HP Series. Installation and Operation Manual

Transcription

1 Important: Read and save these instructions. This guide to be left with equipment owner. HP Series Installation and Operation Manual Includes installation, operation maintenance and troubleshooting information for your HP Series humidifier C 05 JUL 2011

2 Thank you for choosing Nortec. INSTALLATION DATE (MM/DD/YYYY) MODEL # SERIAL SERIAL # CYLINDER CYLINDER # Proprietary Notice This document and the information disclosed herein are proprietary data of NORTEC HUMIDITY LTD. Neither this document nor the information contained herein shall be reproduced, used, or disclosed to others without the written authorization of NORTEC HUMIDITY LTD., except to the extent required for installation or maintenance of recipient s equipment. All references to the Nortec name should be taken as referring to NORTEC HUMIDITY LTD. Liability Notice Nortec does not accept any liability for installations of humidity equipment installed by unqualified personnel or the use of parts/components/equipment that are not authorized or approved by Nortec. Copyright Notice Copyright 2011, NORTEC HUMIDITY LTD. All rights reserved.

3 Contents 2 Introduction 2 About HP 2 Receiving and Unpacking Equipment 3 Absorption Distances 3 Components 6 Water Quality 6 Multiple Zones 8 Installation 8 Pre-Installation 10 Construction of a Wet Duct Section 11 Pump Module 11 Installing the Pump 14 Installation of the HP HVAC Manifolds 18 Installation of the Piping Between Valve Block and Manifolds 19 Check Valve 19 Installation of the Needle Valve 20 Installation of the Valve Block 22 High Pressure Piping 37 HP HVAC Start-up Checklist 38 Operation 39 Maintenance 42 Danfoss Stainless Steel Axial Piston Pump 42 Electrical Motor Service 43 Inlet Water Filters 43 High and Low Pressure Lines and Hoses 43 Atomization Nozzles 44 Mist Eliminator Maintenance 44 End of Season Shutdown 45 Decommissioning / Freeze Protecting 45 Inlet Water Pressure Switch 46 Troubleshooting 50 Spare Parts 60 Wiring & Installation Diagrams 22 Low Pressure Piping 22 Valve Controller Installation 23 Wiring of the System 25 Pump Controller Wiring Notes 27 Mist Eliminator Installation 34 Startup, Operation, and Maintenance 35 Commissioning and Startup

4 CAUTION: Servicing Disconnect main power before any servicing. The plumbing and electrical compartments contain high voltage components and wiring. Access should be limited to authorized personnel only. During and following operation of the humidifier, the steam and components in contact with the steam such as the blower pack, steam lines, steam distributors, and condensate lines can become hot and can burn if touched. Walter Meier does not accept any liability for installations of humidity equipment installed by unqualified personnel or the use of parts/components/equipment that are not authorized or approved by Walter Meier. CAUTION: Electrical All electrical work should be done according to local and national electrical code. Electrical connection to be performed by a licensed electrician. CAUTION: Plumbing Plumbing to be performed by a licensed plumber. Drain water from humidifier can be very hot. Do not drain to public sink. All plumbing work should be done according to local plumbing code. CAUTION: Installation Do not mount on hot surfaces. Do not mount in area where freezing can occur. Do not mount on vibrating surface. Do not mount on floor. LiveSteam produces steam at atmospheric pressure no devices which could block steam output should be connected to the steam outlet. Steam lines must be installed so that no restriction can produce backpressure in the humidifier. Regardless of selecting on/off or modulating control method, Nortec humidifiers must have a closed circuit across its on/off security loop control terminal to operate. Nortec highly recommends the use of a duct high limit humidistat. 1 HP Series Installation Manual

5 Introduction HP HVAC (Adiabatic Humidification System) Congratulations on the purchase of your NORTEC HP HVAC humidification system. This system was designed to be efficient and reliable, and is manufactured from high quality materials to provide long trouble free operation. In order for the system to operate as intended it must be installed properly. This guide details the design, installation, commissioning, operation, and troubleshooting of the HP HVAC system. Please take the time to familiarize yourself with this guide before beginning to ensure that the system is installed the way it was designed. This ensures a long and trouble free life of the humidifier. About HP (Adiabatic Humidification System) The HP (High Pressure) HVAC system is designed to be installed inside an AHU or duct system to humidify air to a desired relative humidity. Proper humidity levels have been shown to be important for health and comfort of occupants. Maintaining proper humidity is also important for many industrial and manufacturing processes. The HP system uses a series of nozzles to spray a very fine mist of water droplets into an air stream. During this process the air absorbs moisture increasing its relative humidity levels. As the water droplets evaporate, they absorb some energy in the form of heat from the air. This loss of heat causes the air temperature to drop, resulting in a phenomenon known as adiabatic cooling. The HP HVAC adiabatic system has 2 effects: The relative humidity of the air increases (humidification) The temperature of the air falls (adiabatic cooling) Humidification of the air is the main goal of the HP HVAC system. The cooling of the air is secondary and is frequently beneficial since it is free cooling. In cases where air-cooling is undesired, preheating of the air is required. In general a HP system has the following advantages over other humidification technologies: Low frequency of maintenance, since there are few moving or expendable parts. Replacing components is quick and requires minimal system disassembly. A free air-cooling benefit from water extracting latent heat from the air. Receiving and Unpacking Equipment Check packing slip to ensure ALL material has been delivered. All material shortages are to be reported to Nortec within 48 hours from receipt of goods. Nortec assumes no responsibility for any material shortages beyond this period. Inspect shipping boxes for damage and note on shipping waybill accordingly. HP Series Installation Manual 2

6 After unpacking, inspect equipment for damage and if damage is found, notify the shipper promptly. All Nortec products are shipped on an F.O.B. factory basis. Any and all damage, breakage or loss claims are to be made directly to the shipping company. Absorption Distances An important consideration in the planning of a HP HVAC system is the absorption distance, or the distance it takes for the droplets to evaporate inside the HVAC system. The absorption distance is relative to the air velocity, temperature, atmospheric pressure, and the amount of water in the incoming air. In applications where space is limited, such as in an air-handler, precautions should be taken to prevent the wetting of sensitive components downstream. Components Nortec Supplied Nortec will supply the following components: 1 High pressure pump skid 2 Valve controller 3 Valve block assembly 4 Nozzle manifolds 5 In-duct plumbing 6 Mist eliminator (optional) 7 Air proving switch (optional) 8 High limit humidistat (optional) 9 Humidistat (optional) 10 Reverse osmosis system (optional) Field Supplied The Installer is responsible for supplying the following: 1 Electrical disconnects 2 All electrical wiring 3 Piping from the RO system to pump module 4 High pressure piping between pump and manifolds 5 Flex hose 6 P-traps 7 Drain funnels 8 Wet duct section (drain pans, wall sections, sealants, fasteners) 9 Pump skid vibration dampening 10 Electricity, water, and airflow 3 HP Series Installation Manual

7 Figure 1: Typical Installation with Medium Pump HP Series Installation Manual 4

8 5 HP Series Installation Manual Figure 2: Typical Installation with Large Pump

9 Water Quality Water used with the HP HVAC system must be very pure. Dissolved solids, and impurities contained in the water will precipitate out when the water evaporates, causing dust and minerals to be deposited into ducts, and/or the humidified space. Dusting can have adverse effects on filters, fans, heating and cooling coils, human health, and may promote corrosion and bacteria growth in ducts. For this reason only Reverse Osmosis (RO) or De-Ionized (DI) water can be used with a HP HVAC humidification system. DI water is very aggressive, in applications where DI water is used all components (including wet section of ducting and drains) must be constructed from stainless steel. To ensure that the HP HVAC nozzles do not become blocked or damaged over time, the following conditions should also be met: Conductivity: 20 micromhos or less Ph: Multiple Zones Oftentimes a single pump package will be used to serve different ducts or zones. In this case each duct will have its own set of manifolds, valve controller and valve block making it fully independent of the other zones. The pump should be sized to handle the full flow capacity of all zones combined to ensure reliable operation. Care must be taken when laying out the piping between the pump and the valve blocks at each zone to prevent vibration transmission or water hammering effects. The piping should be securely supported using appropriate cushion clamps (by others) and long straight runs should be avoided. HP Series Installation Manual 6

