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Summary of Contents for DriSteem VAPOR-LOGIC3
- Page 1 Read and save these instructions! VAPOR-LOGIC ® Microprocessor-based humidifier control system Installation and operation manual...
- Page 2 Corporate headquarters European office 14949 Technology Drive • Eden Prairie, MN 55344 Bell Place, Bell Lane • Syresham, Brackley • NNN13 5HP, UK 952-949-2415 • 800-328-4447 • 952-229-3200 (fax) +44 1280 850122 • +44 1280 850124 (fax) sales@dristeem.com (e-mail) 106277.1443@compuserve.com (e-mail)
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Page 3: Table Of Contents
VAPOR-LOGIC ® table of contents. Product overview Operation Features summary ..........1-2 Start-up checklist ..........24-25 Circuit board diagram ..........3 Keypad/display overview ........26 Main control board connections ......4-6 Menu structure ............27 Expansion board connections ........7 “Set Up”... -
Page 5: Product Overview
Product overview VAPOR-LOGIC features overview. ® Accurate, responsive Control mode options microprocessor control • On-off operating mode controls single or Our newest controller, VAPOR-LOGIC multiple electric staged outputs. provides unprecedented, comprehensive control for Expected accuracies: ±5-7% RH DRI-STEEM humidifiers. With expanded capabilities, easy-to-use keypad, and modular, open protocol design, •... - Page 6 Product overview VAPOR-LOGIC features overview. ® Summary of features • Tank temperature sensor: • PID control provides the most accurate, responsive and adjustable relative humidity (RH) – preheats tanks for uninterrupted operation control. – senses for freeze protection • Self-diagnostic test at start-up –...
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Page 7: Vapor-Logic
Product overview VAPOR-LOGIC ® circuit board. Figure 3-1: VAPOR-LOGIC printed circuit board Ready Power water RJ-11 indicator indicator Ø 2mm Cable RJ-45 (6) mounting holes keypad Cable Service network indicator To expansion board (ribbon cable) Jumper connector R=Resistive input I=Current input V=Voltage input 89.5 OM-VL3-3... -
Page 8: Main Control Board Connections
Product overview Main control board connections. ® J8 Connector receives necessary continuity input VAPOR-LOGIC main control board connections signals from water detection devices: J1 Wire terminal supplies 24 VAC to power the VAPOR-LOGIC control board. • Probe system water level detection –... - Page 9 Product overview Main control board connections (cont.). J18 Identical to J17 input selector pins except used to Main control board connections (cont.) configure duct high limit RH input (terminals 24 Important note about J17, J18 and J19: through 26) for wire connector terminal J27 All connection diagrams show connector shunts J19 Identical to J17 input selector pins except used to on J17, J18 and J19.
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Page 10: Main Control Board Connections
Product overview Main control board connections (cont.). J27 Wire terminal connector receives the necessary Main control board connections (cont.) signal from the duct high limit RH sensor. J23 Wire terminal connection provides optically • Terminal 24: Positive polarity 21 VDC supply isolated connection to air flow proving switch and safety circuit. -
Page 11: Expansion Board Connections
Product overview Expansion board connections. ® ® J8 Wire terminal connector supplies 24 VAC voltage and VAPORSTREAM expansion board with terminal pairs 1 and 2, 3 and 4, and 5 and 6 to connections either contactors or GTS ignition controllers. J1 Push-on connector for earth ground (Terminals 1, 3 and 5 supply the 24 VAC. -
Page 12: Program Code Nomenclature
Product overview Program code nomenclature. F. System kilograms output: Program code explained ##### = Output capacity ® A 14-digit VAPOR-LOGIC program code appears on (e.g., 00128 = output capacity in kg/hr) the front of the control cabinet and on the wiring G. - Page 13 Product overview Program code nomenclature. Program code example 00022 A. English ® B. HUMIDI-TECH One-tank system Single keypad One heat stage 21.5 kg/hr capacity Standard water with autodrain TP operating mode No VAV option No temp comp option 4-20 mA transmitter Product overview: Program code nomenclature...
