Vapac LEC05 Manuale utente

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

LEC Electrode Boiler Units

Installation & Operation Manual

Edition 1.1

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.

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

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

CONTENTS

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

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

1.2 Positioning the steam pipes......................................................................................................................6

1.2.1 General.................................................................................................................................................6

1.2.2 Steam Hose Connection .......................................................................................................................6

1.3 Plumbing Considerations. ........................................................................................................................7

1.4 Electrical Connections..............................................................................................................................8

1.4.1 Important E.M.C. Considerations........................................................................................................8

1.4.2 Power Supply Connection....................................................................................................................8

1.4.2 Power Supply Connection....................................................................................................................9

1.4.2.1 Volt free alarm outputs.........................................................................................................................9

1.4.2.2 Unit control terminals...........................................................................................................................9

1.4.3 Electrical Connections........................................................................................................................10

1.4.4 Cable Entry Provision ........................................................................................................................10

1.4.5 Vapac Control Circuit Transformer....................................................................................................10

1.5 Cylinder Electrical demand loads...........................................................................................................11

1.6 Control Circuit Connections...................................................................................................................12

1.6.1 Control Circuit Wiring .......................................................................................................................12

1.6.2 Proportional Control...........................................................................................................................12

1.6.3 Control Signal Selection.....................................................................................................................12

1.6.4 On/Off Control...................................................................................................................................12

1.6.5 Sensing Head......................................................................................................................................13

1.6.6 Security Circuit / E.P.O. Shutdown....................................................................................................13

1.6.7 Load Shed Option...............................................................................................................................13

1.6.8 Master/Slave System..........................................................................................................................14

2.0 Start-Up / Operation...................................................................................................................................14

2.0 Start-Up / Operation...................................................................................................................................15

2.0.1 Start-up check list...............................................................................................................................15

2.0.2 Start-Up Instructions ..........................................................................................................................15

2.0.3 Commissioning/Start-Up....................................................................................................................15

2.0.4 Features of VAPANET Electode Boiler Unit.....................................................................................15

2.1 Service Advice .......................................................................................................................................16

2.1.1 Procedure for cylinder Exchange. ......................................................................................................16

2.1.2 Typical Cylinder / Electrode Layouts.................................................................................................16

2.2.1 Feed Valve with Strainer....................................................................................................................17

2.2.2 Drain Pump ........................................................................................................................................17

3.0 Indicators....................................................................................................................................................18

3.1 User LED ...............................................................................................................................................18

3.2 Fascia Label symbols .............................................................................................................................19

3.3 Other Options.........................................................................................................................................19

4.0 Trouble-shooting Check List......................................................................................................................20

5.0 Wiring diagram ..........................................................................................................................................21

Appendix 1.............................................................................................................................................................28

A Guide to Positioning Steam Pipes: .................................................................................................................28

Appendix 2.............................................................................................................................................................29

Appendix 2.............................................................................................................................................................30

A Guide to Positioning Multipipes:....................................................................................................................30

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.

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

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.

To comply with EMC aspects see recommendations on page 10.

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.

85 85

1000 500

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.

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.

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.

1.1 Vapac LE unit dimensions

Cabinet Sz 4 (5 – 45 kg/h Models) Minimum

Clearances.

Cabinet Sz 4 (5 – 45 kg/h Models)

55 990

360

20.5"(520) 468

31.1"(790)

505

176 6

360

152 343

343

70 850

237

190

610

810

322

346

190

610

73555

Steam Outlets

54 mm

Gland Plate

120 X 120 Gland Plate

120 X 120

Left:

Top View Showing Steam

O/let position

Below: Rear View

showing wall mounting

points.

Left:

Bottom View Showing

“F” (Feed connection) ¾”

BSP male connection for

flexible hose provided

with unit.

“D” (Drain connection)

35 mm pipe.

NB:

Entry hole for gland

plates is approx.

105 mm x 90 mm

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

1.1.1 LEC 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 .

Vapanet model Dry Kg Wet Kg

LEC05 68 96

LEC09 71 100

LEC18 72 125

LEC30 74 127

LEC45 75 128

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 90oelbows in the

steam line.

Steam Distribution Pipe requirement

Electrode Boiler

Unit Model LEC05

LEC09

LEC18

LEC30

LEC45

35mm

∅

Pipe

No.

54mm ∅.

Pipe No.

*Duct Pressure

Pa. +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 per cylinder

1.20 l/min

2.50 l/min

LEC05

LEC09

LEC18

LEC30

LEC45

2 Cylinder per unit

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

= pump discharge rate of max 16.8 l/min at 50 Hz.