10 Installation 7 HP Series Installation Manual

11 Pre-Installation Prior to beginning installation of the HP HVAC system, the required tools should be obtained, and all contractor-supplied parts (indicated as parts By Others throughout this manual) should be gathered. Required Tools In order to assemble an HP HVAC system the following tools and supplies are required: 1 Hammer 2 Socket Set, common imperial and sizes 3 Box-end wrenches various sizes 4 Pipe Bender 5 Screwdriver Set, including standard flathead and Phillips 6 Caulking 7 Caulking Gun 8 Metal Snips 9 Hacksaw 10 Plumbing Tape Required Components The following components must also be supplied to complete the installation: Electrical Disconnect Switches Disconnect switches must be supplied to isolate the humidifier for maintenance and in the case of emergency. If the control panel and disconnect is to be located outdoors, NEMA rated disconnect switches should be used per national and local codes. Sizing High Pressure Stainless Steel Tubing Stainless steel piping must be supplied for distances between the HP pump module and the HP manifolds. These distances should be kept to a minimum to minimize pressure losses and maximize system performance, however it is important to avoid over-sizing the lines. For most installations a 1/2 line is appropriate. Stainless Steel Pipe Fittings Stainless steel compression fittings are required for all high-pressure line connections. When using swage type fittings to connect feed lines together, use fittings of the same material as the feel lines. Never use a brass compression fitting on a stainless steel tube, as the brass will not properly hold the harder stainless steel pipe. Follow manufacturers instructions when installing fittings. Recommended tube material: 304L stainless steel tube, ½ Outside Diameter, Wall thickness Recommended fittings: 316 stainless steel, ½, double ferrule compression connections. HP Series Installation Manual 8

12 Reinforced Flexible Hose The HP pump module features a modern high precision pump. Despite this some degree of vibration is unavoidable when the system is operating. Vibration effects can be further amplified by long lengths of solid piping and can be transmitted over distances. To avoid this reinforced flexible hose is recommended between the pump outlet and the feed piping, as well as between the feed piping and the valve block. The lengths of reinforce flexible hose used at these points should be at least 2ft (61 cm). This will dampen vibrations transmitted from the pump and air-handler / ducting. Reinforced flexible hose should be selected to withstand pressures of 1200 psi or greater to provide a safety factor for any water hammer effects or pump over-pressurization. Care must be taken when using reinforced flexible hose. It must not be allowed to sag unduly, vibrate excessively, be bent around a radius of less than 2 (50 mm), or come into contact with sharp edges. Always leave some extra line when going around corners and making bends. Avoid twisting and kinking the lines while un-spooling and installing. When supporting the hose, keep in mind that thermoplastic hose has a tendency to return to position it was supplied in. Pipe Supports and Fasteners The installer must also supply support for feed piping. When selecting brackets, pipe strapping, and various other supports, ensure that local and national plumbing codes are followed. The use of heavy-duty vibration control clamps is strongly recommended. For long runs, ensure that there is no more than 5 feet between supports. Various fasteners may be required to complete the installation of the HP HVAC system. These should be sized to adequately support any anticipated loads. Follow local codes for installing pipe hangers and bolts. Recommended supports: Stauff Cushion Clamps or equivalent Primary Wiring for Pump Module Appropriate primary wiring is required for connection to the pumps. Refer to the specification labels on the pump and valve controllers for voltages and currents. Follow local and national codes for wiring. Vibration Isolation The pump skid will generate some degree of vibrations by its nature. It is recommended that the pump skid be installed on a vibration-damping mat or vibration isolators to reduce vibrations and noise. 9 HP Series Installation Manual

13 Construction of a Wet Duct Section General The section of ductwork that the HP HVAC manifolds are installed to be in needs to be capable of handling excess water that is not absorbed by the air. Nortec requires that a wet section be installed in the duct. The wet section should be as long as expected wetting distance. In most cases Nortec recommends the wet section extend 1.5 feet upstream and 6 feet downstream of the HP manifolds. A wet duct section consists of; a double walled plenum, drain pan, and drains. All material used in the wet section should be made of stainless steel. All seams should be sealed properly with caulking to prevent leaks. Double Walled Plenum A stainless steel liner should be secured to the existing wall. The objective of this is to cover any exposed insulation, seams, and any existing ducting materials that may not be corrosion resistant or suited for constant exposure to water. The liner should cover both sides and ceiling of the plenum. All seams should be caulked and sealed to prevent leakage. Drain Pan A stainless steel drain pan should be installed on the floor of the duct. This pan should slope downwards in the direction of airflow from the HP manifolds to end of the wet section. The drain pan should terminate with a drain connected to a P trap. The P trap should be at least 2 inches taller (center to center) that the duct static pressure, and should drain to an open funnel drain. For systems up to 750 lb/s per hour a 1 diameter drain should be used. For larger systems a 2 diameter drain, or multiple 1 diameter drains should be used. HP HVAC systems must NOT drain onto a roof. Building damage could result. Any drain lines routed outdoors must be insulated and heat traced to protect from freezing. Ensure that all traps are primed by filling them with water. Mist Elimination In some cases, the HP HVAC system will need to be installed in tight spaces or where water sensitive equipment is present a short distance downstream. In these cases a mist eliminator is required. The mist eliminator will be located immediately after the drain in the wet section. A second drain will be then installed immediately after the mist eliminator. Air Handler Installations In many cases the HP HVAC system is installed in an air handler upstream of the cooling coil. Many air handlers include a wet section around the cooling cool as a standard offering. These cooling coils also function as natural mist eliminators and thus an additional mist eliminator may not be required. Consult the air handler manufacturer for further information. HP Series Installation Manual 10

14 The above is not true for a heating coil; most heating coils are not designed to be wetted. If installing upstream of a heating coil a mist eliminator must be used. Pump Module The pump module location should be selected with the following guidelines in mind: Available Power: The pump should be located close to its supply power source. Available Water: The pump should be located close to its RO or DI water source. Proximity to Manifolds: The pump should be located as close as possible to the manifolds to minimize pressure losses in the lines. See Table 4 Piping Pressure Losses for more information. Available Drain: To prevent damage to other equipment in the event that the pump module should leak, it is recommended that the pump module be located near a floor drain. Proper Ventilation: The pump will generate heat during operation. Covered pump modules include cooling fans, while uncovered pump modules typically rely on natural airflow in the room for cooling. Ensure that the pump module is located in an area where it can receive a reasonable amount of airflow. Avoid installing other equipment on top of or in front of the pump module. Occupants: The pump will generate some noise and vibration during operation. The pump should be located somewhere in a place noise and vibrations will not disturb occupants of the building. Installing the pump module on vibration isolators is recommended to minimize vibrations. Optional pump covers are available for large pump skids to minimize noise. Installing the Pump Move the pump to the location selected and secure it to the floor. Confirm that primary power source matches the specification label on the pump. It is strongly recommended that the pump module have a dedicated power supply to prevent brownouts when the pump module starts. Install a manual disconnect switch for the pump module. Install connection to the reverse osmosis / de-ionized water supply. Ensure that supply water pressure from the RO or DI water system is at least 25 psi (1.7 bar) at the inlet to the pump skid. Never exceed 60 psig inlet pressure (Danfoss Stainless Steel Pump) or 90 psig (Giant Brass Pumps). The water system capacity must be a minimum of 120% of the humidification system capacity. Running the pump on any voltage other than what is listed on the spec label can serious equipment damage and may ignite a fire. 11 HP Series Installation Manual

15 Figure 3: Medium Pump Module Installation Drawing HP Series Installation Manual 12

16 13 HP Series Installation Manual Figure 4: Large Pump Module Installation Drawing

