as indicated in the diagrams below (twin cylinder units have two supplies A1,A2,A3 & B1,B2,B3).

Twin cylinder units’ have terminals for the connection of two power supply input circuits. On twin cylinder units’ this allows individual external protection of each steam cylinder. Fused disconnect/isolator or MCB provision must be linked to ensure both 3 phase supply inputs are disconnected simultaneously.

1. All units must have a PE earth connection connected to the units terminal.

2. Unit with N.A. in the following tables means NOT AVAILABLE there is not a unit available to run at the voltage and phases shown. Please check that the correct model reference is ordered and installed, for the low or high voltage required, and at the desired steam output.

3. Standard design is for 50 Hz. Supplies. Design for 60 Hz. Also available - 60 Hz. Supply must be specified with order as the standard pump is only 50Hz.

1.4.4 Cable Entry Provision

Cable glands must be used to ensure cables are held securely at the entry position. All Vapac cabinets are equipped with a removable gland-plate. The installing electrician should remove this and take it to a workbench to drill for the required cable gland size.

1.4.5 Vapac Control Circuit Transformer

The internal control circuit of the Vapac unit operates at 24Vac - the transformer secondary is set at 24V.

As standard the Vapac VAPANET includes a transformer with alternative primary winding options 200V, 230, 380, 415, and 440V and requires on site adjustment to match it to the Voltage connected to Vapac terminals A1 and A2. The transformer also has a 9V secondary tapping which provides power to the VAPANET 1150630 PCB.

Important: The Vapac transformer must NOT be used to power other equipment or the warranty will be invalidated.

1.4.6 RDU Connection

Vapac terminals 25 & 26 are included to provide a 230Vac electrical supply for the fan motor in the RDU (Room Distribution Unit) . Note: The 230Vac at terminals is derived from the incoming electrical supply to the Vapac. If the local supply cannot provide 230Vac (example 400V No Neutral supply) it will be necessary for a transformer to be fitted in the RDU as indicated below.

UNITS AS INDICATED IN THE CONNECTION DIAGRAMS ON THE FOLLOWING PAGES.

RDU Connection

The three type’s of RDU are for various voltages and phase without neutrals connections that can be made to the Vapanet unit. Please refer to the Microvap connection diagram on the following three pages as to which type of unit is required. On twin cylinder units two fan circuits as shown below one for each cylinder will be in the RDU unit.

RDU electrical loads

Model RDU05LE RDU09LE RDU18LE RDU30L RDU45LE Number of fans 2 3 3 5 7 Fan voltage 230 v 230 v 230 v 230v 230v Each fan current 50Hz RDU total load current 50Hz

(60 Hz)

115 mA

(60 Hz)

225 mA

(105 mA)

(210 mA)

115 mA 345 mA

(105 mA)

(315 mA)

115 mA 345 mA

(105 mA)

(315 mA)

115mA 575mA

(105mA)

(525mA)

115 mA 805 mA

(105 mA)

(735 mA)

Page 13

Power connection

details for LExx

Units

(Units without Solid

State Relays).

Details for LExxP

Units

(Units fitted with

Solid State Relays)

200 – 250 V 1Ph. N + earth

200 – 250 V 2Ph. + earth

380 – 440 V 2Ph + earth

TRANSFORMER PRIMARY 380 – 440 V SECONDARY 210 – 250 V

Page 14

Model Ref.

LE05

LE09

Model Ref.

LE05

-3

LE09

-3

Model Ref.

LE18

LE30

1.5 Cylinder Electrical demand loads

1.5.1 LExx Units

Nominal Output Kg/hr 5 5 5 5 5 5 9 9 9 9 9 9 Nominal Output lb/hr 11 11 11 11 11 11 19.8 19.8 19.8 19.8 19.8 19.8 Voltage V 200 230 380 400 415 440 200 230 380 400 415 440 Power input rating Kw 3.71 3.72 3.8 3.81 3.75 3.77 6.76 6.68 6.7 6.86 6.72 6.7 Electrical Supply Ph's Ph+N or

2Ph

No. of electrodes

2 2 2 2 2 2 2 2 2 2 2 2 Full load Current A 19.5 17 10.5 10 9.5 9 35.5 30.5 18.5 18 17 16 Maximum overcurrent A 29.25 25.5 15.75 15 14.25 13.5 53.25 45.75 27.75 27 25.5 24 Fuse Rating/phase A 32 32 20 20 16 16 63 50 32 32 32 32 Supply cable terminals mm

10 10 10 10 10 10 16 16 16 16 16 16 Wiring diagram Cabinet size

Nominal Output Kg/hr 5 5 5 5 5 5 9 9 9 9 9 9 Nominal Output lb/hr 11 11 11 11 11 11 19.8 19.8 19.8 19.8 19.8 19.8 Voltage V 200 230 380 400 415 440 200 230 380 400 415 440 Power input rating Kw 3.79 3.79 3.76 3.96 3.77 3.99 6.76 6.83 6.9 6.93 6.85 6.9 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes

3 3 3 3 3 3 3 3 3 3 3 3 Full load Current A 11.5 10 6 6 5.5 5.5 20.5 18 11 10.5 10 9.5 Maximum overcurrent A 17.25 15 9 9 8.25 8.25 30.75 27 16.5 15.75 15 14.25 Fuse Rating/phase A 25 20 16 16 10 10 32 32 20 20 20 16 Supply cable terminals mm

10 10 10 10 10 10 10 10 10 10 10 10 Wiring diagram Cabinet size

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

A4-LZD-559 A4-LZD-559

1 1

A4-LZD-559 A4-LZD-559

1 2

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Nominal Output Kg/hr 18 18 18 18 18 18 30 30 30 30 30 30 Nominal Output lb/hr 39.6 39.6 39.6 39.6 39.6 39.6 66 66 66 66 66 66 Voltage V 200 230 380 400 415 440 200 230 380 400 415 440 Power input rating Kw 13.36 13.47 13.48 13.53 13.35 13.43 22.43 22.38 22.25 22.43 22.25 22.5 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes

3 3 3 3 3 3 6 6 3 3 3 3 Full load Current A 40.5 35.5 21.5 20.5 19.5 18.5 68 59 35.5 34 32.5 31 Maximum overcurrent A 44.55 39.05 23.65 22.55 21.45 20.35 74.8 64.9 39.05 37.4 35.75 34.1 Fuse Rating/phase A 50 50 32 32 25 25 80 80 50 50 40 40 Supply cable terminals mm Wiring diagram Cabinet size

16 16 16 16 16 16 35 35 16 16 16 16

A4-LZD-559 A4-LZD-560 A4-LZD-559

1 2

Page 15

Model Ref.

LE45 LE55

Model Ref.

LE60

Model Ref.

