Vapac VapaNet Series Bedienungsanleitung

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

2006/95/

EEC and the EMC

Directive

2004/108/

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

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

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

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

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 over-

humidification 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.

675.0

430.0

6.0265.055.0

6.0

140.0

285.0

74.0444.0

172.0203.0

204.0

70.0

203.0172.0

120.0

62.0

50.0

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.

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

1.1 Vapac LE unit dimensions

Cabinet Size 1.

Covering model references:

LE05 – All

LE09 – All

LE18

–

All

Left:

Top view of unit

showing steam outlet

position (35 mm spigot)

Below:

Rear view of unit

showing wall mounting

points.

Right:

View from beneath unit

showing the electrical gland

plate (approx 120mm x

120mm) with an entry hole

(approx 105mm x 90mm)

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.

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

186

360

520

810

Steam Outlet 54 mm

Gland Plate

120 X 120

305

330

305

299

73555

165

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

Cabinet Size 2.

Covering model references:

LE30 – All

LE45 – All

LE55

All

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.

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)

Left:

Top view of unit showing

steam outlet position

(54 mm spigot)

Below:

Rear view of unit showing

wall mounting points.

55 990

360

20.5"(520) 468

31.1"(790)

505

176

360

152

343

70 850

237

190

610

810

322

346

190

610

73555

F F

Steam Outlets

54 mm

Gland Plate

120 X 120

Gland Plate

120 X 120

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

Cabinet Size 4.

Covering model references:

LE60 – All

LE90 – All

LE110 – All

Left:

Top view of unit showing

steam outlet positions

(54 mm spigots)

Below:

Rear view of unit showing

wall mounting points.

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.

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)

Cabinet Sz 1 with RDU

Dimensions

L L

Cabinet

size 2 with

RDU

Dimensions

RDU 30 kg/h

A = 602mm

B = 205mm

RDU 45 kg/h

A = 842mm

B = 360mm

Clearance around LE Units

Unit L H

min

LE05 All

(No RDU) 85 1000 500 -

LE05 All

(With RDU) 85 1000 - 200

LE09 All

(No RDU) 85 1000 500 -

LE09 All

(With RDU) 85 1000 - 250

LE18 All

(No RDU) 85 1000 500 -

LE18 All

(With RDU) 85 1000 - 500

LE30 All

(No RDU) 85 1000 500 -

LE30 All

(With RDU) 100 1000 - 750

LE45/LE55

(No RDU) 85 1000 500 -

LE45/55

(With RDU) 200 1000 - 775

LE60 - 110 All (Twin

Cylinder No RDU) 85 1000 500 -

A minimum clear space of 1 m is required in

front of the unit for maintenance access

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

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

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-

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

Do obtain project engineer's instruction/drawing for

pipe position relative to the top & bottom of the

duct (or sides if airflow is vertical.

Do check if alternative slope of Ø35mm pipe has

been specified.

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

extra support.

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

or in heat resistant plastic pipe.

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 90

elbows in the

steam line.

Steam Distribution Pipe requirement

Electrode

Boiler Unit

Model

LE05(P)

LE09(P)

LE18(P)

LE30(P)

LE45(P)

LE55

LE60(P)

LE90(P)

LE110

35mm

∅

Pipe No.

54mm ∅.

Pipe No.

Duct

Pressure

Pa.

+2000

-600

+2000

-600

35mm

∅

Pipe Selection

54mm

∅

Pipe Selection

Duct width

B mm

In-duct Length

L mm

Duct width

B mm

In-duct Length

L mm

320-470

470-620

620-770

770-920

920-1070

1070-1200

300

450

600

750

900

1050

700-950

950-1450

1450+

(Kg)

650 (1.8)

900 (2.2)

1400 (3.2)

R min for 35

∅

Pipe = 250mm

R min for 54 ∅Pipe = 500mm

Flexible Steam

Pipe.

No Sags!

Distance to first

bend.

VAPAC

HUMIDIFIER

Flexible Steam

Pipe.

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.

35 or 54 mm

copper or

stainless steel

steam pipe with

Insulation.

Fig 6

For guidance on positioning of steam pipes see Appendix 1.

For guidance on use of Multipipes see Appendix 2.

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

LE05

LE09

LE18

LE30

LE45/LE55

LE60

LE90/LE110

LE05P

LE09P

LE18P

LE30P

LE45P

LE60P

LE90P

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.

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)

l/min Hz

16.8

17.2

60.

Do’s

Do use copper or plastic pipe rated for 110

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

Clips.

L 35∅copper or plastic Drain for 110°C

Water with supports.

M Tundish

N U-trap side exit.

S Optional Strainer

V Isolation stop cock

Single Cylinder Units 30-55 kg/h

Twin Cylinder units 60-110 kg/h

Fig 7

G S V

1.4 Electrical Connections

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

Control Cable / Security Circuit

Screening Arrangement

Tail to be kept short

(less than 50mm)

Cables to control terminals

Screen left intact

Outer insulation

Earthed back panel

Important Power Connection Information

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.

Note:

24 V a.c. Control circuit -

9 V a.c. PCB Circuit -

Transformer Primary Circuit -

And RDU.

230V ac Pump Supply. -

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.

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.

Electrical section metalwork

Metal conduit

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