17 Only reverse osmosis or de-ionized water can be used with the HP HVAC system. Connect the primary electrical supply to the pump. Refer to the wiring diagram located in this manual. Installation of the HP HVAC Manifolds The HP HVAC system uses vertical manifolds with that spray into the airstream. These manifolds are supported at both the top and the bottom by horizontal mounting rails. Since each system is sized and built to a certain duct size, some test fitting will be necessary to properly install the rails. If a wet section has not yet been constructed in the duct or air-handler, it should be constructed before the humidifier installation has started. If the duct is greater than 8 feet in width, install mounting rail extensions (P/N ) onto the mounting rails. Assemble all vibration clamps on the mounting rails as detailed in the following figure. There should be an equal number of clamps on both of the supplied mounting rails. Leave the clamps loosely installed for now, to allow for movement and the installation of the HP manifolds. Figure 5: Vibration Clamps Securely fasten the gusset to vibration pad and duct walls with the supplied screws. (2 screws per gusset). Figure 6: Gusset HP Series Installation Manual 14

18 Secure the mounting rails to the gussets using the supplied fasteners. (1 3 fasteners per gusset). Figure 7: Mounting Rail Installation Install the manifolds onto the mounting rails using the previously installed mounting rail clamps. The manifolds should be equally spaced in the duct. There should be at least 6 from the top of the duct to the mounting rails. Mounting rails should be installed on the upstream side of the manifolds. 15 HP Series Installation Manual Figure 8: Rail and Clamp

19 Install the air break end caps onto the one end of the HP manifolds. Figure 9: Endcap Install the manifold fittings to the bottom end of the HP manifolds. Figure 10: HP HVAC Manifold and Plumbing Installation HP Series Installation Manual 16

20 4 Min 4 Min 4 Min 4 Min 6 Min ZO NE VALVE ASSEM BLY Figure 11: Manifold Minimum Spacing 6 Min Figure 12: Nozzle Aiming 17 HP Series Installation Manual

21 Installation of the Piping Between Valve Block and Manifolds The valve block should be located in such a way as to feed the manifolds using the supplied piping and fittings. Refer to the piping diagram for your specific unit (On/Off, 3 Stage, 6 Stage). For High-Resolution HP HVAC installations, refer to the piping diagram included in the documentation package from proper piping. It is helpful to place the valve block in its approximate location to assist with measuring piping lengths and placing fittings. The valve block can be installed in the duct or outside of the duct. The piping between the valve block and the manifolds should have a slight decline towards the valve blocks. This allows for water to drain from the manifolds and lines when the system is not in use. In installations where water hammer is of concern, it is recommended to install some flexible piping between the valve block and the manifold feed lines. Using flexible feed lines between the valve block and the manifold supply piping can also simplify the installation procedure and allow for some misalignment among the manifold feed lines and the valve block. The valves are threaded to accept ½ G fittings. A qualified plumber should install all pipe-fittings and perform connections. To Manifolds In Duct (3/8" OD SS Tube) Check valve ( ) RO or DI Water psig Pump Skid ½ OD SS Tube Needle Valve ( ) Valve Block Funnel drain with air gap Figure 13: Hydraulic Schematic for HP Systems It is strongly recommended to flush all lines with clean with clean water prior to installation. This prevents any accumulated dirt, loose flash, or metal fillings from degrading nozzle performance. HP Series Installation Manual 18

22 Check Valve Install check valve as close to pump as possible Ensure that arrow matches direction of flow. Tighten compression fittings. 3.1 in. ( 78 mm ) O 0.5 in. ( 13 mm ) 0.9 in. ( 23 mm ) 1.0 in. ( 24 mm ) Figure 14: P/N Check Valve Installation of the Needle Valve Connection Type - ½ compression fittings on the inlet and outlet. Install near inlet to valve block. 19 HP Series Installation Manual

23 Installation of the Valve Block Please refer to the valve block schematics for your specific unit in the Wiring Diagram Section for clarification of the below instructions. For High-Resolution systems, please refer to the schematics that were included in the documentation package. Securely fasten the valve block in place. The valve block can either be installed inside or outside of the duct, however installing in-duct reduces the quantity of holes which must be drilled through the duct. The valves have threaded connections with a ½ G thread. Connect the high-pressure supply line from the pump to the valve block inlet. It is recommended to use a 2 foot flexible hose connection between the pump supply line and soft charge valve block. This flexible line prevents the transmission of vibrations through piping. If the pump is only a short distance away it is recommended to use high pressure flexible hose for the entire run. Vibrations can be transmitted from air-handlers, the HP pump modules, or other mechanical room equipment, it is strongly recommended to use a 2 ft (0.6 m) length of flexible piping at the valve blocks, and HP pump module to protect the equipment from damage. Install drain piping on the valve block. When the manifolds are not in use, they are drained to prevent stagnant water, which can lead to microbial growth. The volume of water drained is equal to the volume of the manifolds and their supply lines. The drain line can be solid pipe or flexible hose for convenience. It must flow to an open-air funnel or nearby floor drain. The water can also be reclaimed and returned to the RO system for processing. The drain line must flow to an open-air funnel. Solid connection to a drain can result in backflow, failure to drain, and dripping nozzles. HP Series Installation Manual 20

24 21 HP Series Installation Manual Figure 15: Typical Valve Block Assembly

25 High Pressure Piping Install high pressure piping between the valve blocks and the HP pump module. The valve blocks are threaded to accept ½ G fittings. For short runs, it is recommended to install flexible piping for this purpose. For longer runs use flexible piping at the pump outlet and valve inlet to minimize vibration transmission. Ensure that flexible piping is rated for pressure and water type in the application. Flush piping prior to installation to clear any debris. Debris will inhibit nozzle operation. Low Pressure Piping Low-pressure piping should be connected to the inlet of the pump. Ensure that water inlet pressure is between 20 and 100 psig. The pump inlet accepts a 3/4 NPT threaded connection. The low-pressure inlet connection can be a flexible hose or a stainless steel pipe. Stainless steel pipe is recommended for longer runs of piping, while flexible hose is recommended for shorter runs. If stainless lines are used, it is recommended to install a length of flexible hose between the metal piping and the pump inlet to minimize vibration transmission. Flush low pressure piping with water prior to installation to clear any debris. A drain line for the pump must also be connected; this line should connect flow to an open-air funnel or floor drain to prevent backpressure on the pump. Water can also be reclaimed and returned to the RO or DI system for processing. The pump drain port is threaded to accept a ¼ NPT connection. Valve Controller Installation The valve controller should be located near the pump and valve blocks. Refer to schematics for valve controller dimensions. Using suitable screws, mount the control panel at a convenient height on a wall or suitable structure. Refer to the spec label on the valve controller; ensure that the voltage matches the electrical voltage being supplied to it. In most cases this voltage will be 120VAC 60Hz single phase. At this voltage, the controller draws 2.7A (except high resolution systems). Install a dedicated disconnect on the electricity source to allow the controller to be isolated. HP Series Installation Manual 22

26 Leave the disconnect in an open (off) position until all wiring has been completed Connect the input voltage to the valve controller. Input voltage connections are clearly indicated by labels inside of the valve controller box. Wiring of the System On-Off Safety Devices Safety switches are available to prevent the humidifier from operating excessively or at incorrect times. These may include; air proving switches (A), duct high limit switches (B), disable switches (C), other on-off type devices. Install these devices in accordance with their respective installation instructions. All on-off style devices should be wired in series and connected between terminals 1 and 2 on the valve controller terminal strip. The circuit between terminals 1 and 2 is a 24VDC circuit, 16 or 18 AWG standard wire should be used for this purpose. The humidifier will only operate if there is continuity between terminals 1 and 2. If no on/off style safeties are to be used, install a jumper between terminals 1 and HP Series Installation Manual