LE90

Cylinder Nominal Output Kg/hr 44 45 45 45 45 45 55 55 55 55 55 55 Nominal Output lb/hr 96.8 99 99 99 99 99 NA NA 121 121 121 121 Voltage V 200 230 380 400 415 440 200 230 380 400 415 440 Power input rating Kw 32.66 33.39 33.85 33.65 33.54 33.39 NA NA 41.37 40.91 41.07 41.37 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph NA NA 3Ph 3Ph 3Ph 3Ph No. of electrodes Full load Current A 99 88 54 51 49 46 NA NA 66 62 60 57 Maximum overcurrent A 108.9 96.8 59.4 56.1 53.9 50.6 NA NA 72.6 68.2 66 62.7 Fuse Rating/phase A 125 125 63 63 63 63 NA NA 80 80 80 80 Supply cable terminals mm Wiring diagram Cabinet size

Cylinder Nominal Output Kg/hr 30 30 30 30 30 30 30 30 30 30 30 30 Nominal Output lb/hr 66 66 66 66 66 66 66 66 66 66 66 66 Voltage V 200 200 230 230 380 380 400 400 415 415 440 440 Power input rating Kw 22.43 22.43 22.38 22.38 22.25 22.25 22.43 22.43 22.25 22.25 22.5 22.5 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes Full load Current A 68 68 59 59 35.5 35.5 34 34 32.5 32.5 31 31 Maximum overcurrent A 74.8 74.8 64.9 64.9 39.05 39.05 37.4 37.4 35.75 35.75 34.1 34.1 Fuse Rating/phase A 80 80 80 80 50 50 50 50 40 40 40 40 Supply cable terminals mm Unit Total F.L.C. A 136 118 71 68 65 62 Wiring diagram Cabinet size

Cylinder Nominal Output Kg/hr 44 44 45 45 45 45 45 45 45 45 45 45 Nominal Output lb/hr 96.8 96.8 99 99 99 99 99 99 99 99 99 99 Voltage V 200 200 230 230 380 380 400 400 415 415 440 440 Power input rating Kw 32.66 32.66 33.39 33.39 33.85 33.85 33.65 33.65 33.54 33.54 33.39 33.39 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes Full load Current A 99 99 88 88 54 54 51 51 49 49 46 46 Maximum overcurrent A 108.9 108.9 96.8 96.8 59.4 59.4 56.1 56.1 53.9 53.9 50.6 50.6 Fuse Rating/phase A 125 125 125 125 80 80 60 60 60 60 60 60 Supply cable terminals mm Unit Total F.L.C. A 198 176 108 102 98 92 Wiring diagram Cabinet size

1 1 1 1 1 1 1 1 1 1 1 1

6 6 6 6 6 6 NA NA 6 6 6 6

35 35 35 35 35 35 NA NA 35 35 35 35

A4-LZD-560 A4-LZD-560

2 2

1 2 1 2 1 2 1 2 1 2 1 2

6 6 6 6 3 3 3 3 3 3 3 3

35 35 35 35 16 16 16 16 16 16 16 16

A4-LZD-560 A4-LZD-559

1 2 1 2 1 2 1 2 1 1 1 1

6 6 6 6 6 6 6 6 6 6 6 6

35 35 35 35 35 35 35 35 35 35 35 35

A4-LZD-560

Page 16

Model Ref.

LE110

Cylinder Nominal Output Kg/hr 55 55 55 55 55 55 55 55 55 55 55 55 Nominal Output lb/hr 121 121 121 121 121 121 121 121 121 121 121 121 Voltage V 200 200 230 230 380 380 400 400 415 415 440 440 Power input rating Kw N.A. N.A. N.A. N.A. 41.37 41.37 40.91 40.91 41.07 41.07 41.37 41.37 Electrical Supply Ph's N.A. N.A. N.A. N.A. 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes Full load Current A N.A. N.A. N.A. N.A. 66 66 62 62 60 60 57 57 Maximum overcurrent A N.A. N.A. N.A. N.A. 72.6 72.6 68.2 68.2 66 66 62.7 62.7 Fuse Rating/phase A N.A. N.A. N.A. N.A. 80 80 80 80 80 80 80 80 Supply cable terminals mm Unit Total F.L.C. A N.A. N.A. N.A. N.A. 132 124 120 114 Wiring diagram A4-LZDCabinet size

1 2 1 2 1 2 1 2 1 2 1 2

N.A. N.A. N.A. N.A. 6 6 6 6 6 6 6 6

N.A. N.A. N.A. N.A. 35 35 35 35 35 35 35 35

560 560 562 560 562 560 562 560 562

Page 17

Model Ref.

LE05P

LE09P

Model Ref.

LE05P

-3

LE09P

Model Ref.

LE18P

LE30P

1.5.2 LExxP Units

Nominal Output Kg/hr 5 5 5 5 5 5 9 9 9 9 9 9 Nominal Output lb/hr 11 11 11 11 11 11 19.8 19.8 19.8 19.8 19.8 19.8 Voltage V 200 230 380 400 415 440 200 230 380 400 415 440 Power input rating Kw 3.73 3.71 3.78 3.81 3.78 3.83 6.71 6.76 6.77 6.79 6.7 6.74 Electrical Supply Ph's Ph+N or

2Ph

No. of electrodes

2 2 2 2 2 2 2 2 2 2 2 2 Full load Current A 22.5 19.5 12 11.5 11 10.5 40.5 35.5 21.5 20.5 19.5 18.5 Maximum overcurrent A 33.75 29.25 18 17.25 16.5 15.75 60.75 53.25 32.25 30.75 29.25 27.75 Fuse Rating/phase A 40 32 20 20 20 20 63 63 40 32 32 32 Supply cable terminals mm

10 10 10 10 10 10 16 16 16 16 16 16 Wiring diagram Cabinet size

Nominal Output Kg/hr 5 5 5 5 5 5 9 9 9 9 9 9 Nominal Output lb/hr 11 11 11 11 11 11 19.8 19.8 19.8 19.8 19.8 19.8 Voltage V 200 230 380 400 415 440 200 230 380 400 415 440 Power input rating Kw 3.73 3.79 3.82 3.73 3.87 3.79 6.74 6.76 6.81 6.89 6.85 6.94 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes

3 3 3 3 3 3 3 3 3 3 3 3 Full load Current A 13 11.5 7 6.5 6.5 6 23.5 20.5 12.5 12 11.5 11 Maximum overcurrent A 19.5 17.25 10.5 9.75 9.75 9 35.25 30.75 18.75 18 17.25 16.5 Fuse Rating/phase A 25 20 16 16 16 16 40 32 20 20 20 20 Supply cable terminals mm

10 10 10 10 10 10 10 10 10 10 10 10 Wiring diagram Cabinet size

Nominal Output Kg/hr 18 18 18 18 18 18 30 30 30 30 30 30 Nominal Output lb/hr 39.6 39.6 39.6 39.6 39.6 39.6 66 66 66 66 66 66 Voltage V 200 230 380 400 415 440 200 230 380 400 415 440 Power input rating Kw 13.34 13.36 13.35 13.48 13.39 13.57 22.38 22.43 22.35 22.38 22.32 22.41 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes

3 3 3 3 3 3 6 6 3 3 3 3 Full load Current A 46.5 40.5 24.5 23.5 22.5 21.5 78 68 41 39 37.5 35.5 Maximum overcurrent A 51.15 44.55 26.95 25.85 24.75 23.65 85.8 74.8 45.1 42.9 41.25 39.05 Fuse Rating/phase A 60 50 32 32 32 32 100 100 50 50 50 50 Supply cable terminals mm

16 16 16 16 16 16 35 35 16 16 16 16 Wiring diagram Cabinet size

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

Ph+N or

2Ph

A4-LZD-559 A4-LZD-559

1 1

A4-LZD-559 A4-LZD-559

1 1

A4-LZD-559 A4-LZD-561 A4-LZD-559

1 2

Ph+N or

2Ph

Ph+N or

2Ph

Page 18

Model Ref.

LE45P

Model Ref.

LE60P

Model Ref.

LE90P

Cylinder

1 1 1 1 1 1 Nominal Output Kg/hr 45 45 45 45 45 45 Nominal Output lb/hr NA NA 99 99 99 99 Voltage V 200 230 380 400 415 440 Power input rating Kw NA NA 33.79 33.85 33.93 33.45 Electrical Supply Ph's NA NA 3Ph 3Ph 3Ph 3Ph No. of electrodes

NA NA 6 6 6 6 Full load Current A NA NA 62 59 57 53 Maximum overcurrent A NA NA 68.2 64.9 62.7 58.3 Fuse Rating/phase A NA NA 80 80 80 80 Supply cable terminals mm Wiring diagram Cabinet size

NA NA 35 35 35 35

A4-LZD-561

Cylinder

1 2 1 2 1 2 1 2 1 2 1 2 Nominal Output Kg/hr 30 30 30 30 30 30 30 30 30 30 30 30 Nominal Output lb/hr 66 66 66 66 66 66 66 66 66 66 66 66 Voltage V 200 200 230 230 380 380 400 400 415 415 440 440 Power input rating Kw 22.38 22.43 22.43 22.38 22.35 22.25 22.38 22.43 22.32 22.25 22.41 22.5 Electrical Supply Ph's 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes

6 6 6 6 3 3 3 3 3 3 3 3 Full load Current A 78 68 68 59 41 35.5 39 34 37.5 32.5 35.5 31 Maximum overcurrent A 85.8 74.8 74.8 64.9 45.1 39.05 42.9 37.4 41.25 35.75 39.05 34.1 Fuse Rating/phase A 100 100 100 100 50 50 50 50 50 50 50 50 Supply cable terminals mm

35 35 35 35 16 16 16 16 16 16 16 16 Unit Total F.L.C. A 146 127 76.5 73 70 66.5 Wiring diagram Cabinet size

A4LZD

561 562 561 562 559 562 559 562 -559 562 -559 -562

Cylinder

1 2 1 2 1 2 1 2 1 2 1 2 Nominal Output Kg/hr 45 45 45 45 45 45 45 45 45 45 45 45 Nominal Output lb/hr NA NA NA NA 99 99 99 99 99 99 99 99 Voltage V 200 200 230 230 380 380 400 400 415 415 440 440 Power input rating Kw NA NA NA NA 33.79 33.85 33.85 33.65 33.93 33.54 33.45 33.39 Electrical Supply Ph's NA NA NA NA 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph 3Ph No. of electrodes

NA NA NA NA 6 6 6 6 6 6 6 6 Full load Current A NA NA NA NA 62 54 59 51 57 49 53 46 Maximum overcurrent A NA NA NA NA 68.2 59.4 64.9 56.1 62.7 53.9 58.3 50.6 Fuse Rating/phase A NA NA NA NA 80 80 80 80 80 80 80 80 Supply cable terminals mm

NA NA NA NA 35 35 35 35 35 35 35 35 Unit Total F.L.C. A NA NA 116 110 106 99 Wiring diagram Cabinet size

A4LZD

561 562 561 562 561 562 559 562

Page 19

CR1

1.6 Control Circuit Connections

1.6.1 Control Circuit Wiring

Use a dedicated, earthed metal conduit for both the control signal cable and the security circuit cables, sharing the same conduit if practicable.

Use screened cable for all control and security circuit connections to minimise risk of electrical interference. The screen should be grounded at the VAPANET end only. See detail on page 7. NB. The control signal should be connected to ground at the PCB by connecting either terminal 5 or 6 to terminal 7 –

mportant note if the controller output is referenced to ground, then the “leg” which is ground must be the one linked to terminal 7.

1.6.2 Proportional Control

The VAPANET Electrode Boiler (LExxP) models can all be operated by either a potentiometric signal, a lonworks network signal or by one of 6 standard proprietary DC analogue signals.

Input signal: Potentiometric control 0-5V 0-10V 0-20V

(Actually 0-18V – not phase cut)

2-10V

1-18V 4-20mA Network

Master)

(Ensure jumper J1 is in place)

(Slave unit – demand generated by

Response: 8-100%

1.6.3 Control Signal Selection

Selection of the control signals is done a part of the initial set-up procedure using the keypad display. For confirmation that the signal has been selected, view the information window. If the unit has not got a keypad then this is done on the configuration board 1150634 mounted on the main control board 1150630 using the jumpers provided. The top right hand link should be made indicating that the unit is an “Electrode boiler” and the appropriate left hand link representing the actual site control signal should be linked using the jumper plugs provided

1.6.4 On/Off Control

Vapanet models can be operated by a single step humidistat which has Volt-free contacts – select control option Pot.

CR2

CR4

CSP configuration resistor

NetCR7

CR6

Vapac PART No. 1150630

CR5

CR2

CR3

Jumper J1 should be fitted if control signal is 4 – 20 mA

DC 0 - 20 4 – 20 Ma POTENTIOMETRIC VOLTAGE CURRENT CONTROL CONTROL CONTROL min. 135 Ohms Max. 10,000 Ohms

NOTE :- FOR CURRENT INPUT ONLY JUMPER J1 ON THE

1150630 CONTROL BOARD MUST BE LINKED.

UCP1UCP2

Vapac part no. 1150634

101112

Electro boiler

Pot high

Pot medium

Pot low

Softened

De-iron

De-min

Network or slave

Full o/p

4-20mA

0-20v

1-18v

2-10v

0-10v

0-5v

pot

CR2

1245678

HYGROSTAT WITH VOLT FREE CONTACTS (max. RESISTANCE OF EXTERNAL CONNECTION 100 Ohms.