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Page 14: Warranty
Product overview Two-year limited warranty. DRI-STEEM Humidifier Company (“DRI-STEEM”) DRI-STEEM’s limited warranty is made in lieu of, and warrants to the original user that its products will be DRI-STEEM disclaims all other warranties, whether free from defects in materials and workmanship for a express or implied, including but not limited to any period of two (2) years after installation or twenty-seven IMPLIED WARRANTY OF MERCHANTABILITY,... -
Page 15: Installation Installation Checklist
Installation Installation checklist. ® Before installing your VAPOR-LOGIC control system, q Attach the heater/machine ground lug in the junction box, on the humidifier, to the subpanel review this checklist to ensure proper installation of the machine ground lug with the appropriate wire, product. -
Page 16: Proper Wiring Procedures
Installation Proper wiring procedures. Most noise problems can be prevented by using proper Proper wiring prevents electrical noise wiring practices and techniques to prevent coupling or Electrical noise can produce undesirable effects on inducing of electrical interference into control circuits. electronic control circuits, thereby affecting The following simple wiring practices should minimize controllability. -
Page 17: Proper Wiring Procedures
Installation Proper wiring procedures (cont.). • Return all shielded cable connections to the Proper wiring prevents electrical noise (cont.) control cabinet for grounding. Do not ground • Do not use chassis or safety grounds as current- shield at the device end. carrying commons. -
Page 18: Control Cabinet Installation And Wiring
Installation Control cabinet installation and wiring. ® The VAPOR-LOGIC control board is shipped Class 2 control transformer. The transformer mounted with all internal wiring completed within a provides a 24 VAC supply, and is protected by an control cabinet. All software has been custom integral manual reset circuit breaker. -
Page 19: Keypad/Display Installation
Installation Keypad/display installation. Installing modular cable Installing the keypad/display IMPORTANT: When routing modular cable inside IMPORTANT: Do not locate the keypad/display the control cabinet, route cable away from all power inside the control cabinet. The hardware is premounted wiring and connect the male modular plug into the in the keypad/display case with front access to the VAPOR-LOGIC ®... -
Page 20: Sensing Devices Installation (General)
Installation Sensing devices and humidity control. Important to properly place sensing devices Other factors that affect humidity control Humidity sensing devices must be properly placed to Unsatisfactory humidity control may involve more than achieve accurate humidity control. A typical small air just the controller’s capability to control the system. - Page 21 Installation System Diagram. Figure 17-1: System diagram Line voltage 24 Volt ® ULTRA-SORB Liquid level detectors dispersion unit Electrical supply Keypad/display Line voltage 24 Volt Control cabinet ® VAPORSTREAM VLC humidifier OM-3007 Installation: Component placement...
- Page 22 Installation Placement of sensing devices. Figure 18-1: Recommended sensor locations Best Alternative location Not recommended Best duct high limit humidistat High limit humidistat or high limit transmitter (set at 90% RH max.) placement for VAV Outside air 3 meters applications Air flow switch (sail type recommended...
- Page 23 Installation Wiring of sensing devices. Wiring modulating humidity Wiring on-off humidistats or temperature transmitters DRI-STEEM provides three types of on-off controls: Transmitters provide an analog signal proportional to wall-mounted humidistat, duct-mounted humidistat, or the process variable being measured. All transmitters pneumatic/electric relay.
- Page 24 Installation Wiring of sensing devices. Figure 20-1: Example of proper shielding techniques when ® connecting humidity or temperature devices to VAPOR-LOGIC control inputs Note: The wiring diagram (found on the inside of the humidifier OM-VL3-17 control cabinet) will show the proper controls wiring. IMPORTANT: Consult control cabinet wiring diagram.
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Page 25: Vav Sensing Device Installation
Installation Wiring VAV sensing device. Variable air volume (VAV) option When this occurs, the keypad/display will show the This option is identified as a “V” in the third-from-last message “VAV output limit.” If necessary, the reduction place of your program code nomenclature (for example: of the humidifier output will continue until maximum EV11400285A7VOX). -
Page 26: Temp Comp Sensing Device Installation
Installation Temperature compensation transmitter. Temperature compensation offset option Install using an 1 mm plenum-rated shielded cable for This option is identified as a “T” in the second-from- transmitter wiring with grounding shield at the shield last place of your program code nomenclature (for ground lug in the control cabinet (see Figure 21-1 on example: EV11400285A7OTX). -
Page 27: Changing Control Input
Installation Changing control input. Changing control input VAPOR-LOGIC ® has the ability to accept different 4. Change the last character in the configuration types of demand signals from either an energy string to the desired input signal type identified management system or a humidistat. Follow these steps from the program coded nomenclature information when a signal change is needed: on Pages 8 and 9. -
Page 28: Operation
Operation Start-up checklist. Note: Your humidification system may not have all of q Check the derivative gain setting in the the options listed below. If an item does not “System Set Up” menu of the keypad/display appear, skip to the next item and continue the (default is 0). - Page 29 Operation Start-up checklist (cont.). q Confirm that the high limit humidistat input is q Confirm that all wiring is correct per the wiring closed or that the variable air volume (VAV) diagram. control system high limit transmitter is connected. q Confirm that proper grounding and an approved q With sufficient water in the tank, the air flow earth ground are provided.