27 Figure 16: HP HVAC Terminal Strip Installation Notes Connect wiring as shown. Use 16 or 18 AWG standard wire. For multiple On/Off safeties, connect devices in series. Valve 2 and 3 connections not used for single stage systems. Flush valve is always connected to valve controller terminals 13 (+) and 14 (-) Pump controller terminal 9 (GND) is an available accessory ground. Single Stage Control Options Time proportioning control: Connect a 0-10 humidistat to valve terminals 3 and 4. On/Off Control: Connect a humidistat between valve controller terminals 1 and 2. Also connect a jumper between terminals 1 and 3. HP Series Installation Manual 24

28 Pump Controller Wiring Notes Connections to Nortec Valve Controller The pump controller can accept control input from many different valve controllers at once. This is useful for cases when a single large pump skid is used to supply high-pressure water to different zones / manifold groups. For example, 1 large pump skid supplies water to 3 different air-handlers, each with their own manifolds, valves, and valve controller. If there are more than 4 valve controllers, additional controllers can be added by doubling up wires on the pump controller terminal strip. For example; valve controller 5 would share terminals 1 and 5 with valve controller 1. Connections to Valve Controllers by Others Non-Nortec valve controllers can be used with the HP HVAC system. In these cases the valve controller is wired to the pump controller, as it would be with a Nortec valve controller. The valve controller need only close the loop, and does not need to provide a voltage or current. If the valve controller does provide a signal, it should be wired to a relay which will then close the pump controller loop. Remote Monitoring The pump controller terminal strip features several sets of dry contacts to allow for connections to a building management system, status lights, or other types of equipment. They are controlled by a relay and activated under certain conditions. Wire gauge is determined by the equipment to be using the contacts. Refer to the manufacturers recommendations. On (Terminals 10 and 11): Closed when the HP HVAC system is powered on and ready. Active (Terminals 12 and 13): Closed when the HP HVAC system is humidifying. Service (Terminals 14 and 15): Closed when the HP HVAC system requires regular maintenance. (See Chapter X for service information.) Fault (Terminals 16, 17 and 18): Terminal 16 is normally open and closes when an operation fault occurs. Terminal 18 is normally closed and opens when an operational fault occurs. Terminal 17 is a common terminal for both cases. 25 HP Series Installation Manual

29 Figure 17: Valve Coils Figure 18: Valve Wiring HP Series Installation Manual 26

30 Mist Eliminator Installation General The Nortec Mist Eliminator is a single bank water droplet removal system installed at a predefined distance from the water entry point. The highly humidified air is to come into contact with the Mist Eliminator and any un-absorbed droplets of water are removed from the air stream. The collected water accumulates on the media then descends downward towards the bottom of the Mist Eliminator. During this process much of the collected water is absorbed into passing air while any remaining water is funneled to one of two drains via a pre-installed drain pan. See Figure 19: Mist Eliminator Overview. The Mist Eliminator is available in standard sizes ranging from 4ft high x 4ft wide to 12ft high x 20ft wide with 4ft increments between. If a duct size does not fall under one of our standard sizes simply order the next larger size then cut to fit. The drain pan is to be installed at the bottom of the plenum to remove the water collected by the Mist Eliminator. The height of the drain pan should be not be any less than 3 inches (7.5cm) and should extend past the filter bank 8 inches (20.3cm). A drain with trap before and after the Mist Eliminator is required, shown in Figure 20: For this the duct s static pressure must be known. The drain traps must be 2 inches larger than the duct s static pressure. Ensure that the drain trap is filled with water prior commissioning a high-pressure system. Figure 19: Mist Eliminator Overview 27 HP Series Installation Manual

31 Installation of Mounting Angles Measure the duct height and width. Height = Width = The mounting angles are to completely surround the duct. Mark the duct floor with a line a minimum of 8 from the end of the drain pan and perpendicular to the ducts airflow. Now continue the line up vertically up the walls and finally across the ducts ceiling. Each angle measures 95.5 inches. Enough length of angle is supplied to cover the perimeter of the duct but they must be cut to fit. Over-lapping joints slightly is recommended for the floor angles only as they should be sealed along the entire length of angle with appropriate caulking to prevent free air flow through the drain pan. Angles may have to be cut in half to make-up two 4ft lengths. When securing the mounting angles to the duct place the side with circular holes against the duct and the bent edge along the marked line. Orient the mounting angle as shown in Detail A in Figure 21: Mounting Angles. Using field supplied self taping screws attach the mounting angle to the duct via the round mounting holes. A screw every 18 inches is recommended. Figure 20: Drainage and Drains Figure 21: Mounting Angles HP Series Installation Manual 28

32 Installation of Mounting Channels Before installing the mounting channel or channels the starting mounting point needs to be determinedusing the duct width. If the duct width is 4ft or less then there is no need for a mounting channel, continue to the next step. Table 1. Mounting Channel Locations Duct Width Mounting Position Number of Channels 4ft - 8ft Middle 1 8ft - 12ft Offset 2ft from middle 2 12ft - 16ft Middle 3 16ft - 20ft Offset 2ft from middle 4 Once the mounting location is determined the mounting channel(s) are ready to be cut to fit, keeping in mind that drain pans are not level and lengths may vary. From the starting point, each additional mounting channel is placed at 4ft centers. In the figure below a typical 4ft x 8ft installation is shown with the mounting angle surrounding the perimeter and a mounting channel installed vertically at the center point of the duct. In Figure 23: Large Duct Mounting Channel Locations, a 6ft high x 10ft wide mist eliminator frame is shown. Notice how the mounting channel placement is offset from the center. Installations between 8ft x 12ft to 16ft x 20ft may involve the removal of excess material. Excess material is removed equally from both sides of the frame not from the middle. To secure the mounting channel in place use the factory supplied ½ inch self-threading screws. Use the center row of slotted holes to attach the mounting channel to the mounting angle. Place one screw at the top and one at the bottom making sure that the mounting channel is level or square to the ceiling, this will help for mounting the wire mesh. See Figure 24: Mounting Channel Installation. If the duct height greater than 8 feet a channel extension is needed in order to link 2 mounting channels together. The extension slides inside the mounting channel. Use 4 ½ inch factory supplied screws for each mounting channel as shown in Figure 25: Mounting Channel Extension Kit. 29 HP Series Installation Manual

33 Figure 22: Mounting Channel Location Figure 23: Large Duct Mounting Channel Locations Figure 24: Mounting Channel Installation Figure 25: Mounting Channel Extension Kit HP Series Installation Manual 30

34 Installing 1 inch Screws/Studs In the final step of this instruction Media Clamping Strips are used to secure the media to the frame. In this step the screws used to fasten the Media Clamping Strip to the finished assembly must be installed. Each Media Clamping Strip requires 3 screws evenly spaced. Clamping strips are 46 inches in length upon arrival from the factory however if the Clamping Strip is cut to fit the duct size it will still require 3 screws evenly spaced to properly secure it. After each screw is installed use the factory supplied nuts to lock them in place. Figure 26: 1 Inch Screw / Stud Installation Installation of Wire Mesh The 4ft wide Wire Mesh can now be cut to length (duct height or top mounting stud to bottom mounting studs.) To fasten the Wire Mesh to the assembly use the factory supplied selfthreading ½ inch screws starting from the top angle and middle channels working out and down. Be sure to install the wire mesh square when first fastened otherwise it will not align properly at the opposing end. Notch around screws previously installed for best results. 31 HP Series Installation Manual Figure 27: Mesh Installation

35 Media Installation The recommended way to install the media is taking the entire roll and securing its leading edge to the top of the assembly by working the 1inch screws/studs though the media, see Figure 28: Mesh Installation. Then carefully rolling it downward until it reaches the bottom of the duct. Cut the media at the bottom of the assembly to fit. Once cut, go back and work the rest of the screws through the media. If the recommended method cannot be followed, use a flat, clean surface to pre-cut the media. Be sure to cut the media with precision so not to be short on the final section of the assembly. Figure 28: Mesh Installation Media Clamping Strip Installation The final step is to secure all components of the assembly using the media clamping strip. Place the strips so the 1 inch screw/studs pass through the slotted holes on the media clamping strip then fasten a factory supplied nut to hold the assembly in place. See Figure 29: Clamping Strip Installation. Figure 29: Clamping Strip Installation HP Series Installation Manual 32