Page 20

1.6.5 Sensing Head

The units are designed to operate using a sensing head, supplied by Vapac Humidity Control Ltd. which should be connected as shown below. Other

propriety sensing heads which give a DC signal may also be used, providing the control signal is connected to control terminals 5 & 6, and the sensing head is powered externally from the unit.

If “Frost Protection” is required do not connect the thermistor input from the sensing head to control terminals 1 & 2, which should be used to connect the “frost protection thermistor” (part number 1220275) instead. Frost protection is selected via the display – Set the frost demand above the minimum cylinder demand (LE units >20%; LE(P) & LE(C) units >8%)

Note:

Use of the 24V supply of the VAPANET unit to power other items of equipment will invalidate the Vapac warranty.

1.6.6 Security Circuit / E.P.O. Shutdown

As standard units are shipped such that terminals 9 & 10 are provided for connection of an E.P.O. (Emergency Power Off) switch or fire shutdown facility. Other control interlocks, such as high limit humidistat, airflow switch and/or fan interlock and time switches etc. should be connected to terminals 11 &

12. Please note that if a display is connected to

the unit “DI1 Control Option” must be set to “Shutdown”.

NB breaking terminals 9 & 10 will prevent any unit operation including frost protection.

1.6.7 Load Shed Option

This can only be evoked via a display, either “hard wired” or hand held. When this option is selected, making the connection between terminals 11 & 12 will activate the “load shed” software routine, which will inhibit the operation of either the unit or in the case of twin cylinder units unit or just the 2nd cylinder. This will limit the power used during peak supply periods. If this option is selected, the fan interlock, airflow switch and/or high limit hygrostat should be wired into terminals 9 & 10 with the EPO switch if fitted (as per the drawing on the far right). It should be noted that selection of this option will mean that frost protection cannot be utilized.

Please note that if a display is connected to the unit “DI1 Control Option” must be set to the following: Single cylinder units: “Load shed”. Twin cylinder units: either “Load Shed Cyl 2” or “Load Shed Both”.

125

CN2

NC(b)

G(B)

1 3

Vt(A)

Vapac’s accessory kit part numbers for sensors are Remote Room mounted sensing head FVKIT-107 - 1 And Remote Duct mounted sensing head FVKIT-108 - 1

Standard Operation Load Shed Operation

678

121011

E.P.O. Fire Stop

Fan Interlock

Air Flow Switch

High Limit Hygrostat

9871110

CN1

1 Vi G Vh G

124

E.P.O. Fire Stop

Fan Interlock

Air Flow Switch

High Limit Hygrostat

111012

Load Shed

Page 21

NB. The total cable length of the network (using the cable recommended by V.H.C.L.

– Our part

“system” (including the “master”).

configured].

1.6.8 Master/Slave System

For larger duties, VAPANET “Electrode boiler” units can be interconnected and arranged to operate from one proportional signal as a Master/Slave system. The system allows up to 10 cylinders to be linked in this way. The slave units will all be “on / off” units. The master unit, to which the proportional signal is connected, can be “on / off” but will preferably be a “proportional” unit. To “configure” a system, ensure that the control signal is zero [disconnect the control signal, or switch the units off at the front panel switch]. Press and hold the service pin on the master control PCB, until the user LED’s flash amber, release and check that the LEDs flash red/amber/green, if not repeat the procedure. Then press the service pin (network button) on each of the slave control PCB’s in the order that they are required to operate, the slave user LED1 will flash Green/amber until it is configured, once the light goes out [or flashes red/off], proceed to the next slave. If units of different capacity are used, ensure that the master is equal to or greater than the capacity of the slaves, and that the largest capacity slaves come on before the smaller capacity units]. Once this process is complete, confirm the fact by pressing the service pin on the master PCB until user LED2 goes green [this step is not necessary if all nine slave cylinders are

number 8040251) is 500 m and it should be assumed that there is 1 m of cable in each unit of the

USER LED 2



Network LED Network Button

USER LED 1



CR1

CR2

FRONT VIEW OF 1150630 BOARD

CR4

UCP1 configuration resistor

CR2

CR4

Vapac part no 1150631

9/24V ac Supply

40K 48K

Network Coms, LED

CR1

CR12

Display & Keypad

Net

CR1

Network Button

CR4

UCP1 configuration resistor

CR2

(Optional)

Vapac

xxxxxx xxxxxx xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxx xxxxxxxxxxxxxxxxxxxxxxxxx

Esc





If unit is not fitted with a display then UCP1 configuration resistor is fitted on configuration board 1150634 which is plugged into CR4 on the master unit.

PCB for "Master" or "Slave" unit with display.

J1 see section 1.9.1 Link if control signal is mA current only.

NetCR7

A B A B

CR5

CR6

Vapac PART No. 1150630

Customers terminals within unit

located on low voltage rail

CR3

Remote Indications CR6 gives the following remote indications as Volt-free contacts: Terminal 547 - Unit Run (normally open) Terminal 546 - Unit Run (normally closed) Terminal 545 - Unit Run (Common) Terminal 544 - Unit Alarm (normally open) Terminal 543 - Unit Alarm (normally closed) Terminal 542 - Unit Alarm (Common)

Connection to

PCB for "Slave 1" to "Slave 9" units.

Display if fitted

J1 see section 1.9.1

J1 see section 1.9.1 Not required forNot required for slave unit.slave unit.

NetCR7

CR6

CR5

Vapac PART No. 1150630

Network Expansion to slave units 2 to 9 or other network components.

CR3

Page 22

2.0 Start-Up / Operation

2.0.1 Start-up check list

a) Water supply and Drain Connections:

these should be connected as indicated under Plumbing and in accordance with the relevant local regulations. An isolation valve should be adjacent to the unit. The connecting metal plumbing must be grounded close to the unit.

b) Steam Line: This must be connected

according to the installation instructions with adequate slope and support.

c) Power supply: Wiring to the Vapanet unit

Should be by a qualified electrician and comply with the relevant regulations using appropriately sized cable and cable glands, with disconnect and fuses to suit the maximum fuse rating of the unit at the supply Voltage. The disconnect/fuses should be adjacent to the unit or within easy reach and readily accessible.

d) Control Connections: Ensure the control

signal and security circuit are correctly connected according to the relevant instructions/diagrams.

e) VAPANET 24v / 9V Control Circuit

Transformer: The standard 24V transformer used in the units has primary winding for 200V, 220/240V, 380V, 415V, & 440v 50/60Hz connection derived from the local electrical supply. Note: 60Hz connection must be specified with order as 230V 60Hz pump is required.

f) The maximum output & kW rating of the unit

is determined by a Current Set Plug. It is therefore possible to down rate units to any output, down to approximately 50% of the full rated output.

g) Unit Configuration Plug (U.C.P.). Sets the

maximum current level for the unit. It is fitted directly onto the control P.C.B. If a display is fitted, it is the only resistor required to be fitted to the control P.C.B.. However if no display is present additional resistors need to be fitted, to provide the microprocessor with information relating to the control signal etc. For ease these are fitted to a small PCB fitted to CR4 of the PCB, and resistor selection is via shorting links, see control signal selection on page 13. If insufficient information is available the unit will remain in the “not_config” state (see “Used LED” on page 19) until the information is supplied. This additional information is provided via the keypad – when the display is fitted.