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Page 30: Keypad/Display Overview
Operation Keypad/display overview. The menu system Components of the keypad/display The VAPOR-LOGIC keypad/display software The VAPOR-LOGIC ® keypad/display consists of (see organizes the control of the humidification system under Figure 26-1 below): six top-level screens: • A 128 x 64-pixel backlit LCD display •... -
Page 31: Menu Structure
Operation VAPOR-LOGIC ® menu structure. Main Menu 1. Status Soft key - Main – Returns to the Main Menu screen Soft key - Back – Scrolls to the previous Status item Soft key - Next – Scrolls to the next Status item 2. -
Page 32: X93;Set Up” Menu Information
Operation “Set Up” menu information. “Set Up” menu “Set Up” menu readout description description Range Default RH Set point Relative humidity set point 20-80% RH RH Offset RH offset calibration ±20% RH Dewpoint Set point Dew point set point -7-27°C 10°C Dewpoint Offset Dew point offset calibration... -
Page 33: Keypad/Display Readouts
Operation Keypad/display readouts. Readout displayed Description Filling The unit is filling with water. Skimming The unit has completed a fill cycle and is now skimming. Draining The unit is draining. Flushing The unit is flushing. No Duct Air Flow The air flow proving switch is open. Interlock Disable The interlock circuit is open. -
Page 34: Main Menu Items Explained
Operation Main menu: 1) Status. Status The Status screen is used to view some of the operating parameters of the humidification system. Some of the parameters that may be displayed include: • RH setpoint • Room RH • Dewpoint setpoint •... - Page 35 Operation Main menu: 2) Control Modes. Control Modes In the Control Modes screen, the operational mode of the humidifier can be set. You may choose from auto, test, manual drain or standby. In Auto Mode, the humidifier operates normally. All inputs and outputs are monitored and controlled.
- Page 36 Operation Main menu: 3) Alarms. Alarms The Alarms screen is used to view the alarm log. Use the vertical arrow keys to scroll through the alarm log. The alarm log contains a record of the previous 10 faults that have occurred on the humidifier. The alarms may either be acknowledged or cleared using the soft keys below the display.
- Page 37 Operation Main menu: 4) Set Up. Set Up In the Set Up screen, the operational parameters of the • Skim duration humidifier can be set. Depending on system options, • SDU duration parameters available may include: • Aquastat • RH setpoint •...
- Page 38 Operation Main menu: 5) Diagnostics. Diagnostics Depending on system options and type, diagnostics The Diagnostics screen enables you to troubleshoot available may include: some of the hardware input and output points of the VAPOR-LOGIC ® control system. The soft keys Next •...
- Page 39 Operation Main menu: 6) Reports. Reports The Reports screen is useful for viewing historical information about your humidifier. In this section, you are able to view the amount of water that has been used by your humidifier and the amount of energy it has consumed.
- Page 40 Operation Main menu: Idle screen. Idle Screen The Idle screen allows you to monitor the humidifier’s basic operation. Depending on system options, you may view system set point, the actual space condition and the system demand. The top line of the display informs you of the current mode of the humidifier.