36 33 HP Series Installation Manual

37 Startup, Operation, & Maintenance HP Series Installation Manual 34

38 Commissioning and Startup Once the HP HVAC system has been installed, it can be commissioned. Prior to undertaking the commissioning procedure ensure that the supply water system has been started and that a supply of water is available. 1 Bleed the filters. For Giant pumps, open the water supply valve and press the red button. For Danfoss pumps, disconnect the manifold supply line from the outlet of the pump and wait until water begins to flow. It is helpful to connect a hose to the outlet and route to drain. 2 Disconnect the manifold supply line from the outlet of the pump if not already done in step 1. Connect a hose and route to a suitable container. 3 Turn on pump and run for 1 minute. This will bleed the pump and clear any glycol used to protect the pump during shipping. Temporarily connecting a jumper between terminals 1 and 5 on the pump controller terminal strip will activate the pump. 4 Reconnect the manifold supply line to the outlet of the pump. 5 Disconnect the manifold supply line at the inlet to the valve blocks. Connect a hose and route to drain. In the case where 1 pump feeds multiple zones, work with only 1 zone at a time. 6 Turn on the pump for several minutes and check for leaks. Again, the pump can be activated temporarily using a jumper on terminals 1 and 5. 7 Reconnect the manifold supply line at the valve inlet. 8 Disconnect the manifolds from their individual feed lines ensuring that there is a provision for drainage. This will allow for the valves and lines to be flushed and help protect the nozzles. 9 Apply a 10 Vdc signal to the valve controller to activate it. Setting the humidistat to its maximum value will provide this signal. If the humidifier will still not activate, ensure that all safeties on valve controller terminals 1 and 2 are closed. Under some circumstances humidistat wiring has not been completed at the time of commissioning. For startup and testing procedures only: - It is acceptable to use a jumper to close terminals 1 and 2. - If no 10 Vdc signal is readily available, connecting a fresh 9V battery to terminals 3 and 4 will simulate a demand signal. (Terminal 3 is negative, terminal 4 is positive.) 10 Start the pump in manual mode and check for leaks in the system. The air handler should be operating during this step. 35 HP Series Installation Manual

39 11 Shut the system off and reconnect the manifolds. Restart the system as per step 9 and observe the spray patterns and check for leaks. 12 Ensure that the spray pattern is uniform does not strike duct walls. 13 Ensure that water collects in the drains and does not pool in the duct. 14 If a mist eliminator or cooling coil is used for mist elimination, ensure that no mist is passing through. 15 Select AUTO on the pump skid, ensuring that all testing jumpers have been removed. The system is now ready to run. Calibration The needle valve is used to reduce water that may occur when the valves open and close. For it to work correctly, it must be calibrated. 1 Install the needle valve, and adjust the valve to the fully open position by turning the handle counterclockwise. 2 Run the humidifier full output, so that all valves are open and all nozzles are spraying water. 3 Observe the nozzle spray near the top of the manifolds. Increase the flow restriction by turning the needle valve clockwise until nozzle spray near the top of the manifolds begins to visibly decrease. 4 Turn the needle valve two full turns counterclockwise. Turn the system off and back on. 5 Ensure that the water hammer has decreased. Observe the nozzles to ensure that they are still spraying correctly. Note: After installing the needle valve, the manifolds may take a few seconds to charge and begin spraying. HP Series Installation Manual 36

40 HP HVAC High Pressure Atomizing Humidifiers Start-up Checklist Humidifier Serial Number: Tag / Zones Served: Pump Model: Pump Voltage: System Configuration: Pump Inspection 37 HP Series Installation Manual On/Off 3-Stage 6-Stage High-Resolution RO or DI water supply connected RO or DI water pressure between 20 and 60 psig (do not exceed 60psig) Check valve installed on pump outlet (Danfoss PAH pumps only) Drain line connected to pump Supply voltage matches pump specification label Valve Controller Inspection 120 VAC supply voltage connected 0-10V control signal connected to terminals 3 and 4 On/Off safety devices (or jumper) connected to 1 and 2 Valve Block Inspection Drain line connected Valve coils wired to valve controller High pressure supply connected and tight High pressure supply lines flushed Manifold supply lines connected Manifold Inspection Air-handler drains are connected and open Nozzle manifolds are securely mounted Mist eliminator installed (if applicable) Certification Water piping is free of leaks Pump is installed and operating normally Manifolds and valves installed and operating normally Installed by: (Company Name and Business Address) Inspected by: (Company Name and Business Address) Signed: Date:

41 Operation When the humidification system has been installed and commissioned it will function as follows: 1 The humidistat calls to the valve controller for humidity. 2 If On-Off Safety controls (air proving, high limit humidistat) are closed, the humidifier will activate. 3 The pump module will activate and charge the lines to 1000psi. 4 The soft charge valves will open, softly charging the manifolds to prevent water hammer effects. 5 The valve assembly will open valves as needed to provided water flow to the manifolds. The manifolds will then spray water into the air stream, humidifying the air. 6 When the humidity targets have been met, the valve controller will close the valves and shut off the pump, stopping the spray of water. 7 Water will drain from the manifolds to reduce the microbial growth that may occur in standing water. An air break cap at the top of the manifolds will allow air to enter the lines to facilitate this process. 8 Once every 24 hours, the valve controller will activate the system for 2 minutes to purge the lines of any standing water. This process occurs regardless of demand for humidity at that time. HP Series Installation Manual 38

42 1 stage (on/off) valve assembly: Stage 0 Stage 1 3 stage valve assembly: Stage 0 Stage 1 Stage 2 Stage 3 6 stage valve assembly: Stage 0 Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Stage 6 Table 2. Valve Staging Valve 1 "OFF" - 0% Output Valve 1 "ON" - 100% Output Valve 1,2 "OFF" - 0% Output Valve 1 "ON" - 33% Output Valve 2 "ON" - 66% Output Valve 1 and 2 "ON" % Output Valve 1,2,3 "OFF" - 0% Output Valve 1 "ON" - 17% Output Valve 2 "ON" - 33% Output Valve 3 "ON" - 50% Output Valve 1 and 3 "ON" - 67% Output Valve 2 and 3 "ON" - 83% Output Valve 1, 2, and 3 "ON" - 100% Output Staging for High-Resolution systems are unique to each installation. Please refer to the documentation package that accompanies the humidifier for further information. Maintenance Triplex Ceramic Plunger Pump Maintenance 1 The triplex ceramic plunger pumps (pump skids with Giant pumps) are oil lubricated and require maintenance. The pump has a break-in period of 50 hours. After this time has elapsed, the crankcase oil must be changed. The service indicator light will not illuminate to indicate that the break-in period has elapsed. 2 After the initial break-in period, the oil must be changed every 500 hours. The Service indicator light will illuminate after 400 hours of run time. The pump will then continue to run for another 100 hours before shutting down. The service and fault indicator lights will illuminate to indicate this condition. 3 Remember 500 hours is: Every 9 weeks if operated for 8 hours every day. Every 3 weeks if operated continuously for 24 hours per day. 39 HP Series Installation Manual

43 4 Changing Oil: Identify your pump from the figures on the adjacent page. Remove the oil fill cap and the oil drain plug(s). Dispose of spent oil as per local regulations. Reinstall the drain plug(s). Torque to 18 lb-ft (hand tight). Do not over tighten. Add recommended amount of oil to crankcase. Refer to the chart below for oil capacities. Ensure that oil reaches the center of sight glass. Do not overfill. Reinstall the oil fill cap. Press the reset rocker switch inside the pump controller to reset the counter and shutoff the service indicator. Table 3: Crankcase Oil Capacity Pump Model Giant P205REIB Giant P208REIB Giant P217REIB Giant P218REIB Giant P219REIB Giant P220REIB Giant P56W Giant P420A Oil Capacity - Do Not Overfill 9 fl. oz 9 fl. oz 9 fl. oz 9 fl. oz 9 fl. oz 9 fl. oz 14 fl. oz 30 fl. oz - Synthetic 75w-90 grade oil is recommended for all applications (Mobile1 or equivalent). - Synthetic 15w-50 grade oil can be used as an alternate grade. (Mobile1 or equivalent). - All labels on pump supersede this manual. Incorrect oil grades can cause pump damage. Damage resulting from incorrect oil grades is considered misuse and is not covered by warranty. HP Series Installation Manual 40