2.0.2 Start-Up Instructions

First check: a) That the transformer connection matches

supply Voltage.

b) That the security circuit is closed for unit

operation.

Close the electrical access panel. Turn on the water supply to the unit. Close disconnect/circuit breaker feeding supply to the unit. Close the On/Off switch. The display (if fitted) will now show the Set-Up procedure.

Follow the procedure by:

- selecting: the preferred language,

- Attaching the control PCB to the Display.

- nominating: the type/quality of the supply water.

- nominating: the control signal (or Vapac sensor when being used).

When the control signal has been nominated, the SetUp will be entered into the memory. The Set-Up can then be checked by reading the information menu. If an error has been made, it will be necessary to go back to the Set-up menu. If no display is fitted the information is set using the jumpers on the small resistor PCB 1150634, fitted to CR4 of the control PCB.

2.0.3 Commissioning/Start-Up

Once the Set-Up procedure has been completed, the unit is available to operate according to the requirements of the control signal. When starting with an empty cylinder, the VAPANET programme switches in the contactor and feeds water in until the water reaches the electrodes, and current starts to flow. Thereafter the VAPANET system will continuously monitor and control the conductivity by adjusting the amount of water drained and fed into the cylinder. With no demand the LE unit has the right hand light will flash red the left hand light will be off. When the demand increases or the unit is switched on the cyl 1 LED will flashing green Amber at rate depending on the demand input and the actual current drawn, the actual run current of each cylinder is monitored and until the actual current has two feed above 95 % the LED will flash green amber when the current is above 95% for two consecutive feed the light will flash red. If twin cylinder unit the second cylinder starts in the same way but only when the demand is above 50% to unit

2.0.4 Features of VAPANET Electode

Boiler Unit

The VAPANET system of control is designed to adjust the function to keep the unit operating in the face of changing water quality in the cylinder and changing electrode condition even if, in an adverse operational circumstance, this results in some reduction in output while the situation exists.

Foaming protection *

In particular, the VAPANET is designed to prevent the onset of foaming and to introduce corrective drainage to keep the unit working.

Automatic switch-off

The VAPANET PCB will stop operating in response to extreme fault conditions identified as: Drain Fault STOP (no drain function) Feed Fault STOP (water not reaching cylinder) In each case, the display will show the STOP condition and a Help Message, the User LED’s on the fascia will indicate the condition see table on page 16. A warning signal will be available for remote indication. The STOP condition of a VAPANET PCB will be cleared via the key pad if a display is fitted or by pressing the reset button on the fascia – then switching the unit off and on.

ONLY BE TAKEN ONCE THE CAUSE OF THE PROBLEM HAS BEEN ASCERTAINED AND RECTIFIED.

THIS ACTION SHOULD

Page 23

Size 4 (6 electrode)

2.1

Service Advice

The water hardness and the humidity demand at site will determine the effective life of a steam cylinder. Units located in areas with naturally soft waters will experience the longer cylinder life, possibly upwards of 12 months in calendar terms. With hard waters, a more frequent cylinder exchange must be expected and cylinder exchange 2 or 3 times a year can be the average situation. The normal scaling up of the Vapac steam cylinder is outside the Vapac warranty.

2.1.1 Procedure for cylinder Exchange.

With the power connected to the unit, manually drain the unit, by depressing (and holding) the Run/Off/Drain Switch to the lower momentary drain position.

Disconnect the Vapac from the incoming electrical supply by means of the external isolator (disconnect switch). This should be “locked off” to prevent accidental operation.

Unlock the access panel, and swing open to gain access to the steam cylinder.

Carefully ease off (lever) the electrode caps (1& 2). If the cylinder is to be replaced, care should be taken not to twist the electrode caps while removing the black power caps. As the electrodes can rotate in the cylinder bosses (if the plastic cylinder is hot) and lead to unbalanced electrical loads.

Loosen the hose clip (1) and disconnect the steam hose (4) from the top of the cylinder.

Using a twisting movement, lift the cylinder clear of its seating in the feed/drain manifold and carefully remove the used cylinder from the unit.

Inspect the feed/drain manifold to ensure to ensure this is clear of sediment.

The drain pump can be removed for inspection and cleaning, by following the instructions below.

With the pump back in position, insert the cylinder into the feed/drain manifold, pushing it down firmly to ensure it is seated correctly.

10.

Reconnect the steam hose.

11.

Replace the electrode caps – ensure that they are replaced in the same sequence as when removed. With the cylinder full pin towards the front of the unit, electrode number 1 will be to the left of the white cylinder full electrode. Electrodes 2, 3, 4 etc will be sequentially connected clockwise around the cylinder (from number 1), when viewed from above. The cables carry colour-coded sleeves to indicate the phase and when connected correctly should follow the following sequence. Red/Yellow/Blue/Red/Yellow/Blue when viewed clockwise from the top. (NB The colour sequence for two electrode cylinders will be Red/Blue.

12.

The connections to the cylinder should be routed in as close as possible to their original route.

2.1.2 Typical Cylinder / Electrode Layouts

Component Identification

Fig 1

Size 4 (3 electrode)

Full Pin

Size 1 / 2 (2 electrode)

Full Pin

Size 3 (3 electrode)

See technical data for cylinder size fitted to your unit

Page 24

The pump is a sealed unit and should

removal / replacement are as follows

Steam and Condensate Hoses

Other Maintenance:

• Should only be carried out by a qualified

electrician.

• The steam cylinder should be drained prior to

carrying out any maintenance in the steam section – This must be done prior to isolating the electrical supply, i.e. before removing the front access panel.

• The unit should be isolated from the electrical

supply before any cover or access panel is removed.

2.2 Service and Maintenance

As the operation of the Vapac is entirely automatic, it normally requires no attention on a day-to-day basis. General cleaning and maintenance of the component parts of the Vapac are recommended at intervals of about one year, but this is largely dependent upon the frequency of its use and the quality of the water supply. Where the Vapac is part of an air-conditioning system being serviced regularly, the Vapac should be inspected at the same time.

2.2.1 Feed Valve with Strainer

The nylon bodied solenoid valve incorporates a small nylon strainer which is a push fit in the 3/4" inlet of the valve. With a new plumbing installation, residual loose solid material in the pipework could partially block the strainer after start-up. If for this or any other reason a restriction of the water flow is suspected (outside of supply pressure considerations), it would be possible to clean the strainer as follows:Turn off the water supply to the Unit. Undo the nylon nut connecting the flexible connection to the valve inlet . The strainer can be removed using ‘long-nosed’ pliers to grip the centre flange provided on the strainer for this purpose. Withdraw the strainer. Wash and replace it. Reconnect and turn on water supply. Reconnect electrical supply to allow unit to operate.