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Page 41: Control Modes
Operation Control modes. Demand signal control On-off control With demand signal control, the VAPOR-LOGIC On-off control is the simplest control scheme, and controller provides the output level that a master does exactly what its name implies: the output device control signal calls for. This signal can either be turns fully on, then fully off. -
Page 42: Modulation Types
Operation Modulation types: TP modulation. TP modulation The standard form of modulation with an electric To minimize wear on the contactors that are cycling, humidifier is TP (time-proportioning) modulation. VAPOR-LOGIC ® keeps track of the number of cycles With this type of modulation, the outputs are cycled on all contactors and it will rotate the TP cycling on and off at a certain rate to approximate humidifier contactor through the stages to ensure that they all get... - Page 43 Operation Modulation types: SSR modulation. SSR modulation with contactors % SSR modulation With SSR modulation with contactors, the operation The ultimate in electric humidifier modulation is of the unit is the same as it is with TP Modulation. In 100% SSR Modulation. With this type of control, all this scenario, one of the cycling contactors is replaced heat stages are controlled by SSRs.
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Page 44: Modulation Types
Operation Modulation types: valves and burners. and LTS valve modulation ® ® With a valve system, the modulation is very simple. When individual burner demand falls below its The demand signal simply determines how far the minimum rating (25-90% depending on options), valve is going to open. -
Page 45: Adjusting Set Point
Operation Control functions: adjusting set point. Adjust set point through Set Up menu Set point adjustments are accomplished through the Depending on your options, you may also be able to Set Up menu, which is under the Main Menu (refer to adjust the high limit humidity set point and the dew the menu structure diagram on Page 27). -
Page 46: Pid Tuning
Operation Control functions: PID tuning. The proportional term Tune your system with PID loop The proportional band is the band (in % RH, or °C When your unit is equipped with a humidity or dew for dew point control) in which the humidifier will point transmitter (when you are able to adjust the set modulate. - Page 47 Operation Control functions: PID tuning (cont.). The integral term The integral gain affects how fast the humidifier will set point and is rising, the derivative term will react to a droop condition. The higher the number, the subtract from the demand in anticipation of the faster the reaction.
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Page 48: Vav, Temp Comp, Dew Point Control
Operation VAV, temp comp, dew point control. VAV control Dew point control With VAV control, the system is equipped with a duct Dew point control functions in exactly the same way high limit transmitter. This transmitter sends a signal as RH control except the dew point is being measured ®... -
Page 49: Heat-Up, Sdu Timer, Offsets, Metric Conversion
Operation Aquastat, heat-up, SDU, offsets, metric. Aquastat operation SDU timer The aquastat set point is the minimum tank If your humidifier is equipped with a Space ® temperature the VAPOR-LOGIC controller should Distribution Unit (SDU) or an Area-Type fan, you maintain. -
Page 50: Conductivity Probe
Operation Water level control: conductivity probe. Probe system Standard water systems use a conductivity probe to Each time the fill valve is energized, the probe system control water levels for optimum operating efficiency. is tested by the VAPOR-LOGIC system. If the signal The three-probe system is monitored by the from the probe assembly is beginning to deteriorate, ®... -
Page 51: Float Valve
Operation Water level control: float valve. Float valve system The fill float regulates how much water is added to DI/RO water systems use a float valve system to the tank via a float, float arm and mechanical valve. control water levels for optimum operating efficiency. The valve is adjusted to within 6 mm of the overflow DI/RO systems are used where water/steam purity is (skimmer) port allowing heated and therefore... -
Page 52: Drain, Flush, Skim Functions
Operation Drain and flush, skim. Drain and flush options In the flush at a certain time mode, the humidifier VAPOR-LOGIC ® is preprogrammed to enter an will enter the drain and flush sequence at a specific automatic drain, flush and refill cycle to help keep time, ignoring the amount of water that has been mineral concentrations in the tank to a minimum. -
Page 53: Maintenance Interval, Eos, Date Set