44 Figure 30: P200 Series Pumps Figure 31: P56W Pump Figure 32: P420A Pumps 41 HP Series Installation Manual

45 Danfoss Stainless Steel Axial Piston Pump 1 The stainless steel axial piston pump is water lubricated and does not require any maintenance. This pump has a lifespan of 8000 hours, after which time pump wear will reduce its efficiency. If the pump is removed from service at 8000 hours it can usually be rebuilt and receive another service life. 2 The service indicator light will illuminate after 7900 hours of operation. The pump will continue to operate for another 100 hours after which time the service and fault indicators will illuminate and the pump will shut down. Nortec recommends replacing the pump at this time. Contact your local Nortec representative for further information. 3 After the pump head has been changed, press the reset switch inside the pump controller housing to reset the service indicator and 8000 hour counter. Resetting the counter without changing the pump head will allow the pump to be run to destruction without further warning. Nortec strongly recommends against this, and cannot offer warranty on downstream components damaged by pump debris resulting from pumps run past 8000 hours. Electrical Motor Service 1 Two types of electrical motors are used to drive the pumps; those with sealed rotor bearings and those with external greased bearings. The sealed rotor bearing types are maintenance free, while the external bearing types require periodic lubrication. Please refer to the nameplate on the motor to identify which motor you have. Operation Standard (6 hours/day Severe (18 hours/day) Seasonal (2000 hours per season) Table 4. Electrical Motor Service Service Interval Every 3 years Every year Beginning of each season Frame Size Table 5. Lubricant Volumes Volume cu. in. Relubrication Amounts Fluid oz Electrical motors on the pump modules are pre-greased with a polyurea mineral oil NGLI grade 2-type grease unless stated otherwise on the motor nameplate. Some compatible brands of polyurea mineral base type grease are: Chevron SRI#2, Rykon Premium #2, Shell Oil Doilum R, and Texaco Polystar RB. Motors are properly lubricated at time of manufacture and do not need to be lubricated at the time of installation. HP Series Installation Manual 42

46 Over greasing bearings can cause premature bearing and/or motor failure. The amount of grease added to the motor should be carefully controlled. Inlet Water Filters The 10 micron water filters must be inspected periodically. Inspection is accomplished by comparing the pressure valves on the filter inlet and outlet sides. When the pressure drop across the filters reaches or exceeds 10 psi, the filters are considered spent and should be replaced. The longevity of the filters depends entirely on the quality of the water being supplied to the pump. Nortec recommends replacing the filters at a once per year as preventative maintenance regardless of measured pressure drop. Steps: 1 Turn the pump controller to off. 2 Turn the supply water valve to off. 3 Using a filter wrench, remove the filter housings. 4 Replace filter cartridges paying attention to any directional arrows. 5 Reinstall the filter housings, tighten hand tight with the filter wrench. 6 Turn the supply water back on. 7 Turn the power back on. High and Low Pressure Lines and Hoses The hoses and lines should be periodically inspected for damage, cracking, leaking. Ensure that the pipes are rubbing on any vibrating equipment. Atomization Nozzles The Nortec HP HVAC system is designed to operate only on reverse osmosis or de-ionized water supplies. This allows for long trouble free operation of the nozzles. Occasionally because of either water quality or dirt, an atomization nozzle may become blocked. With the system running, use a nozzle cleaning tool, or.007 (0.177mm) wire inside the nozzle orifice. Spin the tool around until the blockage dislodges. If you are still unable to clear the blockage, contact Nortec for a replacement nozzle. Wear eye protection during this procedure. A proper spray pattern should be circular and measure 2 (50mm) across at a distance of 2 (50mm) from the nozzle. See Figure 33 Nozzle Spray Pattern. Please refer to Figure 34: Nozzle Components for assembly and disassembly of nozzle components. 43 HP Series Installation Manual

47 Figure 33: Nozzle Spray Pattern Figure 34: Nozzle Components Mist Eliminator Maintenance 1 The HP HVAC system should typically be installed downstream of air filters to minimize Mist Eliminator maintenance. In any case, Nortec recommends an annual inspection of mist eliminator media. 2 If the media is becoming contaminated with dust, it should be removed and cleaned with a vacuum or gentle water spray. Do not use any solvents or chemicals for cleaning mist eliminator media. Odors produced could be harmful to occupants downstream. As well, chemicals and solvents could degrade the fire and antibacterial coatings on the media. 3 For optimum performance, Nortec recommends replacing mist eliminator media annually. End of Season Shutdown 1 At the end of a humidification season the system can either be left in standby or shutdown for the off-season. 2 A properly installed system can be left in stand-by as it will flush itself automatically. It may save time and maintenance to allow the HP HVAC system to stay active in standby mode during an off-season. Please note that in standby mode the system will consume some water periodically to flush itself. HP Series Installation Manual 44

48 3 The system can also be shut down for the off-season. If the system is to be shutdown for an extended period of time, all automatic drain valves should be removed and the system completely flushed. Then all water remaining in the lines should be air purged. The supply water to the pump module should be turned off. Empty filter housings of any remaining water and replace filter cartridges with new dry cartridges. Turn off electrical power to the pump module. This will protect against corrosion and damage to the pump and lines. Stainless steel pumps should not be inactive for more than 2 weeks without following the above shutdown procedure. Decommissioning / Freeze Protecting If the system is to be decommissioned (shut-down for an extended period of time), or stored in a cold area, the following procedure is applicable: 1 Disconnect the low pressure line at the inlet of the pump. 2 Connect the pump inlet to a canister containing a mixture of 35% glycol and water. 3 Disconnect the high pressure supply line at the inlet to the valve block. 4 Run the pump briefly to circulate the glycol mixture through the pump and supply lines. 5 Reconnect the high pressure supply lines to the valve block. 6 Disconnect the glycol canister and cap the pump inlet. 7 Decommission the RO system as per manufactures instructions (if applicable). Inlet Water Pressure Switch The inlet water pressure switch is hydraulically actuated, and completes a 24Vac control circuit. The switch is rated to 150 psi, and cut off sensitivity is adjustable between 12 and 100 psi. This switch is preset at 20 psi at the factory and does not require adjustment. 45 HP Series Installation Manual

49 Troubleshooting Troubleshooting 46

50 Table 6: Troubleshooting Problem Cause / Solution Recommendations Pump module will not run. The power supply to pump is off and needs to be turned on. Turn the power supply on. Circuit breaker has interrupted the pumps power supply. Check that the power supply connection to pump is wired correctly. The power supply circuit could be overloaded. Motor contactor is not making contact. Check for correct voltage on transformer 120/208/230/460/575. Breaker on 24 VAC control circuit has blown, check for short circuit. Check alignment and operation of contactor mechanism. Contact surfaces of contactor may be damaged. Check low inlet water pressure. VFD has faulted out. Reset, check error messages for more information. The pump motor may be damaged. The motor bearings may be damaged and have caused a lock up. Inspect and replace if necessary. The motor may have shorted or have been single phased or overloaded without protection. Pump head mechanism may have been damaged. Brass pump crank bearings/connecting rods may have become damaged /frozen causing the motor to lock up. Disassemble pump head and repair/replace as required. Pump module has stopped running and red lamp is on. Thermal overload circuit has blown. The pump module motor could have overheated and its thermal protection circuit needs reset. Check motor FLA rating and check overload setting. Check for a short in the circuit running optional control equipment. Reset Overload and measure actual motor amp draw. The pump module must never be operated above 1200 P.S.I. (83 BAR). Proper ventilation must be provided to prevent the motor from over-heating. The motor may be operating outside its service factor as a result of power supply low voltage. A combination of all of the three previous points could be in effect. 47 Troubleshooting