Note: Always replace the strainer after cleaning as it is required to prevent material lodging in the valve seat or blocking the small flow control restrictor which is fitted in the valve.

Valve with flow

Strainer

restrictor

3/4 Nylon nut with washer as

part of flexible connector

2.2.2 Drain Pump

not be dismantled. Instructions for

1) Place a bucket below the

pump, to catch any water remaining in the housing or pipework.

2) Remove the two screws

holding the pump cover & lift clear.

3) Undo the three screws

holding the pump body to the feed & drain manifold, and remove it - any water trapped in the pump will be released at this point.

4) Fit the replacement pump by

following the above steps in reverse order. Ensuring that the O-ring surrounding the impeller Housing is correctly seated, and That it mates correctly with the Feed / drain manifold.

The hoses used with and in the Vapac should be inspected at the normal service visits as part of normal maintenance. At the first signs of deterioration, a hose should be removed and replaced.

Page 25

3.0 Location of Indicators and Controls

3.1 Positioning of Indicators and controls on Vapac ® Vapanet ® LE Units.

Vapac

Reset Button

Vapac

Esc

Alpha-Numeric Display

User LED's

Power Available Neon

Cylinder 1 On/Off/Drain Switch

Cylinder 2 On/Off/Drain Switch

Network LED (Red)

Network Button (Service Pin)

Power Available Neon

User LED's

1 21 2

Cylinder 1 On/Off/Drain Switch

Cylinder 2 On/Off/Drain Switch

Network LED (Red)

Network Button (Service Pin)

Page 26

UCP1 valid.

3.2 Initial Set-up

User LEDs

During the initialisation process the User LEDs can be in one of the following states

User LED State Description

RED Flashing

2 second period

RED/AMBER Flashing

2 second period

RED/GREEN Flashing

2 second period

User LED 1 -

RED/AMBER/GREEN User LED 2 – OFF

User LED 1 & LED 2 -

RED/AMBER/GREEN

Unit initialising. If remains in this state, then unit does not a valid UCP1 fitted.

For units fitted with a display, the unit requires factory set-up (Number of Electrodes and Number of Turns)

For units fitted with a configuration board, the UCP2 and/or UCP3 are not being detected.

UCP1 valid.

For units fitted with a display, the unit requires site set-up.

This state does not occur if the unit is fitted with a configuration board.

Unit in configuration set-up mode, as instructed from the attached display node.

Invalid configuration. The combination of UCP1 & UCP2 or UCP1 and the number of turns is not valid.

Prior to the start of the initialisation process, the LEDs will flash Green, Red,

Amber repeatedly for 10 seconds to check that the LEDs are operation

correctly.

Remedy:

1 Check that UCP1 is fitted to plug fitted to CR4 pins 7 & 8 for units with Alpha-numeric

display or fitted to configuration PCB part number 1150634, which is fitted to CR4 if no display is fitted. See page 16 of manual for more details. Ensure that good electrical contact is made in each case.

a) For units without a display, check that UCP2 is fitted to the configuration PCB (see page

16 of the “Installation, Operation & Maintenance Manual”) and that jumper J2 is set to “electro boiler” and J1 is set for the correct site control signal.

b) For units with a display, select “factory set-up”, logon using password “2121” and enter the

number of power electrodes and number of times the electrode cable passes through the current sensing transformer (this information can be found in section 1.5 of the manual and drawing LZD557 sheet 3 of 3).

replaced as a new unit will be sent out with the factory set-up pre-installed.

Please note that this will only be necessary if the PCB is

3 For units with a display: Enter “Set-up unit”, enter the “control signal” type and “site

voltage”, see Alpha-numeric display module operating manual..

4 For units with a display: Once the unit has been “set-up” press ok at the prompt “Apply

changes are you sure *?*” when the unit will exit this state.

5 For units with an Alpha-numeric display: Re-enter “Factory set-up” using password

“2121” and re-enter the correct “number of power electrodes” and “number of turns”

information, following the on screen prompts For units without a display: Check that UCP1 & UCP2 are securely fitted to the configuration PCB.

Page 27

3.3 Normal Run / Standby / Start-up – No User Intervention Required

Once the unit has initialised User LED 1 refers to cylinder 1, while User LED 2 refers to Cylinder 2. For combinations of LED 1 and LED 2 being off, RED or RED Flashing refer to following table.

User LED 1 User LED 2 Description

Cylinder 1 and Cylinder 2 (if fitted) in shutdown.

1 OFF OFF

2 OFF

Green Amber Flashing Variable

RED Flashing Variable Period or ON

4 Any

RED Flashing 1 second period

OFF

Green Amber RED

The above are purely indications of the current state of the unit, and require no action from the operator. When the state changes the indication will automatically change.

Or Cylinder 1 in standby and Cylinder 2 in shutdown.

Cylinder 1 and Cylinder 2 (if fitted) in standby

Cylinder 1 Startup. Cylinder 2 (if fitted) in standby.

Cylinder 1 Online. Cylinder 2 (if fitted) in standby

The variable period is determined by the demand signal for cylinder 1 as follows,

Cylinder 1 demand LED ON RED LED OFF

<12.5% 0.5 seconds 3.5 seconds <25% 1.0 seconds 3.0 seconds <37.5% 1.5 seconds 2.5 seconds <50% 2.0 seconds 2.0 seconds <62.5% 2.5 seconds 1.5 seconds <75% 3.0 seconds 1.0 seconds <87.5% 3.5 seconds 0.5 seconds >=87.5% ON RED Continually

Cylinder 2 Start-up Cylinder 2 Online

Page 28

3.4 Fault / Service Indications – Requiring Operator Intervention.

User LED State Description

1 AMBER Drain Fault

AMBER Flashing

1 second period

AMBER Flashing

2 second period

GREEN Flashing

1 second period

Feed Fault

Over current Fault

Service Interval expired or low output.

GREEN Flashing

2 second period

6 GREEN Periodic Drain/Periodic Flush/Manual Drain completed.

RED/AMBER

1 second period

AMBER/OFF/AMBER/OFF

/GREEN/OFF

Periodic Flush/Periodic Drain/Manual Drain/Auto Flush in progress

Constant Output Active/Full Output via UCP3 (Master cylinder only)

No Voltage input

1, 2 & 3 Fault stop: Once the problem has been cleared the fault can be re-set by one of the

following procedures. i) Units fitted with an Alpha-numeric display: Power the unit right off, using the local isolator (not the unit on/off switch), waiting ten seconds then re-applying power. When the message “Cylinder x drain fault” is once again displayed press the o.k. button, and the unit will revert back to it’s operational state. ii) Units not fitted with a display: Power the unit right off, using the local isolator (not the unit on/off switch), waiting ten seconds then re-applying power. When the constant amber “drain fault” indication is showing, press the unit “fault reset” button, which is located on the fascia above the “Vapac” Logo.