Power supply 17.2 l/min at 60 Hz.

Do’s

Do use copper or plastic pipe rated for 110 oC.

Do arrange to discharge drain water from the unit into a

trapped and vented drain at a position where flash steam

rising from the drain line vent will not pose a problem for

the Vapac or other equipment.

Do provide adequate fall for the drain pipework to allow free

flow of water drained from each unit.

Do ensure drain line pipe size will accommodate water being

drained at the same time from all the Vapac units which

are connected to it.

KEY: -

A Tundish Fill-cup

B Steam Cylinder

C Feed Drain Manifold

D Drain Pump

F Feed Solenoid Valve

G Water Connection ¾” BSP.

H Flexible hose ¾” BSP.

K 35∅Steam Hose coupling and Hose

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

LEC Twin C

linder Units 5-45 k

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 RED 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 -

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

1.4.2 Power Supply Connection

The unit requires the following connections as shown in the diagram

below

1.4.2.1 Volt free alarm outputs

The unit has connections for volt free alarm outputs these are on the

three double terminals next to the main power input terminals.

The top terminals are for unit volt free fault alarm as follows:

542 common for fault alarm

543 Normally closed when no fault

544 Normally open when no fault

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

545 Common for run signal

546 Normally closed when unit is in standby or fault

(not running)

547 Normally open when unit is in standby or fault

(not running)

If the unit is part of a master slave system or network, the run

& fault outputs can be selected (via keypad & display) as

either network (system) or unit only. This is selectable at

Service Engineers Level, in the Engineering Menu, in the

window “Fault/Run Scope”. The default is “network”. It is

possible to get both alarm & Run indication in all units: Single

cylinder units will give this indication if the service interval has

expired; Twin Cylinder & Networked units will give this

indication if the service interval has expired or if the master

cylinder is operating and any slave cylinder (or cylinders) are

in fault.

1.4.2.2 Unit control terminals

For unit control and network termination see section

1.6 the terminal layout is shown here.

1.4.3 Electrical Connections

The wiring to the Vapac should be done by a qualified

electrician. The external overcurrent protection and wiring

should comply with the appropriate Regulations and Codes of

Practice.

Important: Make sure the connection to the primary Voltage

winding of the Vapac transformer matches the supply Voltage

which is to be connected between Vapac terminals A1 & A2.If

the actual (measured) site voltage is 400v the preferred

tapping is 380V.

A fused disconnect/isolator or MCB should be used to

disconnect the supply from all electrodes simultaneously.

This must be sized to suit the total maximum phase/line

current of the unit and should be located adjacent to the

Vapac cabinet or within easy reach and readily accessible.

In Vapac VAPANET units terminals A1, A2 and A3 are for the

power supply connections as indicated in the diagrams below

(twin cylinder units have two supplies A1,A2,A3 & B1,B2,B3).

Twin cylinder units’ have terminals for the connection of two

power supply input circuits. On twin cylinder units’ this allows

individual external protection of each steam cylinder. Fused

disconnect/isolator or MCB provision must be linked to

ensure both 3 phase supply inputs are disconnected

simultaneously.

1.4.4 Cable Entry Provision

Cable glands must be used to ensure cables are held

securely at the entry position. All Vapac cabinets are

equipped with a removable gland-plate. The installing

electrician should remove this and take it to a work-bench to

drill for the required cable gland size.

1.4.5 Vapac Control Circuit Transformer

The internal control circuit of the Vapac unit operates at

24Vac - the transformer secondary is set at 24V.

As standard the Vapac VAPANET includes a transformer with

alternative primary winding options 200V, 230, 380, 415, and

440V and requires on site adjustment to match it to the

Voltage connected to Vapac terminals A1 and A2.

The transformer also has a 9V secondary tapping which

provides power to the VAPANET 1150630 PCB.

Important: The Vapac transformer must NOT be used to

power other equipment or the warranty will be invalidated.

Notes:-

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

2. Unit with N.A. in the following tables means NOT AVAILABLE there is not a unit available to run at the voltage

and phases shown. Please check that the correct model reference is ordered and installed, for the low or high

voltage required, and at the desired steam output.

3. Standard design is for 50 Hz. Supplies. Design for 60 Hz. Also available - 60 Hz. Supply must be specified with

order as the standard pump is only 50Hz.

FOR FULL ELECTRO-MAGNETIC COMPATIBILITY A NEUTRAL CONNECTION IS REQUIRED FOR ALL PROPORTIONAL

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

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