Operation Service interval, EOS, date set. Service interval ® The VAPOR-LOGIC controller keeps track of how Setting date and time much water has been converted to steam. After a user- The VAPOR-LOGIC controller contains a real-time defined number of kilograms have been boiled, a clock that is used for several features including the service humidifier message will appear on the drain and flush sequence and the logging of alarms. -
Page 54: Safety Features
Operation Safety features. Fill timer Over-temp fault The VAPOR-LOGIC ® controller keeps track of The tank temperature is constantly monitored by the approximately how much water, in the form of steam, VAPOR-LOGIC controller. If the temperature ever has left the tank. If this total amount exceeds a preset rises above a preset limit, the humidifier is shut down limit without the fill valve being energized, a low and a thermal trip fault is given on the Alarms screen... -
Page 55: Fault Messages, Diagnostics
Operation Fault messages, diagnostics. Alarms screen Fill and drain faults The Alarms screen on the keypad/display logs the last The following is a list of fill and drain faults that can ten alarms that have occurred on the humidifier. To occur. -
Page 56: Fault Messages, Diagnostics
Operation Fault messages, diagnostics (cont.). Humidifier faults • Ignitor No. fault (Ignitor No. Fault) The following is a list of humidifier faults that can The ignition module failed to energize the gas occur. Please note that this is a complete list of faults. valve. -
Page 57: Reports, Multiple Tank Systems
Operation Reports, multiple tank systems. Multiple tank systems Energy usage report ® The VAPOR-LOGIC controller has the ability to be The energy usage report gives an approximate total of connected via a LonTalk ® network to control up to six how much energy has been consumed by the tank humidification systems. -
Page 58: Troubleshooting
Operation Troubleshooting 1, 2, 3. Review troubleshooting index Call us if you’re still having problems If you find that you are having a control-related If the troubleshooting guide does not help you solve problem, first check the problem list on the next page. your problem, call us with the following information If you are having a tank- or dispersion-related available:... - Page 59 Operation Index to troubleshooting guide. The following is an index to possible control-related problems described on the following pages. To find solutions, refer to either the problem number or the page number shown. No. Description Green power indicator light is off ....Page 56 2.
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Page 60: Green Power Indicator Light Is Off
Operation Troubleshooting guide. Problem Problem Possible cause Action number Green power indicator • No control voltage • Check for proper supply voltage. present light is off. • Heater fuses open • Check heater fuses for voltage present at transformer. • Transformer secondary •... -
Page 61: Dew Point Transmitter Fault
Operation Troubleshooting guide. Problem Problem Possible cause number Action Dew point transmitter • Open, shorted, or • Check D.C. supply voltage terminals: fault incorrect wiring of 21+, 23-(21 VDC) transmitter or humidistat • Signal by others. • If there is no output, 4-20 mA, replace Incorrect, out of transmitter. -
Page 62: Vav Humidity Transmitter Fault
Operation Troubleshooting guide. Problem Problem Possible cause Action number VAV humidity • Incorrect high limit • HL input 2, shunt connector J27 across transmitter fault transmitter wiring “I” pins. Measure normal 1-5 VDC range on control HL 25+, 26-. Temp comp transmitter •... -
Page 63: Fill Fault
Operation Troubleshooting guide. Problem Possible cause Action Problem number (continued) • Low water supply pressure minimum (continued) (continued) Fill fault • When in the 170 kPa. • Remove fill valve and check for any fill sequence, VAPOR-LOGIC foreign material plugging valve. allows 40 minutes for •... -
Page 64: Low Water Timer Fault
Operation Troubleshooting guide. Problem Problem Action number Possible cause • Run a test cycle to see if system (continued) • System programmed (continued) activates drain output. Drain fault for manual drain • Insufficient drain line pitch. • Drain line backing up •... -
Page 65: Ml Probe Fault
Operation Troubleshooting guide. Problem Possible cause Problem number Action (continued) (continued) (continued) • Improper water level • Wiring between control cabinet and LL probe fault changes inside tank humidifier exceeds the recommended 50 foot limit. • Check fill and drain plumbing installation. - Page 66 Operation Troubleshooting guide. Problem Possible cause Action Problem number (continued) (continued) ML probe fault • Water in tank • Back pressure from dispersion system, oscillates or jumps distance, elbows, restrictions. • No “P” trap installed on tank and/or plugged. • Over boiling or •...