4 Service Interval Expired / Low Output: Will be seen if either of the following occur.

a) Service Interval Expired: Seen if the unit has run for a period exceeding the service

interval of 4500 hours.

b) Low output: Seen if the cylinder has failed to reach 80% of the demand current after 30

hours run, or if the cylinder achieves this, then the current is monitored and an alarm generated if the current subsequently falls to less than 60% of the demand current for period of 4 hours run time.

If this indication is seen the cylinder should be inspected as soon as possible

If it is not convenient to carry out this inspection immediately it is possible to postpone it for a short time.

3.4.1 To Postpone the Sevice:

Press the reset button once: The appropriate cylinder LED will change to constant “amber” and the external alarm will be reset, allowing the unit to continue to run without an external alarm.

a) Service Interval Expired: If the original alarm was due to this, the alarm will

be reinstated after the unit has run for a further 120 hours.

b) Low output: If the original alarm was due to this, the low output timer will be

reset and a new alarm will be generated if the unit fails to exceed 60% of the demand current after a further four hours run time.

Page 29

When the alarm is repeated, it should be serviced immediately – and not postponed further.

3.4.2 To Service the unit:

Press the reset button:

This will cause the appropriate LED to change to constant “amber”, the external alarm to be reset.

Press the service button again:

(this should be within ten seconds of the first push).

This will cause a manual drain to be implemented. Once the drain is complete,

Isolate the electrical supply: Inspect the cylinder: As described in the maintenance section of the operating and

maintenance manual. Clean/Replace the cylinder: As described in the maintenance section of the operating and maintenance manual.

Power up the unit: Press the reset button:

This will cause the appropriate cylinder LED will change to constant “amber” and the external alarm will be reset, allowing the unit to continue to run without an external alarm.

a) Service Interval Expired: If the original alarm was due to this, the alarm will be reinstated after the unit has run for a further 120 hours. b) Low output: If the original alarm was due to this, the low output timer will be reset and a new alarm will be generated if the unit fails to exceed 60% of the demand current after a further four hours run time.

Press the reset button again:

(this should be within ten seconds of the first push).

This will reset all the relevant timers including the hours run timer.

NB if the button is not pressed a second time then the alarm will only be postponed, and will quickly return.

5 Event in Progress: This is a transitional state while the unit is actually performing a

particular routine. The LED indication is for information only and requires no user intervention.

6 Event Completed: If one of the above conditions have been implemented, when it has been

completed, the unit by default will continue to run, however it is possible to change this to “stop” (via a display either fitted or hand held) if this is the case this condition will be exhibited, and the unit will not run until the condition has been reset, by either: i) Units fitted with an Alpha-numeric display: Power the unit right off, using the local isolator (not the unit on/off switch), waiting ten seconds then re-applying power. When the message “event complete” is once again displayed press the o.k. button, and the unit will revert back to it’s operational state. ii) Units not fitted with a display: Power the unit right off, using the local isolator (not the unit on/off switch), waiting ten seconds then re-applying power. When the constant green “event complete” indication is showing, press the unit “fault reset” button.

7 Constant output:

i) Units fitted with an Alpha-numeric display: This is another transitional state, and once the “constant output period” has expired, the unit will revert to normal “controlled” operation. The LED indication will automatically revert to the cylinder’s “current state”. ii) Units not fitted with a display: Once the testing of the unit is complete, the jumper J1 on the configuration PCB should be removed from the full output position and returned to its normal operating position.

8 No voltage input: Check the wiring to CR6 of the “level sense” daughter board (part number

1150633). If the line voltage can be measured here, check the wiring between CR1 pins 5 & 6, of the same daughter board and CR2 pins 13 & 14 of the main control PCB. If this is also correct then either the daughter board or the main control PCB is faulty. Once the fault has been cleared the LED indications will revert back to the cylinders “current state”.

Page 30

3.5 Fascia Label symbols

Cylinder 1

/periodic Drain/Flush in progress

3.6 Other Options

All selectable via a display (either Hard Wired or Hand held)

Feed With Drain

Used to lower the temperature of the drain water.

Frost Protectiion

When this is activated the unit will operate, at a preset demand level, if the temperature surrounding the unit falls below a preset level, to prevent the pipework from freezing.

It is enabled by setting “frost demand” (via keypad/display) to >0 (it I disabled by setting “frost demand” to 0). However the unit will not operate unless “frost demand” is set above the unit minimum demand level. Minimum demand level for LE units is 21% and for LEP units it is 10%. Frost demand is fully adjustable between 0 & 50%.

Timed Drain down.

Used to drain all the water from the cylinder if the unit remains on standby for longer than a preset (but adjustable) time period.

For information on setting these options please see the display manual.

Network Button

(Service Pin)

User LED1

Red/Green/Amber

Unit Off

On-line

Standby

Drain Fault

Feed Fault

Over

Current

Service Interval

Service Routine/Manual

Periodic Drain/Flush completed

Service Routine/Manual

Constant Output Active/

Full Output via UCP3 (master

Expired

cylinder only).

1 2

Network LED (Red)

Cylinder 2

User LED2 Red/Amber/Green

Unit Off

On-line

Standby

Drain Fault

Feed Fault

Over

Current

Service Interval Expired

Service Routine/Manual /periodic Drain/Flush in progress

Service Routine/Manual Periodic Drain/Flush completed

Constant Output Active/ Full Output via UCP3 (master cylinder only).

(If fitted)

Page 31

4.0 Trouble-shooting Check List

Symptom

Check/Cause/Remedy

Possibilities

Checks

Possibilities

Checks

Possibilities

Checks

Preliminary:

Use manual drain option to check pump operation

Power-On Neon – Off Symbol-LED – Off Display - Blank

Power-On Neon – On Symbol-LED – On Display - Blank

Check main power is connected and switched on. Check power supply fuses.

Check if security circuit is open circuit Check 24V 3.15A fuse mounted at top of Microvap controller PCB 1150630

Automatic STOP – Feed Fault indicated on the Display.

Water is not connected Check water stop valve is open Water connected but not reaching cylinder. Check internal Vapac hose connections for a leak. Water in cylinder and overflowing.

Check float switch operation

Automatic Stop – Drain Fault indicated on the display.

Drain pump function impaired

Float switch failure Check float switch operation Cylinder O/Let Blocked Check & unblock

Unit On-Line but inadequate or no steam production

If pump will not function, empty cylinder by disconnecting at the tundish fill-cup the water supply hose to the cylinder and draining the water into a bucket. Remove, dismantle and clean pump.

Contactor not made Contactor coil, Float switches, Control PCB. MCB’s tripped Cylinder Inspection, inspect elements and float switch

operation.