51 Transformer may be faulty. Check transformer line voltage and secondary voltage. Pump module has stopped running. Inlet water pressure has dropped below 20 PSI. Check inlet water pressure for low conditions. You may have to monitor gauge for water fluctuations. Water leaks out of thermal valve. Water is being restricted from leaving the pump module and it is over heating. Make sure enough nozzles are running to permit enough water to flow from pump module to keep it cool. Filter housing leaks. O-ring may be displaced or broken. Inspect and replace if necessary. Housing could be cracked. If water freezes in housing it will be damaged. Pump module runs but there is no fog coming out of the nozzles. There may be a large leak in the high-pressure plumbing of the system You have loose or missing atomization nozzles. A reusable hose fitting or manifold connection has come loose or has not been made correctly. The drain solenoid on the pump module is stuck open allowing all the pumped water to leave the system. An auto drain valve on manifolds isn t closing, verify that the sealing ball is seating properly. Pump module runs but there is no fog coming out of the nozzles. The water pressure regulator on the pump module may be completely backed off. Check pressure gauge = 1000 psi. Turn the hand wheel on the regulator clockwise to increase pressure to 1000 psi. Valve controller may be restricting the flow of water to any of the nozzles. The pump must never be ran without any high pressure water leaving the system, otherwise the pump will overheat. The low inlet water pressure safety switch may not be isolating the pump and allowing it to run without water. A very dangerous situation, the pump needs water to run cool. Check the inlet water supply and integrity of the pressure switch. Troubleshooting 48

52 49 Troubleshooting

53 Spare Parts Spare Parts 50

54 Motor shown here is equipped with a variable frequency drive, which is an option. Medium Pump Module Spare Parts This pump can either be a stainless steel pump (as shown) or a triplex ceramic plunger pump. Figure 35: Medium Pump Module Spare Parts 51 Spare Parts

55 19 2 Motor shown here is equipped with a variable frequency drive, which is an option. Detail View This pump can either be a stainless steel pump (as shown) or a triplex ceramic plunger pump. Large Pump Module Spare Parts Figure 36. Large Pump Module Spare Parts Spare Parts 52

56 Table 7: HP Spare Parts Nortec Part # Nortec P/N Item Number Pump Model Giant Pumps, No VFD G500 PM 120V/1ph G500 PM 230V/1ph G500 PM 230V/3ph G500 PM 460V/3ph G500 PM 575V/3ph G850 PM 120V/1ph G850 PM 230V/1ph G850 PM 230V/3ph G850 PM 460V/3ph G850 PM 575V/3ph G1100 PM 120V/1ph G1100 PM 230V/1ph G1100 PM 460V/3ph G1100 PM 575V/3ph G1550 PM 230V/1ph G1550 PM 230V/3ph G1550 PM 460V/3ph G1550 PM 575V/3ph G2300 PM 230V/3ph G2300 PM 460V/3ph G2300 PM 575V/3ph G3500 PM 230V/3ph G3500 PM 460V/3ph G5450 PM 230V/3ph G5450 PM 460V/3ph G5450 PM 575V/3ph Pump Motor VFD PRV LP Gauge HP Gauge 20 Filter Cartridge 10 NOM 20 Filter Cartridge 10 Abs 10 Filter Cartridge 10 Abs x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x 53 Spare Parts

57 Part # Nortec P/N Item Number Pump Model Giant Pump, With VFD Pump Motor VFD PRV LP Gauge HP Gauge 20 Filter Cartridge 10 NOM 20 Filter Cartridge 10 Abs 10 Filter Cartridge 10 Abs GVFD950 PM 230V/3ph x GVFD950 PM 460V/3ph x GVFD950 PM 575V/3ph x GVFD1650 PM 230V/3ph x GVFD1650 PM 460V/3ph x GVFD1650 PM 575V/3ph x GVFD2100 PM 230V/3ph x GVFD2100 PM 460V/3ph x GVFD2100 PM 575V/3ph x GVFD3500 PM 230V/3ph x GVFD3500 PM 460V/3ph x GVFD3500 PM 575V/3ph x GVFD5000 PM 230V/3ph x GVFD5000 PM 460V/3ph x GVFD5000 PM 575V/3ph x Spare Parts 54

58 Part # Nortec P/N Item Number Pump Model Danfoss Pump, No VFD Header Pump Motor VFD PRV LP Gauge HP Gauge 20 Filter Cartridge 10 NOM 20 Filter Cartridge 10 Abs 10 Filter Cartridge 10 Abs D500 PM 120V/1ph x x x D500 PM 230V/1ph x x x D500 PM 230V/3ph x x x D500 PM 460V/3ph x x x D500 PM 575V/3ph x x x D1100 PM 120V/1ph x x x D1100 PM 230V/1ph x x x D1100 PM 230V/3ph x x x D1100 PM 460V/3ph x x x D1100 PM 575V/3ph x x x D1800 PM 230V/1ph x x x D1800 PM 230V/3ph x x x D1800 PM 460V/3ph x x x D1800 PM 575V/3ph x x x D2900 PM 230V/3ph x x D2900 PM 460V/3ph x x D2900 PM 575V/3ph x x D3650 PM 230V/3ph x x D3650 PM 460V/3ph x x D3650 PM 575V/3ph x x 55 Spare Parts

59 Nortec P/N Item Number Pump Model Part # Danfoss Pump, With VFD Pump Motor VFD PRV LP Gauge HP Gauge 20 Filter Cartridge 10 NOM 20 Filter Cartridge 10 Abs 10 Filter Cartridge 10 Abs DVFD500 PM 230V/3ph x DVFD500 PM 460V/3ph x x DVFD500 PM 575V/3ph x DVFD1100 PM 230V/3ph x DVFD1100 PM 460V/3ph x x DVFD1100 PM 575V/3ph x DVFD1800 PM 230V/3ph x DVFD1800 PM 460V/3ph x x DVFD1800 PM 575V/3ph X DVFD2900PM x DVFD2900PM x x DVFD2900PM x DVFD3650PM x DVFD3650PM x x DVFD3650PM x Spare Parts 56

60 Table 8: Medium and Large Pump Module Spare Parts Number Description Part Number 8 Switch N Series On Off Drain Lamp Red 24VAC For NHC Panel Lamp Green 24VAC For NCH/AF Panel Lamp Amber 24VAC For AirFog Pressure Switch PSI Fan Axial 118CFM 24 VDC Solenoid Valve 24V N/C 1/4" SS Thermal Sensor, Brass Thermal Sensor, Stainless Steel Large Pump Module Cover Pressure Relief Val Amp Fuse for Transformer Table 9: Valve Assembly Number Description Part Number 1 24 Vdc Coil, Clip-on Valve HP 3/2 SS Valve HP 2/2 NC SS Table 10: Mist Eliminator Spare Parts Part Number Description Media, Mist Eliminator, 48 w X 12 h X 1 d Mesh, Welded Wire, 4x4 304 Stainless Steel Table 11: Manifold Spare Parts Part Number Description Air Break Valve Service Kit (Pack of 5) Replacement Nozzle 12 lbs/hr (No O-Ring) Anti-drip O-Ring for HP Nozzle Anti-drip Ball and Spring Assembly HP Nozzle Replacement Kit, 12 lbs/hr (Pack of 5) 57 Spare Parts