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Page 67: Replace Probes Fault
Operation Troubleshooting guide. Problem Action Possible cause Problem number (continued) (continued) Replace probes fault • Probe wiring. • Check for proper wiring. • Machine ground must be present between control cabinet and humidifier tank. • Do not use shield cable. Individual 1 mm . -
Page 68: Eeprom Fault
Operation Troubleshooting guide. Problem Possible cause number Problem Action • Internal program • Consult DRI-STEEM for EEPROM fault changed reprogramming instructions. (VAPOR-LOGIC detected a change from its previous program check) • The combustion air • Check for proper combustion air Flue fault damper is incorrectly damper wiring. -
Page 69: Ignitor No. Fault
Operation Troubleshooting guide. Problem number Possible cause Problem Action Ignitor No. fault • Broken ignitor • Verify that ignitor glows. • Gas valve/ignitor/ • Verify wire connections to these sensing electrode is components. out of sequence. Blower No. fault • The blower is •... -
Page 70: Unit Does Not Fill With Water
Operation Troubleshooting guide. Problem Problem number Possible cause Action • First, disconnect brown wire and then the • Malfunctioning fill Unit does not fill with orange wire from VAPOR-LOGIC ® board valve water. terminals 30 and 31 of terminal block J8. Fill valve should open. - Page 71 Operation Troubleshooting guide. Problem Possible cause Action number Problem Fill valve does not • Open drain valve • If automatic drain valve is locked in close manual open position, reset to automatic. • Replace valve if there is a broken return spring on the drain valve.
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Page 72: Fill Valve Does Not Close
Operation Troubleshooting guide. Problem number Possible cause Problem Action (continued) (continued) • Check if fill valve is installed Fill valve does not • Fill valve is stuck backwards. If yes, repipe. close • If there is a faulty internal spring or diaphragm in the fill valve, replace valve. -
Page 73: Fill Valve Cycles On And Off Frequently
Operation Troubleshooting guide. Problem number Possible cause Action Problem Fill valve cycles on • If needed, clean probe tips. • Malfunctioning level and off frequently • Check water conductivity. (Minimum control system (several times per conductivity for proper operation of minute). -
Page 74: Noisy Operation
Operation Troubleshooting guide. Problem Possible cause Action number Problem • Normal on larger units, caused by the • “Thunder”-type noise Noisy operation cold fill water collapsing steam in the coming from tank tank. Reduce kPa (minimum of 172 kPa) during refill if inlet water pressure is too high. - Page 75 Operation Troubleshooting guide. Problem number Problem Possible cause Action (continued) (continued) Humidity below desired • No call for humidity • Low or no signal strength from level from humidistat or humidistat. Check for proper wiring. from control and • Check humidity transmitters (4-20 mA high limit humidity output).
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Page 76: Humidity Above Set Point
Operation Troubleshooting guide. Problem Possible cause Problem number Action Humidity above set • High entering relative • Dehumidify. point humidity • Unit oversized • Consult DRI-STEEM. • Reduced air flow • Check fans, dampers, VAV systems, etc. • Improperly located •... -
Page 77: Unit Does Not Perform Autodrain Sequence
Operation Troubleshooting guide. Problem Problem Possible cause Action number (continued) (continued) Hunting • Air volume is varying • Stabilize. (humidity swings rapidly. above and below desired set point) • Air temperature is • Stabilize to ±1°C. varying rapidly. Unit does not perform •... -
Page 78: Unit Does Not Perform Auto-Drain Sequence
Operation Troubleshooting guide. Problem Possible cause number Problem Action (continued) (continued) • Incorrect or • Check for proper supply voltage on Tank does not heat up nonexistent control electrical diagram. voltage • Verify proper transformer voltage characteristics. • Verify proper wiring of transformer . •... -
Page 79: Unit Does Not Perform End Of Season Drain
Operation Troubleshooting guide. Problem Possible cause Action Problem number Unit does not perform • Input signal always • Reduce demand signal. end of season drain has a demand • VAPOR-LOGIC • Program may be arranged for manual program drain. Run a test cycle to see if system operates drain valve. -
Page 80: Replacement Parts
Operation Replacement parts. OM-3007-3 ‚ Description Qty. Part No. Display board 408490-002 Cable 408490-* Main board 408490-001 *Part number varies with cable length. Specify humidifier model and serial number when ordering. ƒ OM-VL3-3 Operation: Replacement parts... -
Page 81: Notes
Operation Notes. Operation: Notes... - Page 82 Operation Notes. Operation: Notes...
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Page 83: Notes
Operation Notes. Operation: Notes... - Page 84 14949 Technology Drive • Eden Prairie, MN 55344 Phone: (952) 949-2415 • Fax: (952) 229-3200 E-Mail: sales@dristeem.com • Web: www.dristeem.com European Office: Bell Place, Bell Lane • Syresham, Brackley • NN13 5HP, U.K. Phone: +44 1280 850122 • Fax: +44 1280 850124 E-Mail: 106277.1443@compuserve.com...
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