SSR’s not switching

SSR Check as described below,

Specialized check of the Solid State Relay

Important: The following check should be carried out by a competent electrician

Equipment needed: An AC Voltmeter, multi-meter set to full AC line voltage or suitable voltage test instrument.

Procedure: 1) Remove access panels from both the steam cylinder and electrical compartments

2) Ensure that the humidifier has an operational level of water in the cylinder. Switch unit

on and check that the display indicates “Vapac on line”.

3) Apply the voltmeter, set to the full line Voltage, across the output terminals of the SSR being tested (i.e. the two terminals carrying the cabling to the elements).

Correct Voltmeter Response – oscillating between full and near zero Voltage.

If Voltmeter reads a constant near zero Volts, Check: a) That the unit is not feeding water – if it is, wait until the feed valve closes and then recheck. The reason for this is that the SSR will hold closed while the feed valve is open). b) That the control PCB is giving the correct pulsed D.C. signal (approx 5V D.C.) to the SSR control input terminals.

SSR Replacement: A faulty SSR should be replaced with an SSR of the same (or higher) Voltage and

amperage rating. Disconnect the unit from the electrical supply. Disconnect the SSR and undo the mounting screws. The SSR is bedded in thermal compound to assist heat transfer – it is important that this is cleaned off, and a layer of fresh compound placed under the replacement SSR, when it is secured in position. Reconnect the SSR, reconnect the electrical supply and check the SSR function (as above) before replacing the access panels.

Note: Use proprietary thread locking compound on the line voltage terminals of the SSR’s.

Page 32

5.0 Wiring diagram

Page 33

Page 34

34 35

Page 35

Page 36

36 37

Page 37

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Page 39

Page 40

40 41

Page 41

Page 42

Page 43

Vapac Humidity Control Ltd. Issue this as a guide

only, and accept no responsibility for

Appendix 1.

A Guide to Positioning Steam Pipes:

the positioning of any pipes in a system. This remains the responsibility of the Project Design Engineer.

min 20mm

AIR

FLOW

AIR

Key; 1 Insulated Steam Hose 2 Steam Distributor Pipe 3 Hose Clip

Condensate Separator.

FLOW

min 300mm

R = 250 minimum radius for 35 Ø pipe. R = 500 minimum

radius for 54 Ø pipe

FLOW

min 20mm

X = 60 minimum height

for a maximum negative pressure

-600 Pa.

Y = 220 minimum height for a maximum positive pressure 2000 Pa.

Fig 1

Notes:

1 Steam pipe to have a minimum slope from

the horizontal of 7° or 12% to allow the condensate to drain back to the cylinder or trap. NO HORIZONTAL RUNS. NO 90°

ELBOWS.

2 Water condensate tube to slope at 10° or

18% from the horizontal for condensate to drain back to drain point.

3 Steam pipes which are mounted

horizontally must discharge vertically upward.

4 Vertically mounted Steam pipes must

discharge horizontally facing upstream airflow.

min 20mm

5 If the total pressure within a duct air flow

exceeds 2000 Pa and the static is below 2000 Pa then the probe may face horizontally at right angles to the air stream.

6 Care should be taken to support steam

hose sufficiently such that no kinks are formed which would flood with condensate causing the bore of the tube to become constricted, leading to excessive pressure in the steam lines.

N.B Standard steam distribution pipes are manufactured such that any condensate is drained back towards the Vapac steam cylinder. Reverse slope pipes are available, and are fitted with a drain connector, to enable condensate to be taken away to a suitable drain.

Page 44

Figure 1

35 Ø 1 Steam Pipe 35 Ø 1 Steam Pipe 35 Ø 2 Steam Pipes

50% H

H > 300

H > 375

Fig 2

H < 300

30 min

H > 350

80 200 min

25%H

33% H

40% H

80 min. 200 min.

250 min.120 min.

H > 600

40% H

33% H

20% H

H > 400 < 600

30% H 60% H

200

54 Ø 1 Steam Pipe 54 Ø 2 Steam Pipes 54 Ø 2 Steam Pipes

shows the versatility of the steam

35 Ø or 54 Ø 1 Steam Pipe

50% W 50% W

W > 200

35 Ø or 54 Ø 2 Steam Pipes

25% 25%50%

W > 200

Fig 3

pipe / steam hose steam delivery system. It also indicates where and how condensate traps / condensate separators should be used. If the steam pipe slopes such that the steam connection is lower than the far end of the pipe, this indicates that a reverse slope steam pipe is required. This is fitted with a drain point to allow condensate to be taken away to a convenient drain.

Figure 2 shows recommendations on how to space one or more steam pipes in a horizontal duct.

Figure 3 shows recommendations on how steam pipes should be spaced in a vertical duct

Figure 4 shows mounting details for 35 and 54 Ø steam pipes

NB. The duct should be clear of obstructions, transformations and bends until the steam has been absorbed into the airflow. A guide to calculating this distance is available from Vapac – Part Number 0411047.

October 02

DUCT MOUNTING DETAIL For 35 Ø Steam Pipe

150

3 x 5.0 Ø

min 200

min 80

Fixing holes on 120 PCD.

DUCT MOUNTING DETAIL For 54 Ø Steam Pipe

170 PCD

min 250

150

min 120

120

150

Fig 4

4 x 6.4 Ø Fixing holes on 170 PCD.

Page 45

Appendix 2

A Guide to Positioning Multipipes:

Vapac Humidity Control Ltd. Issue this as a guide only, and accept no responsibility for the positioning of any pipes in a system. This remains the responsibility of the Project Design Engineer.

Notes:

1 Steam pipe to have a minimum slope from

the horizontal of 7° or 12% to allow the condensate to drain back to the cylinder or trap. NO HORIZONTAL RUNS. NO 90° ELBOWS.

2 Water condensate tube to slope at 10° or

18% from the horizontal for condensate to drain back to drain point. A suitably sized trap will be required to prevent steam from escaping via the condensate drain connection.

3 Care should be taken to support steam hose

sufficiently such that no kinks are formed which would flood with condensate causing the bore of the tube to become constricted, leading to excessive pressure in the steam lines.

4 The duct should be clear of obstructions,

transformations and bends until the steam has been absorbed into the airflow. Vapac Humidity Control Ltd. Suggest a figure of 1.5 times the estimated absorbtion distance stated on the “Multipipe” design sheet. Which is supplied with the quotation.

5 Should it be necessary to slope the steam

hose away from the Vapac Boiler, it will be necessary to fit a condensate separator to remove the condensate at the lowest point. This will need to be taken to a suitable drain.

Nov, 07

Page 46

Made in England by: Vapac Humidity Control Ltd.

Vapac Humidity Control Ltd. reserve the right to change the design or

specification of the equipment described in this manual without prior notice.

April 2014

Printed in Great Britain

0410270