61 Figure 37: 3 and 6 Stage Valve Assembly Spare Parts Spare Parts 58

62 59 Spare Parts

63 Wiring & Installation Diagrams Wiring Diagrams 60

64 61 Wiring Diagrams Figure 38: Pump Control

65 L1 L2 L3 3 Am p s N/O N/C Primary Line Voltage 24vac 24vac COM. Connected to Cabinet GND 24 VAC Cooling Fan for Totally Enclose Model only G L3 L2 L1 24VAC Contactor Humid ON Indicator Lamp Contactor Off/Auto/Manual SW AUTO Warm Water Relief Valve Manual Overload Relay Thermostatic Sensor Water Pressure Switch G Humid Active Indicator Lamp R Humid Fault Indicator Lamp Y Humid Service Indicator Lamp Manifold Control Connection Humid ON Relay Variable Speed Controller Analog input (0-20mA) [ VLT 2800 only ] Analog input (0-20mA) [ VLT FC 200 only ] Com. Analog output Com. Analog input Star/Stop 24 vdc Supply - VDC 10 VDC Supply Humid Active Relay Push to reset hour counter Humid Service Relay Humid Fault Relay Pump Controller with Danfoss VLT 2800 or VLT Aqua FC 200 Wiring Diagram number Rev. F 12/22/09 COM L3 L2 L1 Humid ON Humid Active Humid Service Humid Fault Figure 39: Pump Controller with Danfoss VLT 2800 or VLT Aqua 800 Wiring Diagrams 62

66 63 Wiring Diagrams Figure 40: Pump Controller with Danfoss Integrated VFD

67 Figure 41: 1 Stage Valve Controller Wiring Diagrams 64

68 65 Wiring Diagrams Figure 42: 3 Stage Valve Controller

69 Figure 43: 6 Stage Valve Controller Wiring Diagrams 66

70 6.6 in. ( 168 mm ) 4.5 in. ( 114 mm ) 3.0 in. ( 75 mm ) 1.5 in. ( 39 mm ) 8.0 in. ( 203 mm ) 3.1 in. ( 80 mm ) 3.6 in. ( 92 mm ) O 0.4 in. ( 10 mm ) 6.8 in. ( 171 mm) 3.2 in. ( 80 mm ) 6.0 in. ( 152 mm ) 8.4 in. ( 214 mm ) 8.4 in. ( 214 mm ) 6.0 in. ( 152 mm ) 4.0 in. ( 100 mm ) 1.4 in. ( 34 mm ) 3.2 in. 2.3 in. ( 80 mm ) ( 57 mm ) 0.6 in. ( 15 mm ) 2.6 in. ( 66 mm ) 4.0 in. ( 102 mm ) 8.0 in. ( 203 mm ) Voltage: 24VDC Power: 18 W per coil, 3 coils total Inlet Connection: ½ compression fitting Drain Connection: ½ compression fitting Manifold Connection: 3/8 compression fitting Max. Pressure: 2000 psig (138 bar) Min. Flow: 0.3 gpm (1 Lpm) Max. Flow: 7.9 gpm (30 Lpm) Pressure Loss: 36 max flow (2.5 bar) Weight: 16 lbs (7 kg) Material: 304 stainless steel and plastic HP HVAC Soft Charge Valve Assembly - 1 Stage Part # April 25, 2010 Figure 44: HP HVAC Soft Charge Valve Assembly 1 Stage 67 Wiring Diagrams

71 6.6 in. ( 168 mm ) 4.5 in. ( 114 mm ) 3.0 in. ( 75 mm ) 1.5 in. ( 39 mm ) 1/2" Compression O 0.4 in. ( 10 mm ) 2.1 in. ( 55 mm ) 4.1 in. ( 105 mm ) 6.8 in. ( 171 mm) 3.6 in. ( 92 mm ) 3/8" Compression 8.4 in. ( 214 mm ) 2.3 in. ( 57 mm ) 6.0 in. ( 152 mm ) 4.0 in. ( 100 mm ) 1.4 in. ( 34 mm ) 3.2 in. 2.3 in. ( 80 mm ) ( 57 mm ) 2.6 in. ( 66 mm ) 1.5 in. ( 39 mm ) 6.0 in. ( 152 mm ) 8.0 in. ( 203 mm ) Voltage: 24VDC Power: 18 W per coil, 5 coils total Inlet Connection: ½ compression fitting Drain Connection: ½ compression fitting Manifold Connection: 3/8 compression fitting Max. Pressure: 2000 psig (138 bar) Min. Flow: 0.3 gpm (1 Lpm) Max. Flow: 7.9 gpm (30 Lpm) Pressure Loss: 36 max flow (2.5 bar) Weight: 28 lbs (13 kg) Material: 304 stainless steel and plastic HP HVAC Soft Charge Valve Assembly - 3 Stage Part # April 26, 2010 Figure 45: HP HVAC Soft Charge Valve Assembly 3 Stage Wiring Diagrams 68

72 6.6 in. ( 168 mm ) 4.5 in. ( 114 mm ) 3.0 in. ( 75 mm ) 1.5 in. ( 39 mm ) O 0.4 in. ( 10 mm ) 2.9 in. ( 74 mm ) 4.9 in. ( 123 mm ) 3.6 in. ( 92 mm ) 6.8 in. ( 171 mm) 0.9 in. ( 24 mm ) 3/8" Compression 2.3 in. ( 57 mm ) 8.4 in. ( 214 mm ) 6.0 in. ( 152 mm ) 4.0 in. ( 100 mm ) 3.2 in. ( 80 mm ) 1.4 in. ( 34 mm ) 1/2" Compression 2.3 in. ( 57 mm ) 2.6 in. ( 66 mm ) 1.5 in. ( 39 mm ) 8.0 in. ( 202 mm ) 8.0 in. ( 203 mm ) Voltage: 24VDC Power: 18 W per coil, 7 coils total Inlet Connection: ½ compression fitting Drain Connection: ½ compression fitting Manifold Connection: 3/8 compression fitting Max. Pressure: 2000 psig (138 bar) Min. Flow: 0.3 gpm (1 Lpm) Max. Flow: 7.9 gpm (30 Lpm) Pressure Loss: 36 max flow (2.5 bar) Weight: 38 lbs (17kg) Material: 304 stainless steel and plastic HP HVAC Soft Charge Valve Assembly - 6 Stage Part # April 26, 2010 Figure 46: HP HVAC Soft Charge Valve Assembly 6 Stage 69 Wiring Diagrams

73 April 9, 2010 Figure 47: HP Valve Controller Wiring Diagrams 70

74 71 Wiring Diagrams

75 Warranty Nortec Humidity Inc. and/or Nortec Humidity Ltd. (hereinafter collectively referred to as THE COMPANY), warrant for a period of two years after installation or 30 months from manufacturer s ship date, whichever date is earlier, that THE COMPANY s manufactured and assembled products, not otherwise expressly warranted, are free from defects in material and workmanship. No warranty is made against corrosion, deterioration, or suitability of substituted materials used as a result of compliance with government regulations. THE COMPANY s obligations and liabilities under this warranty are limited to furnishing replacement parts to the customer, F.O.B. THE COMPANY s factory, providing the defective part(s) is returned freight prepaid by the customer. Parts used for repairs are warranted for the balance of the term of the warranty on the original humidifier or 90 days, whichever is longer. The warranties set forth herein are in lieu of all other warranties expressed or implied by law. No liability whatsoever shall be attached to THE COMPANY until said products have been paid for in full and then said liability shall be limited to the original purchase price for the product. Any further warranty must be in writing, signed by an officer of THE COMPANY. THE COMPANY s limited warranty on accessories, not of the companies manufacture, such as controls, humidistats, pumps, etc. is limited to the warranty of the original equipment manufacturer from date of original shipment of humidifier. THE COMPANY makes no warranty and assumes no liability unless the equipment is installed in strict accordance with a copy of the catalog and installation manual in effect at the date of purchase and by a contractor approved by THE COMPANY to install such equipment. THE COMPANY makes no warranty and assumes no liability whatsoever for consequential damage or damage resulting directly from misapplication, incorrect sizing or lack of proper maintenance of the equipment. THE COMPANY makes no warranty and assumes no liability whatsoever for damage resulting from freezing of the humidifier, supply lines, drain lines, or steam distribution systems. THE COMPANY retains the right to change the design, specification and performance criteria of its products without notice or obligation.

76 U.S.A Renaissance Blvd. Sturtevant, WI Proctor Avenue Ogdensburg, NY CANADA 2740 Fenton Road Ottawa, Ontario K1T 3T7 TEL: NORTEC1 WEBSITE: